US20050023168A1

US20050023168A1 - Shipping and display system

Info

Publication number: US20050023168A1
Application number: US10/631,646
Authority: US
Inventors: Craig Marnocha
Original assignee: SCHREIBER FOODS ENGINEERING
Current assignee: SCHREIBER FOODS ENGINEERING
Priority date: 2003-07-31
Filing date: 2003-07-31
Publication date: 2005-02-03
Also published as: AU2003261325A1; WO2005016773A1

Abstract

A light-weight, disposable and re-cycleable base for shipping and displaying multiple product packaging units, and which may be capable of supporting relatively heavy product loads. Several corrugated fiberboard support units having an internal brace element may be secured to each other to create a base. The base is placed upon a pallet and one or more layers of product cases containing the product to be shipped and displayed are placed on top of the base. Advertising graphics advertising the product to be displayed and sold may be placed on the exterior of the base or on a sleeve or wrap secured to the base for that purpose. The base and products may be secured together by for shipping. The entire system may be loaded by forklift into a standard trailer and a second unit may be loaded directly on top of the first unit. The units may be shipped to the end user, unloaded and placed directly on a sales floor display and sale of the products.

Description

BACKGROUND OF THE INVENTION

1. Technical Field.
This application relates to a product shipping display system. In particular, the present invention relates to a light-weight, disposable and re-cycleable shipping and display stand support structure for the shipping and displaying of products.
2. Related Art.
The expenses associated with shipping and displaying retail products that are typically sold in grocery stores, drug stores, and other similar retail operations are a large part of the overall cost of merchandising such products.
Shipping and display stands formed of foldable sheet material, such as paperboard or corrugated board, are known for use in the shipping and display of merchandise items for sale in retail outlets. Shipping and display stands include pallet based units upon which multiple cases of products are stacked and secured to the pallet by various methods, including shrink wrapping, corrugated pallet wraps and the like. These shipping and display units utilize the actual product containing boxes to support and display products. The product cases are shipped on the pallet to the end user and placed on the sales floor as a display unit.
In use, the top boxes are cut open to permit customers to access the products therein. As the products in the uppermost layer of boxes are depleted, the empty boxes are removed and the next layer of boxes is opened. As product box layers are removed from the unit, the height of the unit correspondingly decreases. Unless product cases are continually replenished, to obtain products from the bottommost layers of the unit, consumers must bend over and reach into the product boxes for the product. Replenishment of empty cases in the topmost layers requires the added effort of rotating older products on the bottommost layers to the top so as to avoid the risk of newer products being sold first, thus increasing the expense of using such units. This is particularly important in the case of perishable or dated items. Those items that are not rotated to the top layers of the unit may expire or spoil and, thus, become unsuitable for sale to consumers and have to been thrown out, resulting in product waste.
Other product support and display units are constructed of metal, plastic, or other material and may be bulky, heavy or difficult to dispose of when no longer needed. Further product support and display units have included corrugated units for the support and display of products. These units may be light-weight and disposable, however, these units are not capable of supporting the shipment of one or more pallets of product cases, or are limited in the amount of weight the unit can hold before collapsing, either in transit or at the end retail location. Further, these product support and display units require complicated assembly or disassembly by the retail outlet using such units.
Therefore, there is a need for a light-weight, reusable, and re-cycleable product shipping and product display system that can is capable of supporting relatively heavy loads through multiple shipping and display cycles.

SUMMARY

This invention relates to a re-usable support base for a combination product shipping and retail product display system. In particular, the invention relates to a light-weight, disposable and re-cycleable base for shipping and displaying multiple product packaging units, and which may be capable of supporting relatively heavy product loads. The shipping and display system may be re-usable through multiple shipping and displaying cycles of the same or different products.
In a first aspect, the invention is a light-weight, disposable base for use in a product shipping and display system, said base comprising at least two corrugated fiberboard support units each having at least one corrugated fiberboard internal brace element, where the total compression strength of the base is at least about 1500 lbs, and the compression strength of the base is at least 100 lbs per square foot of top surface area of the base.
In a second aspect, the invention is a system for shipping and displaying products comprising a pallet, a base, and at least one product container secured to the base, where the base comprises at least two adjacent non-product containing corrugated fiberboard support units, each support unit having an internal brace element within the support unit and a compression strength of at least 150 lbs per square foot of top surface area the support unit.
In a third aspect, the invention is a light-weight, disposable structure for use in a product shipping and display system, said structure comprising four non-product containing corrugated fiberboard support units each having at least one corrugated fiberboard internal brace element, where the support units have been secured to one another to form the structure, and where the structure will support at least 3000 lbs without collapsing.
In yet another aspect, the invention is a product shipping and display system comprising (a) a first shipping and display unit including a first pallet, a first corrugated corrugated fiberboard base placed on the pallet, a plurality of product containers placed on and secured to a top surface of the base, and (b) a second shipping and display unit including a second pallet placed on the product containers, a second corrugated corrugated fiberboard base placed on the second pallet, and a second plurality of product containers placed on and secured to a top surface of the second base, where the first and second bases comprise a plurality of substantially empty corrugated fiberboard support units each having an internal brace element and a compression strength of at least 150 lbs per square foot of the top surface of each support unit, and where the first shipping and display unit supports the second shipping and display unit during transit of the units without collapsing.
In still another aspect, the invention is a method of shipping consumer products comprising securing at least two substantially empty corrugated corrugated fiberboard support units each having an internal brace element to one another to form a base; placing the base onto a pallet; placing at least one layer of product containing units onto the base; securing the product containing units to the base to form a combined pallet, base and product container shipping unit; and shipping the shipping unit to a merchandiser.
In a preferred embodiment, several corrugated fiberboard support units having an internal weight bearing support structure are secured to each other to create the base. The base is placed upon a pallet and one or more layers of product cases containing the product to be shipped and displayed are placed on top of the base. Advertising graphics advertising the product to be displayed and sold may be placed on the exterior of the base or on a sleeve or wrap secured to the base for that purpose. At least the base and products may be secured together by, for example stretch or shrink wrap, for shipping. The entire unit may be loaded by forklift into a standard trailer and a second unit may be loaded directly on top of the first unit. The units may be shipped to the end user, unloaded and placed directly on a sales floor display and sale of the products.
Other systems, methods, features and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
FIG. 1 is a perspective view of a shipping and display system according to the present invention.
FIG. 2 is a perspective view of a base on a pallet used in the shipping and display system of FIG. 1.
FIG. 3 is a perspective view of a base secured by a securing wrap used in the shipping and display system of FIG. 1.
FIG. 4 is a top view of a support unit, shown with top flaps opened, used in the shipping and display system of FIG. 1.
FIG. 5A is a schematic drawing of a support unit illustrating one embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5B is a schematic drawing of a support unit with a second embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5C is a schematic drawing of a support unit with a third embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5D is a schematic drawing of a support unit with a fourth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5E is a schematic drawing of a support unit with a fifth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5F is a schematic drawing of a support unit with a sixth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5G is a schematic drawing of a support unit with a seventh embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5H is a schematic drawing of a support unit with a eighth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5I is a schematic drawing of a support unit illustrating a ninth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5J is a schematic drawing of a support unit illustrating a tenth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5K is a schematic drawing of a support unit illustrating an eleventh embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5L is a schematic drawing of a support unit illustrating a twelfth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5M is a schematic drawing of a support unit illustrating a thirteenth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5N is a schematic drawing of a support unit illustrating a fourteenth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5O is a schematic drawing of a support unit illustrating an fifteenth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 5P is a schematic drawing of a support unit illustrating a sixteenth embodiment of an internal brace element used in the support unit of FIG. 4.
FIG. 6A is a perspective view of a single wall corrugated medium used for the support unit and the internal brace elements of FIGS. 5A-5P.
FIG. 6B is a perspective view of a double wall corrugated medium used for the support unit and the internal brace elements of FIGS. 5A-5P.
FIG. 6C is a perspective view of a triple wall corrugated medium used for the support unit and the internal brace elements of FIGS. 5A-5P.

DETAILED DESCRIPTION OF THE DRAWINGS AND PREFERRED EMBODIMENTS

The preferred shipping and display system 10, as shown in FIG. 1, includes a base 12, a pallet 14, and an advertising element 16, such as a sleeve or decals. Product containers 18, for example boxes containing products to be shipped and sold to a retailer, may be stacked in single or multiple layers on top of base 12 and secured to base 12 for shipping to the retailer. The product containers 18 may be secured to the base 12 by any means known to those of skill in the art. For example, the product containers 18 may be secured to the base 12 by means of shrink wrap, stretch wrap or other like material. The shipping and display system 10 then may be loaded onto a vehicle and shipped to the retailer for display and sale of the products.
Base 12 may include a plurality of corrugated fiberboard support units 20, as shown in FIG. 2. Base 12 includes at least two and preferably four support units 20. The support units 20 may be secured together to form base 12. Support units 20 may be secured to each other by any means including adhesive, ultrasonic bonding, staples, tape or the like. As shown in FIG. 3, support units 20 may be secured to form base 12 by a securing wrap 22 that is placed at least around the outer perimeter of the support units 20. The securing wrap 22 also may be placed over at least the top edges 24 of the base 12 as shown in FIG. 3. The securing wrap 22 also may be placed over at least the bottom edges of base 12 or may merely surround the perimeter of base 12. The securing wrap 22 may be sealed or attached to the base 12 by adhesive, or other known means of securement such as staples, ultrasonic bonds, tape, or the like. The securing wrap 22 may also be shrink-wrap, stretch wrap, or a pre-made sleeve of material constructed to the dimensions of the combined support units. If the support units 20 are secured by alternative means, securing wrap 22 may not be necessary.
Support units 20 may be corrugated fiberboard boxes of identical dimensions. Differently sized support units are also contemplated. As shown in FIG. 2, support units 20 may be sized such that the surface area covered by the combined units is substantially equal to the surface area of a standard sized pallet of about 48 inches by 40 inches. For example, the outside dimensions of each of the units 20 may be from about 15 to about 30 inches in length, from about 15 to about 30 inches in width, and from about 20 to about 25 inches in height. In another example, the units may be from about 20 to about 25 inches in width, from about 20 to about 25 inches in length, and from about 20 to about 25 inches in height. The support units 20 are not intended to contain any product or other saleable item. As shown in FIG. 2, the support units 20 may be sealed empty, as shown in FIG. 4, and then secured together to form base 12.
The support units 20 may be of any geometric shape. For example, support units 20 may be square or rectangular, though other geometric shapes such as triangles may be used to form bases of unique shapes. For example, five triangular support units could be used to form a pentagonally shaped base, six triangular support units could be combined to form a hexagon or other desired configuration.
As shown in FIGS. 2 and 4, each of the support units 20 may include a floor 26, cover flaps 28, side walls 30, and at least one internal brace element 32. Internal brace element 32 may be of any configuration and positioned in the interior of each support unit 20. The internal brace element 32 may include one or more walls along the interior perimeter of the unit 20 and/or walls dividing the interior of the support unit 20 into one or more compartments. For example, a single wall may comprise the internal brace element 32 and may bisect the interior of the support unit 20 into two separate compartments. As shown in FIG. 5N, a single diagonal element may bisect support unit 20 into two triangular compartments. Alternatively, a single horizontal or vertical element may bisect the interior of the support unit into two square or rectangular components. As shown in FIGS. 5B, 5C, 5J, 5K, 5M, 5O and 5P, internal brace elements 32 comprising multiple members may divide the interior of the unit into several interior compartments. Other configurations are also contemplated.
Internal brace element 32 may include one or more members that are co-extensive with the internal perimeter of the support unit 20. For example, as shown in FIGS. 5A, 5E, 5F, 5G, 5H, 5I, 5L and 5P, the internal brace element 32 may include one or more members that are each co-extensive with an internal side wall 30 of the support unit 20. For example, as shown in FIGS. 5A, 5H, 5L and 5P, the internal brace element 32 may include four members that are co-extensive with the four internal side walls 30 of a support unit 20. Additional members, as shown throughout the Figures, may divide the interior of the support unit 20 into compartments. The walls of the internal brace element 32 may be a single piece of corrugated fiberboard that is folded into the desired configuration, or the internal brace element may be separate pieces. For example, as shown in FIGS. 5E and 5I, the internal brace element may be a single sheet of corrugated fiberboard folded into the shape of the letter “Z.” As shown in FIG. 4, the internal brace element may be a single corrugated fiberboard sheet folded into a rectangle with a central divider separating the rectangle into two equal smaller rectangles. As shown in FIGS. 5A-5P, various configurations for the internal brace element are contemplated.
Side walls 30 and internal brace element 32 of the support units 20 may distribute the weight of product cases 18 and additional shipping and display systems 10 placed upon base 12 to prevent collapsing of the shipping and display system 10 in transit or while in use as a display unit. In this way, multiple layers of product cases can be placed on top of base 12 and additional shipping and display systems may be placed on top of each other.
As shown in FIG. 4, support units 20 may include one or more cover flaps 28. For example, each unit 20 may include at least one or more cover flaps that are adjacent a top edge 34 of side wall 30 of the support unit 20. Cover flaps 28 may be folded at 90° relative to an external side wall 30 over the top opening of the support unit 20 and sealed. In one example, the cover may comprise a single flap. Alternatively, the cover may comprise a separate lid for each individual support unit 20 or for the entire base 12.
Support units 20 may be made of any suitable material. Support units 20 may be made of corrugated fiberboard having a top-to-bottom crush resistance, as measured by the Edge Crush Test (ECT value), in the range of from about 23 ECT to about 82 ECT, and for example from about 32 ECT to about 61 ECT. Preferably, support units 20 may be made of corrugated fiberboard having a top-to-bottom crush resistance, as measured by the Edge Crush Test (ECT value), in the range of from about 40 ECT to about 55 ECT, for example 44 ECT.
The Edge Crust Test provides a measure of the compression resistance (the stacking strength) of corrugated fiberboard, and is expressed in terms of pounds of force required to cause a dynamic failure in fiberboard. ECT is the edgewise compressive strength, parallel to the flutes of a short column of corrugated fiberboard. Test results are reported as the pound-force per inch required to cause compressive failure. As used herein, ECT correlates directly to support unit compression strength.
The compression strength of a corrugated fiberboard unit may be predicted by the McKee formula:
C=5.87 Pm·{square root}{square root over (h)}{square root}{square root over (z)}
where C is the top to bottom compression strength,

- Pm is the ECT value,
- h is the fiberboard caliper, and
- z is the unit perimeter (2L×2W).

In one embodiment, the support units 20 according to the present invention are made of corrugated fiberboard having an ECT value of 32 or greater, and more preferably of 40 or greater. The support unit side walls 30 and the internal brace element 32 may be constructed of corrugated fiberboard having the same ECT value or the ECT values may be different as long as the ECT value for each is at least 23.
The corrugated fiberboard may be or single, double or triple wall fiberboard, and may be A, B, C, E or F-fluted or any combination thereof. The type of fiberboard is defined by its corrugated medium and how many layers are present. The corrugated medium is the paperboard that is used in forming the fluted portion of the fiberboard. A “flute” is one of the “waves” or “arch” shapes formed in the corrugated medium. The letters of the fluted corrugated medium define the type of material, in terms of the number of corrugations per unit length and height.
A-fluted corrugated medium has the highest flute size and 36 flutes to the foot. B-fluted corrugated medium has lower arch heights than A-fluted corrugated medium and 50 flutes to the foot. C-fluted corrugated medium is thinner than A-fluted corrugated medium, but thicker than B-fluted corrugated medium, and has 42 flutes to the foot. E-fluted corrugated medium has the greatest number of flutes per foot at 94 and is thinner than C-fluted corrugated medium. F-fluted corrugated medium has half the thickness of E-fluted corrugated medium.
As shown in FIG. 6A, single wall fiberboard consists of a corrugated medium with a linerboard facing adhered to both sides. As shown in FIG. 6B, double wall fiberboard consists of two corrugated mediums with a linerboard facing adhered between them and to both sides. As shown in FIG. 6C, triple wall corrugated fiberboard consists of three corrugated mediums and four linerboard facings.
Suitable corrugated medium for construction of the corrugated fiberboards include A, B, C, E and F-fluted corrugated medium, and any combination thereof, and may be single wall, double wall, triple wall, and combinations thereof. Suitable corrugated fiberboard constructions are shown at FIGS. 6A-C.
The thickness of corrugated fiberboard is described as its caliper and is the thickness of the linerboard and the corrugated medium expressed in terms of thousandths of an inch. A “point” of caliper is one-thousandth of an inch. The caliper of the corrugated fiberboard suitable for use with the support units 20 ranges from about 0.06 inches to about 0.45 inches, preferably from about 0.12 to about 0.26 inches, and more preferably about 0.15 to about 0.20 inches. For example, the caliper of the fiberboard is from about 0.16 to 0.18 inches. In one embodiment, the corrugated fiberboard is single wall, C-flute corrugated fiberboard and has a caliper of about 0.17 inches. Suitable corrugated fiberboard is commercially available from Green Bay Packaging, Green Bay, Wis.
The support units 20 each may have a total compression strength of from about 500 lbs to greater than 3000 lbs. For example, the support units 20 each may have a compression strength of at least 750 lbs. In one embodiment, the support units 20 each have a total compression strength of at least 1000 lbs, and preferably of at least 1500 lbs, and more preferably of at least 2000 lbs. In a preferred embodiment, the support unit 20 may have a total compression strength greater than about 3000 lbs. A support unit 20 may support from about 100 lbs to greater than about 1200 lbs per square foot of top surface area of the support unit. For example, a support unit 20 may support at least 150 lbs per square foot of top surface area of the support unit 20 without collapsing and, preferably at least 200 lbs per square foot of top surface area of the support unit 20 without collapsing. In one embodiment, the support unit 20 may support at least 300 lbs per square foot of top surface area of the support unit 20 without collapsing, and for example, at least 400 lbs per square foot of top surface area of the support unit 20 without collapsing.
The internal brace element 32 may have a total compression strength of from about 100 lbs to about 1200 lbs. For example, the internal brace element may have a total compression strength of at least 150 lbs, and preferably of at least 200 lbs. In another example, the internal brace element 32 may have a total compression strength of at least 250 lbs. In a preferred embodiment, the internal brace element 32 may have a total compression strength of at least 300 lbs. In yet another embodiment, the total compression strength of the internal brace 32 may be at least 400 lbs.
Base 12 may have a total compression strength of at least about 1500 lbs and preferably at least 2000 lbs. In one embodiment, the base 12 may have a total compression strength of at least 3000 lbs, and preferably at least 4000 lbs. In one embodiment, the base 12 may have a total compression strength of greater than 6000 lbs. In a preferred embodiment, base 12 may support at least 750 lbs of product containers, and a second palleted base supporting an additional at least 750 lbs of product containers without collapsing. Base 12 may have a compression strength at least 100 lbs per square foot of top surface area of the base 12, for example, base 12 a compression strength at least 150 lbs per square foot of top surface area of the base 12. In one embodiment, base 12 may have a compression strength at least 200 lbs per square foot of top surface area of the base 12.
The support structure of the present invention may include, in addition to the securing wrap 22, an advertising element 16, such as an additional wrap or sleeve, as shown in FIG. 1, upon which advertising material may be placed. Alternatively, the securing wrap 22 may constitute the advertising element by having advertising material printed directly thereon. The advertising element 16 may fully or only partially surround the base 12. The advertising element 16 may be secured to the base 12 by any known means, including by adhesive, staples, shrink wrap, stretch wrap, tape or the like. Alternatively, advertising element 16 may slide over the support boxes in a replaceable sleeve-like manner. In this way, base 12 can be re-used for different products or products from different vendors.
In use, base 12, once assembled, is placed upon a pallet 14 and one or more layers of product cases containing the product to be shipped and displayed may be placed on top of base 12 and secured thereto by shrink wrap, stretch wrap, corrugated wrap or other known material. The completed shipping and display system 10 then may be loaded unto a delivery vehicle and delivered to a retailer. Upon arrival, the unit may be placed directly on the sales floor, unwrapped and product cases opened for sale.
As the product supply from the cases placed on the base 12 is depleted, further cases of product can be placed on the unit. In this way, packages of product are easily accessible to the customer and additional products are easily stocked atop the support base by the retailer once the original product cases are depleted of product. As a result, this display prevents the problem of older, dated products remaining at the bottom of the display while newer products are placed on top and sold first.
The support base may be used multiple times for the same or different products to be displayed and sold. When the base is no longer needed or is to be replaced by a new base, the base can easily be dismantled, flattened and disposed of.

EXAMPLE 1

An internal brace element, as shown in FIG. 5A, comprising single wall, C-fluted, 44 ECT fiber board and having four side walls and a central divider were tested for compression strength by the Compression Test Procedure by ASTM Standard D 642. The side walls of the internal brace element had dimensions of 22-⅜″ L×18-½″ W×23-¼″ H. The divider was 18-{fraction (5/16)}″ in length. The internal brace element was placed between upper and lower platens of the test machine. The lower platen was raised to bring both platens in contact with the specimen and an initial pressure or pre-load 50 lbs/ft was applied. Pressure was increased in a continuous manner until failure of the structure (collapse) occurred. The maximum load was recorded at 1150 lbs.

EXAMPLE 2

A support unit having an internal brace element, as shown in FIG. 4, comprising single wall, c-fluted, 44 ECT fiber board was tested for compression strength by the Compression Test Procedure by ASTM Standard D 642. The support unit had dimensions of 23-{fraction (1/16)}″ L×19-⅛″ W×23-⅞″ H. The internal brace element had four side walls co-extensive with the internal perimeter of the unit and a central divider separating the interior of the unit into two equal compartments. The side walls of the internal brace element had dimensions of 22-⅜″ L×18-½″ W×23-¼″ H. The divider was 18-{fraction (5/16)}″ in length. The support unit was placed between upper and lower platens of the test machine. The lower platen was raised to bring both platens in contact with the specimen and an initial pressure or pre-load 50 lbs/ft was applied. Pressure was increased in a continuous manner until failure of the unit (collapse) occurred. The maximum load was recorded at 2010 lbs.

EXAMPLE 3

A base comprising four support units as described in Example 2 above, and as shown in FIG. 3, was tested for compression strength by the Compression Test Procedure by ASTM Standard D 642 as described above. The base included a securing wrap secured to the outer perimeter of the base. The base had dimensions of 46-⅜″ L×38-{fraction (9/16)}″ W×23-¾″ H. The maximum load was recorded at 6000 lbs.
The above examples are exemplary and presented for purposes of illustration only. These examples are not intended in any limiting sense.
While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

Claims

1. A light-weight, disposable base for use in a product shipping and display system, said base comprising at least two corrugated fiberboard support units each having at least one corrugated fiberboard internal brace element, where the total compression strength of the base is at least about 1500 lbs, and the compression strength of the base is at least 100 lbs per square foot of top surface area of the base.

2. The base of claim 1 where the total compression strength of the base is at least about 2000 lbs.

3. The base of claim 2 where the total compression strength of the base is at least about 3000 lbs.

4. The base of claim 1 wherein the compression strength of the base is at least 150 per square foot of top surface area of the base.

5. The base of claim 4 wherein the compression strength of the base is at least 200 per square foot of top surface area of the base.

6. The base of claim 1 where the compression strength of each support unit is at least about 100 lbs per square foot of top surface area of the support unit.

7. The base of claim 6 where the compression strength of each support unit is at least about 200 lbs per square foot of top surface area of the support unit.

8. The base of claim 7 where the compression strength of each support unit is at least about 300 lbs per square foot of top surface area of the support unit.

9. The base of claim 1 where the total compression strength of the brace element is from about 100 lbs to about 1200 lbs.

10. The base of claim 1 wherein the base comprises four corrugated fiberboard support units of substantially identical dimensions.

11. The base of claim 1 where the corrugated fiberboard has an ECT of at least 32.

12. The base of claim 1 where the corrugated fiberboard has an ECT of at least 40.

13. The base of claim 1 where the corrugated fiberboard has an ECT of at least 44.

14. The support unit of claim 1 where the internal brace element comprises a plurality of brace members.

15. The support unit of claim 14 where internal brace element comprises at least one brace member that is co-extensive with at least one support unit side wall.

16. The support structure of claim 15 where the internal brace element further comprises at least one brace member that divides the interior of the support unit.

17. The support unit of claim 16 wherein the internal brace element comprises four members that are each co-extensive with an internal side wall of the support unit and at least one member that divides the interior of the support unit into at least two compartments.

18. The base of claim 11 where the support units comprise corrugated fiberboard selected from the group consisting of A, B, C, E or F-fluted corrugated fiberboard and combinations thereof.

19. The base of claim 18 where the support units comprise corrugated fiberboard selected from the group consisting of single-wall, double-wall or triple wall corrugated fiberboard and combinations thereof.

20. The base of claim 18 where the support units comprise C-fluted, single-wall corrugated fiberboard.

21. A system for shipping and displaying products comprising:

a) a pallet,

b) a base, and

c) at least one product container secured to the base,

d) where the base comprises at least two adjacent non-product containing corrugated fiberboard support units, each support unit having an internal brace element within the support unit and a compression strength of at least 150 lbs per square foot of top surface area the support unit.

22. The system of claim 21 where the base has a total compression strength of at least 2000 lbs.

23. The system of claim 21 where the base has a total compression strength of at least 3000 lbs

24. A light-weight, disposable structure for use in a product shipping and display system, said structure comprising four non-product containing corrugated fiberboard support units each having at least one corrugated fiberboard internal brace element, where the support units have been secured to one another to form the structure, and where the structure will support at least 3000 lbs without collapsing.

25. The structure of claim 24 where the structure will support at least 4000 lbs without collapsing.

26. The structure of claim 24 where the structure will support at least 5000 lbs without collapsing.

27. The structure of claim 24 where the structure will support about 6000 lbs without collapsing.

28. A product shipping and display system comprising:

a) a first shipping and display unit comprising:

i) a first pallet,

ii) a first corrugated corrugated fiberboard base placed on the pallet,

iii) a plurality of product containers placed on and secured to a top surface of the base, and

b) a second shipping and display unit comprising:

i) a second pallet placed on the product containers,

ii) a second corrugated corrugated fiberboard base placed on the second pallet, and

iii) a second plurality of product containers placed on and secured to a top surface of the second base,

c) wherein the first and second bases comprise a plurality of substantially empty corrugated fiberboard support units each having an internal brace element and a compression strength of at least 150 lbs per square foot of the top surface of each support unit, and where the first shipping and display unit supports the second shipping and display unit during transit of the units without collapsing.

29. A method of shipping consumer products comprising:

a) securing at least two substantially empty corrugated corrugated fiberboard support units each having an internal brace element to one another to form a base;

b) placing the base onto a pallet;

c) placing at least one layer of product containing units onto the base;

d) securing the product containing units to the base to form a combined pallet, base and product container shipping unit; and

e) shipping the shipping unit to a merchandiser.

30. The method of claim 29 comprising placing a second shipping unit on top of the first shipping unit.