Pallet Display Package With Nested Uprights for Double-Stack Shipping
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Solution Overview
Problem
Tall pallet displays for books and other merchandise are difficult to ship compactly, leading to wasted freight space and higher shipping costs, as they cannot be double-stacked in standard tractor trailers due to their height.
Innovation Solution
A compact point-of-purchase display package design featuring a tray with bottom uprights and stowed top uprights that can be easily assembled and secured without adhesives or external fasteners, allowing for double-stacking and including a shroud and corrugated board construction for efficient shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If tall pallet displays (50-60 inches height) are used for visibility and attention-grabbing in stores, then consumer visibility and attention are improved, but the displays cannot be double-stacked in standard 100 inch tractor trailers, resulting in wasted freight space and higher shipping costs
Solution Approach 1:
The display is divided into two separate components: a bottom portion and a top portion. The bottom portion contains the base structure and lower display elements, while the top portion contains the upper display elements that provide the height advantage. This segmentation allows each component to be compact enough for efficient stacking during shipping, while still achieving the desired display height when assembled at the destination.
Solution Approach 2:
The top portion is designed to nest within or alongside the bottom portion during shipping. The top uprights can be positioned within the space created by the bottom uprights arrangement, allowing the components to occupy less freight space. This nesting capability enables double-stacking in standard tractor trailers, significantly improving freight space utilization while maintaining the ability to assemble a tall display structure at the retail location.
2Productivity
If four-sided shelved pallet displays are made tall (50-60 inches) to grab consumer attention in main drive aisles, then impulse purchases and visibility are improved, but shipping efficiency deteriorates due to inability to double-stack
Solution Approach 1:
By segmenting the display into bottom and top portions, the invention enables efficient shipping while maintaining the tall display structure needed for impulse purchase generation. The segmented design allows standard shipping practices to be used, reducing shipping costs while preserving the productivity benefit of high-visibility displays.
Solution Approach 2:
The invention transitions from a single vertical dimension problem to a two-dimensional shipping arrangement. By arranging bottom and top portions side-by-side or nesting them during shipping, the display components can fit within standard trailer height constraints, enabling double-stacking and improving shipping efficiency without sacrificing the vertical display height needed for consumer engagement.
3Ease of manufacture
If pallet displays are designed with sufficient panels and structural elements for enhanced consumer attraction and messaging, then aesthetic appeal and information provision are improved, but device complexity and shipping compactness deteriorate
Solution Approach 1:
The display structure is segmented into bottom and top portions, each containing relevant panels and structural elements. This segmentation allows the complex aesthetic features to be distributed across manageable components that can be compacted for shipping. The panels and structural elements in each portion can be arranged to maximize compactness during transport while maintaining the overall aesthetic appeal when assembled.
Data Source
AI summary
A package that may be constructed into a point of purchase display includes a plurality of bottom uprights set in a tray, and a plurality of top uprights that are kept in folded form in a space between the bottom uprights. The top uprights are assembled and placed on top of the bottom uprights to form a completed display. The bottom uprights may contain shelves with product stocked thereon, and the space between the bottom uprights may contain product to be stocked on the top uprights after the top uprights are assembled on top of the bottom uprights. The top uprights may be assembled and placed on top of the bottom uprights by a retailer or other end user without requiring glue or fasteners.