CORRUGATED HUTCH

Abstract

The present invention provides a hutch having a pair of opposed sidewalls and a back wall and a shelf having a first planar surface extending between the sidewalls supported by four support panels each having a second planar surface transverse to the first planar surface.

Claims

1-47. (canceled)

48. A hutch for supporting heavy objects comprising: a back panel having a first slot, a first side panel extending from a first side of the back panel; a second side panel extending from a second side of the back panel; a front panel extending between a front portion for the first side panel and a front portion of the second side panel; a first shelf foldably connected to the front panel, the first shelf having a horizontal support panel and a first tab; a first intermediate panel extending between the first side panel and the second side panel between the back panel and the front panel; a first shelf support panel foldably connected to the first intermediate panel, the first support panel having a panel portion configured to engage the first slot of the back panel and a slot configured to receive the first tab of the first shelf, the first shelf support positioned immediately below the first shelf to support a back end of the horizontal support surface of the first shelf; a second intermediate panel extending between the first side panel and the second side panel between the back panel and the front panel; and, a first middle support panel foldably connected to the second intermediate panel for supporting a middle portion of the first shelf.

49. The hutch of claim 48 wherein the first shelf includes a first vertical panel and a second vertical panel at a front portion.

50. The hutch of claim 48 wherein the first shelf support panel includes a first vertical panel.

51. The hutch of claim 50 wherein the first middle support panel includes a first vertical panel at a first end, the first vertical panel of the first middle support panel positioned in face to face contact with the first vertical panel of the first shelf support panel.

52. The hutch of claim 51 wherein the first middle support panel includes a second vertical panel at a second end.

53. The hutch of claim 48 comprising a second shelf foldably connected to the front panel, the second shelf having a horizontal support surface extending back toward the back panel.

54. The hutch of claim 53 comprising a second shelf support panel foldably connected to the first intermediate panel, the second shelf support shelf support panel positioned immediately below the second shelf to support a back end of the horizontal support surface of the second shelf.

55. The hutch of claim 54 wherein the back panel includes a second slot and the second shelf support panel having a panel portion configured to engage the second slot of the back panel.

56. The hutch of claim 55 wherein the second shelf support panel includes a vertical panel at one end.

57. The hutch of claim 55 comprising a second middle support panel foldably connected to the second intermediate panel.

58. The hutch of claim 57 wherein the second middle support panel includes an upper horizontal support panel that extends towards the back panel and is configured to abut a lower surface of the second shelf.

59. The hutch of claim 58 wherein the second middle support panel includes a vertical panel at one end and wherein the upper horizontal support panel of the second middle support panel extends from an upper edge of the vertical panel of the second middle support panel.

60. The hutch of claim 59 wherein the second middle support panel includes a lower horizontal panel that extends toward the back panel from a lower edge of the vertical panel of the second middle support panel.

61. The hutch of claim 60 wherein the back panel has a third slot and the lower horizontal panel includes a tab configured to fit in the third slot.

62. The hutch of claim 57 further comprising a third shelf foldably connected to the front panel.

63. The hutch of claim 62 further comprising a third shelf support panel foldably connected to the first intermediate panel for supporting an end of the third shelf

64. The hutch of claim 63 wherein the third shelf includes a tab configured to fit in a slot on the third shelf support panel.

65. The hutch of claim 63 further comprising a third middle support panel foldably connected to the second intermediate panel for supporting a middle portion of the third shelf.

66. The hutch of claim 48 wherein the hutch is made from a single blank of material.

67. The hutch of claim 66 wherein the material is a corrugated paper.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0012] FIG. 1 shows a plan view of a blank of paperboard material for forming a hutch and indicating the vertical fold lines.

[0013] FIGS. 2-6 show a top plan view of the paperboard blank when folding along vertical fold lines.

[0014] FIG. 7 shows a plan view of a blank of paperboard material for forming a hutch and indicating the horizontal fold lines.

[0015] FIG. 8 is a photograph of a hutch displaying products on three shelves.

[0016] FIG. 9 is a side elevation view taken along a line through a center of the shelves from front to back.

[0017] FIG. 10 is a photograph of a top or first shelf before folding along horizontal fold lines.

[0018] FIG. 11 is a photograph of a front view of a second shelf before folding along horizontal fold lines.

[0019] FIG. 12 is a photograph of a front view of a third shelf before folding along horizontal fold lines.

[0020] FIG. 13 is a front elevation view of a rear wall of the hutch.

[0021] FIG. 14 shows a plan view of a blank of paperboard material for forming a hutch having four shelves.

[0022] FIG. 15 is a photograph of two hutches, one having four shelves displaying soft drink products and another having three shelves.

DETAILED DESCRIPTION

[0023] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and attachments, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.

[0024] FIGS. 1 and 7 show a paperboard blank 100 having a plurality of panels divided along vertical fold lines (FIG. 1) and horizontal fold lines (FIG. 7). When properly folded the blank forms a hutch 200 (FIG. 8) having three shelves for supporting relatively heavy items. FIG. 14 shows a blank when properly folded forms a hutch 202 having four shelves. FIG. 8 shows a hutch 200 having three shelves and FIG. 15 shows a hutch 202 having four shelves and a hutch 200 having three shelves. Notwithstanding the number of shelves, the hutch will be referred to hereafter as hutch 200. The hutch 200 is suitable as a point of sales display for items like bottles of soft drinks and cases of cans of liquids as is shown in FIG. 8. In a preferred form of the invention, a single blank 100, even more preferably a single blank 100 having a continuous planar surface, will be used to form the hutch 200. It is contemplated, however, that two or more blanks could be used to form the hutch without departing from the present invention.

[0025] In one preferred form of the invention, the blank 100 is first folded along the vertical fold lines shown in FIG. 1 to form the structures shown in FIGS. 2-6, and then the blank 100 is folded along the horizontal fold lines shown in FIGS. 7, 10-12. While the folding is described in a certain order it should be understood that what is described is an exemplary method and the folding could proceed in a different order to form the hutch 200 shown in FIGS. 8 and 15. Additionally, directional or positional words, such as top, upper, vertical, left/right, etc., are used with respect to the blank 100 and hutch 200 as shown in the various figures and are not meant to limit the invention.

[0026] Starting with the folding along vertical fold lines, a panel 18 and those panels to the left are folded along line 1.5, 90? to form a generally L-shaped blank shown in FIG. 2. The L-shaped blank is then folded along line 2.5, 90? to the right placing panels 12, 13 and 14 in registration with panel 6 to form a generally U-shaped blank defining a chamber 100 therebetween (FIG. 3). Then, panel 4 and the panels to its right are folded 90? along line 3.5; panels 1, 2, 3 are folded 90? along line 4.5; panel 5 is reverse folded 90? along line 5.5, and panel 5 is attached to an inner surface of panel 18. In one preferred form of the invention, panel 5 is attached to panel 18 with glue, for example.

[0027] Panel 19 and the panels to its left are folded 90? along line 6.5 toward panel 6 as shown in FIG. 5. Panel 20 and those to the left are folded 180? along line 7.5 placing panel 20 into face-to-face contact with an outer surface of panel 4 and panels 7-10 are folded 90? along line 8.5 to extend parallel to panels 1, 2, 3. Panel 20 is attached to an outer surface of panel 4 with glue, for example. Panel 11 is reverse folded 90? along line 9.5 and attached to an inner surface of panel 18 as shown in FIG. 6. Panels 16 and 17 are respectively folded 180?, in opposite directions, along lines 10.5 and 11.5 into face-to-face contact with an inner surface of panels 19 and 18 and attached thereto with glue, for example.

[0028] FIG. 7 shows horizontal fold lines designated with a prime (). The panels are folded along the horizontal fold lines to complete three shelves vertically spaced from one another (FIGS. 10-12). While three shelves are shown in FIG. 8 and four shelves are shown in FIG. 15 it is contemplated having as few as two shelves and as many as needed and fits within the dimensional limitations of use. In one preferred form of the invention the hutch will have from two to six shelves.

[0029] The following folds are for completing the top shelf or first shelf. FIG. 10 shows the first shelf in an unfolded state and FIG. 9 shows all of the shelves in a folded state. Panel 1 has three horizontal fold lines and three sub-panels 50, 51, 52, and slot 53 centrally disposed on fold line 2.5. To construct this part of the shelf, fold panel 50 90? along line 1.5 toward panel 6, and panel 52 90? along line 2.5 and insert panel 50 through slot 54 of panel 6 (See FIG. 13). Panel 53 is oriented horizontally, panel 51 is oriented vertically, and slot 53 faces upwardly. An inner surface of panel 50 is in face-to-face contact with a portion of an outer surface of panel 6 and a surface 55 of the slot 54 abuts a portion of a lower surface of panel 52 along line 1.5 and supports panel 52. In a preferred form of the invention, panel 50 points downwardly. Panel 9 has a tab 56 centrally disposed along a distal end edge and is folded along line 3.5 90? upward toward panel 6 and inserted into tab 58 in panel 6 and extends outward from a rear surface of panel 6 (See FIGS. 9 and 13).

[0030] Panel 7 has two fold lines 6.5, 7.5 and three sub-panels 70, 72, 74. To construct this part of the shelf, fold panel 70 90? along line 6.5 and panel 72 along line 7.5 to form a U-shaped member with panels 70 and 74 being disposed vertically in parallel spaced relationship and panel 72 oriented horizontally. Panel 70 is placed into face-to-face contact with panel 51 of panel 1 (FIG. 9).

[0031] Panel 15 has two fold lines 8.5 and 9.5, three panels 80, 82, 84, and a tab 86. The tab 86 can be pressed and broken away from the panel 80 to pivot along a hinge 85. The tab 86 has a peripheral edge that can be weakened, for example by partially cutting through the panel so that three edges are frangibly connected to the panel 80 and one edge 85 forms a hinge. To construct this part of the shelf, fold panel 82 180? toward the back wall and downward along line 8.5 to place panel 82 into face-to-face contact with a rear surface of panel 84 (FIG. 9). Thus, panel 82 provides vertical support from above panel 15. Fold panel 80 90? upward and toward back wall 6 and over panels 52, 72, and deform tab 86 downward and insert it into slot 53. Slot 53 retains the tab 86 and, in a preferred form of the invention, releasably retains the tab so that it can be removed without destroying the tab 86. Panel 80 is in surface contact and is supported by panels 52, 72. Thus, as shown in FIG. 9, the first shelf has three horizontally extending supports panels 52,72,80 supported along the entire length of four horizontally extending and horizontally spaced fold lines 1.5,2.5,7.5,9.5 by vertically extending panels 6 through slot 55,4,20,82. Panels 6 through slot 55, 4 and 20 provide support from below panel 15 and panel 82 provides support from above panel 15.

[0032] The following describes the folding of the panels (FIG. 11) to complete the second shelf vertically spaced below the first shelf. FIG. 7 shows panel 2 has three panels 60, 61, 62, two horizontal fold lines 4.5 and 5.5 and two slots 63, 66. Fold panel 60 90? along line 4.5 toward the back panel 6; fold panel 62 90? along line 5.5 toward the back wall 6 and insert panel 60 into slot 64 of the back panel 6 and place slit 66 of panel 60 over tab 56 to form an interference fit therewith (FIGS. 9 and 13). An inner surface of panel 66 is in face-to-face contact with a portion of an outer surface of panel 6. A top surface 65 of the slot 64 abuts an underside surface of panel 62 along fold line 5.5 and supports panel 62 in a horizontal orientation. When so folded, panel 2 defines a generally U-shaped structure with two vertical panels 60 and 61 and one horizontal panel 62 connecting the vertical panels. The U-shaped structure 60,61,62 is positioned within a U-shaped structure formed by horizontally extending panel 9 on the bottom, horizontally extending panel 90 on the top and vertically extending panel 92 connecting panels 9,90 (FIG. 9).

[0033] Panel 8 has panels 90 and 92, separated by fold line 10.5, tab 94 centrally disposed on panel 90 and frangibly connected thereto, and slot 96 is centrally disposed along line 10.5. Panel 90 is folded 90? downward toward the back wall and tab 94 is folded 90? downward to form an L-shaped member and inserted into slot 63 of panel 2. Slot 96 and a surface of panel 90 face upwardly and panel 92 has a planar surface oriented vertically.

[0034] Panel 14 has three panels 100, 102, 104, and a tab 106 frangibly connected and centrally disposed on panel 100. Panel 102 is folded 180? toward the back panel 6 along line 11.5 and positioned in face-to-face contact with an inner surface of panel 104. Panel 100 is folded 90? upward along fold line 12.5. Tab 106 is pressed downward from panel 100 and remains connected along a hinge 108 and the remainder of the tab is inserted into slot 96. This completes a second shelf with a horizontal surface with panels 14, 8, 2 supported along a length dimension by supports 102 and 104 providing support from above the second shelf and panels 92, 61 and 60 from below panel 8 and 14.

[0035] The following describes the folding of the panels to complete the third shelf (FIG. 12) or bottom shelf vertically spaced below the second shelf. FIG. 7 shows panel 3 has five panels 130, 132, 134, 136, 138; cutout 140; and a slot 142. In a preliminary fold, panel 3 is folded along lines 13.5 to 15.5 to place panel 130 into contact with an inner surface of panel 136 to form a first rectangular prism with panel 134 forming a horizontally extending surface and panels 136 and 138 oriented with a vertically extending and coplanar surface. This preliminary fold is not shown in the figures. The rectangular prism is then rotated about fold line 16.5 90? so that panel 132 forms a bottom wall extending horizontally, panel 136 forms a top wall extending horizontally, panel 134 extends vertically and abuts an inner surface of the back panel 6, panel 130 is positioned inside the rectangular prism extending roughly vertically and abuts against an inner surface of panel 138 which has a vertically extending planar surface as is shown in FIG. 9. Cutout 140 is provided for ease of folding.

[0036] As shown in FIG. 7, panel 10 has four panels 150, 152, 154, 156; and a cutout 158. Panel 10 is folded along lines 17.5 to 19.5 to form a second rectangular prism with panel 154 forming a horizontally extending planar surface and panels 152 and 156 having a vertically extending planar surface. Cutout 158 is provided for ease of folding.

[0037] As shown in FIG. 7, panel 13 has two panels 170, 172, and tab 174 frangibly connected to and centrally disposed on panel 170 and connected by a hinge 176. Panel 13 is folded 90? toward the back panel along line 20.5 and tab 174 is pushed downwardly and inserted into slot 142. This completes the bottom shelf. Thus, the bottom shelf has five horizontally extending supports 170, 132, 136, 150, 154 and seven vertical supports 130, 132, 134, 138, 152, 156, 172.

[0038] Four foot panels 180 are folded 90? along line 21.5 toward an interior of the hutch to form feet.

[0039] While the present invention is described in connection with what is presently considered to be the most practical and preferred embodiments, it should be appreciated that the invention is not limited to the disclosed embodiments, and is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the claims. Modifications and variations in the present invention may be made without departing from the novel aspects of the invention as defined in the claims. The appended claims should be construed broadly and in a manner consistent with the spirit and the scope of the invention herein.