U.S. patent application number 09/748874 was filed with the patent office on 2002-06-27 for prevention of loss of produce transported in flats.
Invention is credited to Biddle, James R..
Application Number | 20020079358 09/748874 |
Document ID | / |
Family ID | 25011293 |
Filed Date | 2002-06-27 |
United States Patent
Application |
20020079358 |
Kind Code |
A1 |
Biddle, James R. |
June 27, 2002 |
Prevention of loss of produce transported in flats
Abstract
A protective cover for preventing loss of produce from
open-topped cardboard flats during transport comprises a flexible
sheet of paper coated with a moisture-resistant layer. The sheet
has flaps with adhesive strips which may be affixed to sides of the
flat after stretching the sheet over the open part of the flat. The
protective covers are supplied in stacks, mounted on a rod, and may
be torn off one by one. In one embodiment the sheet is supplied in
a folded condition in which the moisture-resistant layer also
serves as a release layer temporarily covering the adhesive strips.
In another embodiment, the adhesive strips on all but one layer in
the stack are protected by the moisture-resistant layer of a next
sheet in the stack. In a third embodiment, the adhesive strips are
protected by peelable release liners.
Inventors: |
Biddle, James R.; (Blue
Bell, PA) |
Correspondence
Address: |
HOWSON AND HOWSON
Spring House Corporate Center
P.O. Box 457
Spring House
PA
19477
US
|
Family ID: |
25011293 |
Appl. No.: |
09/748874 |
Filed: |
December 27, 2000 |
Current U.S.
Class: |
229/125.19 ;
229/125.33; 53/397 |
Current CPC
Class: |
B65D 5/64 20130101; B65D
5/42 20130101 |
Class at
Publication: |
229/125.19 ;
53/397; 229/125.33 |
International
Class: |
B65D 043/02 |
Claims
I claim:
1. A protective cover for preventing loss of produce during
transport, wherein plural packages, each containing multiple units
of produce, are contained in a cardboard flat having a bottom and
four sides and having an at least partially open top, the cover
comprising: a flexible sheet capable of being disposed in a plane,
and, when disposed in said plane, comprising a central section
having two ends and a pair of flaps extending in opposite
directions from the ends of the central section; the flexible sheet
comprising a layer of paper having first and second opposite faces,
and having strips of self-sticking adhesive on the first face, the
strips of adhesive being disposed on the flaps; whereby the
protective cover can be affixed to a flat by positioning its
central section over the at least partially open top of a flat,
with the moisture-resistant coating facing the contents of the
flat, and securing the flaps to two of the four sides of the flat
by means of the self-sticking adhesive strips.
2. A protective cover according to claim 1, in which the central
section has substantially parallel side edges each extending from
one of said two ends to the other, the spacing of the side edges
from each other defining a width of the central section.
3. A protective cover according to claim 1, in which the central
section has substantially parallel side edges each extending from
one of said two ends to the other, the spacing of the side edges
from each other defining a width of the central section, and in
which the flaps are narrower than the central section.
4. A protective cover according to claim 1, in which the paper
layer has a moisture-resistant coating on the first face.
5. A protective cover according to claim 1, in which the central
section has substantially parallel side edges each extending from
one of said two ends to the other, the spacing of the side edges
from each other defining a width of the central section, and in
which the flaps are narrower than the central section, and in which
said sheet is substantially symmetrical about an imaginary line,
parallel to, and located midway between, said parallel side edges
of the central section.
6. A protective cover according to claim 1, in which the central
section has substantially parallel side edges each extending from
one of said two ends to the other, the spacing of the side edges
from each other defining a width of the central section, in which
the flaps are narrower than the central section, and in which the
sheet also comprises a pair of tapered sections, each said tapered
section connecting one of said flaps to the central section.
7. A protective cover according to claim 1, in which the paper
layer has a moisture-resistant coating on the first face, in which
said moisture-resistant coating covers substantially the entire
area of the first face of the layer of paper, and in which the
strips of adhesive overlie parts of the moisture-resistant
coating.
8. A protective cover according to claim 1, in which the paper
layer has a moisture-resistant coating on the first face, and in
which said moisture-resistant coating covers substantially the
entire area of the first face of the layer of paper except for
those areas covered by the moisture-resistant coating.
9. A protective cover according to claim 1, in which the paper
layer has a moisture-resistant coating on the first face, and in
which said sheet is folded on itself, along a first pair of
parallel creases in the central section thereof, in directions such
that the second face is inside each fold at said creases of the
first pair, and in which said sheet is also folded on itself along
a second pair of parallel creases such that the first face is
inside each fold at said creases of the second pair, the creases
being positioned so that the adhesive strips on said first face are
directly opposed to, and in contact with, the moisture-resistant
coating on the first face, whereby the moisture-resistant coating
serves as a release layer allowing the protective cover to be
unfolded and brought to a stretched condition by manually pulling
on said flaps.
10. A protective cover according to claim 9, in a stack of
protective covers, in which all of the protective covers in the
stack are substantially identical to one another.
11. A protective cover according to claim 9, in a stack of
protective covers, in which all of the protective covers in the
stack are substantially identical to one another, each protective
cover having a punched hole adjacent to one of its side edges, and
the punched holes of all of the protective covers in the stack
being aligned with one another.
12. A protective cover according to claim 1, in which the paper
layer has a moisture-resistant coating on the first face, in which
said sheet is folded on itself, along a first pair of parallel
creases in the central section thereof, in directions such that the
second face is inside each fold at said creases of the first pair,
and in which said sheet is also folded on itself along a second
pair of parallel creases such that the first face is inside each
fold at said creases of the second pair, the creases being
positioned so that the adhesive strips on said first face are
directly opposed to, and in contact with, the moisture-resistant
coating on the first face and so that the flaps extend beyond the
creases of the first pair, whereby the moisture-resistant coating
serves as a release layer allowing the protective cover to be
unfolded and brought to a stretched condition by manually pulling
on said flaps.
13. A protective cover according to claim 12, in a stack of
protective covers, in which all of the protective covers in the
stack are substantially identical to one another.
14. A protective cover according to claim 12, in a stack of
protective covers, in which all of the protective covers in the
stack are substantially identical to one another, each protective
cover having a punched hole adjacent to one of its side edges, and
the punched holes of all of the protective covers in the stack
being aligned with one another.
15. A protective cover according to claim 1, having a release layer
on the second face, the release layer being in two sections, one
opposite each adhesive strip.
16. A protective cover according to claim 15, in a stack of
protective covers, in which all of the protective covers in the
stack are substantially identical to one another, and in which each
adhesive strip on all but one of protective covers is in contact
with a release layer section on an adjacent protective cover.
17. A protective cover according to claim 16, each protective cover
having a punched hole in one of its flaps adjacent to an edge
thereof, and the punched holes of all of the protective covers in
the stack being aligned with one another.
18. A protective cover according to claim 1 in combination with a
produce flat having a bottom, four sides, an at least partially
open top, and plural packages, each containing multiple units of
produce, contained in said flat and exposed through said at least
partially open top, the protective cover having its central section
overlying at least part of said exposed packages, and having its
flaps secured to two opposed sides of said four sides of the
flat.
19. A protective cover according to claim 1 in combination with a
produce flat having a bottom, four sides, an at least partially
open top, and plural packages, each containing multiple units of
produce, contained in said flat and exposed through said at least
partially open top, the protective cover having its central section
overlying at least part of each of said exposed packages, and
having its flaps secured to two opposed sides of said four sides of
the flat.
20. A protective cover according to claim 1, in a stack of
protective covers, in which all of the protective covers in the
stack are substantially identical to one another, a flap of each
protective cover in the stack has a perforation line extending
parallel, and in spaced relation, to an edge thereof remote from
the central section, the portion of each flap between the
perforation line and said remote edge thereof having a punched
mounting hole, the mounting holes of all of the protective covers
in the stack being aligned with one another, and the said remote
edges of the flaps being secured together by a layer of glue,
whereby the protective covers of the stack form a tablet from which
an individual protective cover can be removed by tearing along its
perforation line.
21. A protective cover according to claim 1, in which each strip of
self-sticking adhesive is covered by a peelable release liner
having a width substantially greater than the width of the release
liner which it covers, whereby the release liner can be grasped
easily for removal.
22. A method for preventing loss of produce during transport,
wherein plural packages, each containing multiple units of produce,
are contained in a cardboard flat having a bottom and four sides
and having an at least partially open top, the method comprising:
removing a single flexible sheet from a stack of flexible sheets,
each having a central section and a pair of flaps extending
laterally from the central section, and exposing a self-sticking
adhesive strip on each flap; stretching said removed flexible sheet
over the at least partially open top of the flat; and securing the
flaps to two opposed sides of said four sides of the flat by means
of said self-sticking adhesive strips.
23. The method of claim 22, in which the self-sticking adhesive
strip on each flap of said single flexible sheet is initially
protected by a release layer area on a next adjacent flexible sheet
in the stack, and exposed by removing the single flexible sheet
from the stack.
24. The method of claim 22, in which the single flexible sheet is
folded when in the stack, and the self-sticking adhesive strip on
each flap of said single flexible sheet is initially protected by
virtue of contact with a moisture-resistant release layer formed on
said single, flexible sheet, and is exposed by pulling the flaps
apart from each other, thereby unfolding the sheet following
removal of the single flexible sheet from the stack.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to the field of packaging, and
particularly to a novel temporary cover for containers known as
"flats," used in the transportation of produce articles such as
blueberries, strawberries, cherry tomatoes and the like.
[0002] Relatively small items of produce, such as berries, cherry
tomatoes, etc. are typically sold to the consumer in plastics
containers each holding multiple units, usually measured in terms
of weight, e.g. 1/2 pound, 1 pound, etc. The plastics containers
may be in the form of baskets having film covers, or blow-molded,
transparent containers having hinged lids which snap closed. These
containers are transported from a food distribution warehouse to
food retailers in flats, which are cardboard boxes having a bottom
and four sides.
[0003] The tops of the flats are ordinarily at least partially
open. Some flats, for example those used to ship cherry tomatoes,
are relatively shallow and entirely open at the top. On the other
hand, flats used for shipping blueberries typically have flanges
which extend from their end walls and overlie part of the contents.
The top opening between the flanges may extend downward into the
sidewalls. The openings make it easy for retail store personnel to
remove containers from the flats for placement on shelves, and of
course also reduce costs by eliminating unnecessary material in the
flats. The flanges, on the other hand, enable the flats to be
placed one on top of another without causing damage to the
contents.
[0004] At the warehouse, flats are typically loaded into large
trailers, and may be stacked one on top of another. During
transport, the contents of each flat except for the uppermost flat
in a stack are held in place by the flat or flats above them. The
contents of the uppermost flat, however, are not similarly
protected, and it is common for blow molded containers to bounce
out of the flats in which they are situated. It is also common for
the lids of blow-molded containers to snap open when the containers
are jarred or dropped, causing the contents to spill. Damage to, or
loss of, the contents of other types of containers can also occur
if they bounce out of their flats during transport. Spillage of
produce in this manner, during transport from the warehouse to the
retailer results in significant monetary losses to the
wholesaler.
[0005] A retailer often has occasion to return flats of produce
previously ordered, and is customarily given credit for intact
flats returned. However, as the trailer generally carries a much
lighter load on its way back to the warehouse. Because of the
reduced load, the trailer tends to be more susceptible to bouncing
during the return trip, and consequently there is an even greater
likelihood of loss in the case of returns. If the flat is not
returned with all of its contents intact, the retailer typically
does not receive credit for the returned goods.
[0006] The wholesaler receives flats from a centrally located
produce market in flats on skids. The flats on each skid are
covered with stretch wrap, and consequently it is rare that the
wholesaler will undergo any loss while receiving the produce.
Significant losses, however, occur later in the distribution
process.
[0007] After the wholesaler receives the skids, the stretch wrap is
cut open and the skids are sent to distribution shelves at
different locations in the warehouse. At the warehouse, a forklift
driver loads various orders into a tractor trailer, on skids.
Usually, one or more skids are designated for a specific retail
store. A single skid will not ordinarily have two different
locations assigned to it. Thus, a partially loaded skid may be sent
to a particular retail store. Typically, items less susceptible to
damage are placed on the skid first. More fragile items such as
berries, cherry tomatoes, etc. are placed on top of other
items.
[0008] The flats containing berries, cherry tomatoes, etc. are open
at the top. In the peak season there can be as many as five or six
layers of berry containers in one flat. Therefore, when the
berries, etc. are being transported to the retailer, spillage can
occur. The containers in the flats tend to pop open when the flats
are jarred during transport. When this occurs, the berries bounce
out of the containers. The flats may also slip off their stacks and
fall, again causing containers to pop open.
[0009] During the peak season, a single flat of strawberries might
cost the wholesaler $17.50, and might be sold to a retailer for
$24.00. If some of the berries on the flat are damaged on the way
to the retailer, the flat may be sent back to the wholesaler. The
wholesaler would then throw out the entire flat and take a loss of
at least $17.50. In the off season a similar flat of strawberries
might cost the wholesaler $40.00 to $45.00, and might be sold to
the retailer for about $53.00. Thus, damage even to a part of the
contents of a flat will result in a loss to the wholesaler which,
on the average is well in excess of $17.50. In a given year, a
single, warehouse of medium size may undergo a loss in the vicinity
of $250,000.00 resulting solely to the rejection of flats due to
spillage in transport.
[0010] The retailer may also undergo losses due to spillage in
transport. For example, a retailer might orders 28 flats of
strawberries and actually need only 22 flats. In this situation,
referred to in the trade as a "mispick," the retailer will send the
excess flats back to the wholesaler. These flats, riding on the
floor of a partially empty tractor-trailer on its way back to the
warehouse, sometimes with intermediate delivery stops, are
particularly susceptible to damage. They are often completely
destroyed by the time they reach the warehouse. The destroyed flats
cannot be used, and are thrown out. The retailer bears the cost of
loss due to mispicks.
[0011] In practice, if six flats are returned, there is a high
likelihood that all six flats will be thrown out. If the retailer
was charged $32.50 per flat, for example, the retailer's loss would
amount to $195.00.
SUMMARY OF THE INVENTION
[0012] It can readily be seen that the losses to wholesalers and
retailers due to spillage of small produce items amount to millions
of dollars per year nationwide. An important object of this
invention, therefore, is to reduce losses due to spillage of
packaged produce. An object of the invention is also to provide a
simple, inexpensive, and easily used temporary flat cover to
prevent spillage.
[0013] The protective cover in accordance with the invention is
designed for preventing loss of produce during transport, where
plural packages, each containing multiple units of produce, are
contained in a cardboard flat having a bottom and four sides and
having an at least partially open top. The protective cover
comprises a flexible sheet capable of being disposed in a plane.
When so disposed, the flexible sheet comprises a central section
having two ends and substantially parallel side edges each
extending from one of the two ends to the other. The spacing of the
side edges from each other defines the width of the central
section. The sheet also comprises a pair of flaps extending in
opposite directions from the ends of the central section when the
sheet is disposed in a plane. The flaps are preferably narrower
than the central section.
[0014] The flexible sheet is composed of a layer of paper having
first and second opposite faces. The paper layer may have a
moisture-resistant coating on the first face covering at least a
major part of the area of the central section, and strips of
self-sticking adhesive also on the first face, the strips of
adhesive being disposed on the flaps. The protective cover can be
affixed to a flat by positioning its central section over the at
least partially open top of a flat, with the moisture-resistant
coating facing the contents of the flat, and securing the flaps to
two of the four sides of the flat by means of the self-sticking
adhesive strips.
[0015] Preferably, the sheet is substantially symmetrical about an
imaginary line, parallel to, and located midway between, said
parallel side edges of the central section.
[0016] The sheet also preferably comprises a pair of tapered
sections, each connecting one of the flaps to the central section
while minimizing the risk of tearing when the flaps are grasped and
pulled away from each other, either to unfold the sheet or to
stretch the sheet before securing it to a produce flat.
[0017] The moisture-resistant coating may cover substantially the
entire area of the first face of the layer of paper, with the
strips of adhesive overlying parts of the moisture-resistant
coating. Alternatively, the moisture-resistant coating may cover
substantially the entire area of the first face of the layer of
paper except for those areas covered by the adhesive.
[0018] In a first major embodiment of the invention, the sheet is
folded on itself, along a first pair of parallel creases in the
central section thereof, in directions such that the second face is
inside each fold at the creases. The sheet is also folded on itself
along a second pair of parallel creases such that the first face is
inside each fold at the creases of the second pair. The creases are
positioned so that the adhesive strips on the first face are
directly opposed to, and in contact with, the moisture-resistant
coating on the first face, and preferably so that the flaps extend
beyond the creases of the first pair. The moisture-resistant
coating serves as a release layer allowing the protective cover to
be unfolded and brought to a stretched condition by manually
pulling on the flaps.
[0019] The protective may be supplied as one protective cover in a
stack of substantially identical protective covers, each having a
punched hole adjacent to one of its side edges, and the punched
holes of all of the protective covers in the stack being aligned
with one another.
[0020] In a second major embodiment, the protective cover has a
release layer on its second face, the release layer being in two
sections, one opposite each adhesive strip. When the protective
covers of the second major embodiment are supplied in a stack of
substantially identical protective covers, each adhesive strip on
all but one of protective covers is in contact with a release layer
section on an adjacent protective cover. The protective covers can
then be supplied in an unfolded condition. In this case, each
protective cover preferably has a punched hole in one of its flaps
adjacent to an edge thereof, and the punched holes of all of the
protective covers in the stack are aligned with one another.
[0021] When secured to a produce flat having a bottom, four sides,
an at least partially open top, and plural packages, each
containing multiple units of produce, contained therein and exposed
through the at least partially open top, the protective cover has
its central section overlying at least part of the exposed packages
and preferably at least part of each of the exposed packages. Its
flaps are secured to two opposed sides of the four sides of the
flat.
[0022] The invention also resides in a novel method for preventing
loss of produce during transport, wherein plural packages, each
containing multiple units of produce, are contained in a cardboard
flat having a bottom and four sides and having an at least
partially open top, the method comprising: removing a single
flexible sheet from a stack of flexible sheets, each having a
central section and a pair of flaps extending laterally from the
central section, and exposing a self-sticking adhesive strip on
each flap; stretching the removed flexible sheet over the at least
partially open top of the flat; and securing the flaps to two
opposed sides of the four sides of the flat by means of the
self-sticking adhesive strips.
[0023] The self-sticking adhesive strip on each flap of said single
flexible sheet is initially protected by a release layer area on a
next adjacent flexible sheet in the stack, and exposed by removing
the single flexible sheet from the stack.
[0024] Alternatively, the single flexible sheet may be folded when
in the stack, and the self-sticking adhesive strip on each flap of
said single flexible sheet may be initially protected by virtue of
contact with a moisture-resistant release layer formed on said
single, flexible sheet, and exposed by pulling the flaps apart from
each other, thereby unfolding the sheet following removal of the
single flexible sheet from the stack. In still another alternative,
the adhesive strips may be protected by peelable release
liners.
[0025] The invention affords the produce distributor several
important advantages. First, with the protective cover affixed to
each flat being shipped, losses due to spillage of packaged produce
are substantially eliminated, with a resultant increase in profit
both to at the distribution and retail levels. Second, the
protective cover is very inexpensive to produce, so that the saving
achieved by the elimination of spillage far exceeds the cost of the
protective covers. Third, the labor involved in the use of the
protective cover is minimal, and it can be used effectively by
warehouse personnel without the need for extensive training.
[0026] Other objects, details and advantages of the invention will
be apparent from the following detailed description when read in
conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is an elevational view of a protective cover in
accordance with a first embodiment of the invention, showing the
cover in a folded condition, as supplied to the warehouseman;
[0028] FIG. 2 is an elevational view illustrating the process of
unfolding the cover of FIG. 1 for placement on a produce flat;
[0029] FIG. 3 is an exploded, perspective view, showing the
unfolded protective sheet of FIGS. 1 and 2 about to be secured to a
flat;
[0030] FIG. 4 is a perspective view, showing the protective sheet
secured to a flat;
[0031] FIG. 5 is a perspective view showing a supply of protective
sheets, of the kind illustrated in FIG. 1, attached to a post of a
warehouse rack;
[0032] FIG. 6 is an elevational view, partly in section, showing
the manner in which the supply of sheets is attached to the post of
FIG. 5;
[0033] FIG. 7 is a bottom plan view of a protective cover in
accordance with a second embodiment of the invention;
[0034] FIG. 8 is a top plan view of the protective cover of FIG.
7;
[0035] FIG. 9 is a perspective view showing a supply of protective
sheets, of the kind illustrated in FIGS. 7 and 8, attached to a
post of a warehouse rack;
[0036] FIG. 10 is a rear elevation illustrating a protective cover
in accordance with a third embodiment of the invention; and
[0037] FIG. 11 is a perspective view of a supply of protective
sheets of the kind illustrated in FIG. 10.
DETAILED DESCRIPTION
[0038] The protective cover 10 in accordance with a first
embodiment of the invention, as illustrated in FIG. 1, is supplied
in the form of a folded sheet. The sheet has a central section 12
having two substantially parallel, straight line side edges 14 and
16. The central section is folded inwardly on itself at creases 18
and 20, and the substantially parallel side edges continue into the
folded portions of the central section, terminating at points 22,
24, 26 and 28, which define the ends of the central section. From
these points the sheet is tapered inward, having two tapered
sections, one being defined between oblique edges 32 and 34, and
the other being defined between oblique edges 36 and 38.
[0039] The sheet is again folded, this time outward on itself, at
creases 40 and 42, forming outwardly projecting layers. The oblique
edges continue into the outwardly projecting layers, terminating at
points 44, 46, 48 and 50. Creases 40 and 42 are located in close
proximity to each other at intermediate positions in the tapered
sections, approximately at the location of an imaginary line which
is perpendicular to side edges 14 and 16 and about which the sheet
is preferably substantially symmetrical. Flap 52 is defined between
parallel, straight edges 54 and 56 of one of the outwardly
projecting layers, these edges extending from points 44 and 46
respectively. Flap 58 is similarly defined between parallel,
straight edges 60 and 62, which extend from points 48 and 50
respectively.
[0040] The tapered sections allow the flaps to be narrower than the
central section of the sheet without significantly impairing the
strength of the sheet. Thus, the tapered sections minimize the risk
of inadvertently tearing the sheet when the flaps are grasped and
pulled away from each other.
[0041] The sheet is preferably formed from paper having a smooth
polyethylene coating on one face, which will be referred to as the
"bottom face." The polyethylene coating, seen at 64 in FIG. 1,
preferably covers the entire bottom face of the sheet, and serves
as a moisture-resistant barrier, preventing moisture from protected
produce from weakening the paper layer.
[0042] The sheet also has a pair of self-sticking adhesive strips
66 and 68 (see also FIG. 3) disposed on the flaps. The adhesive
material is preferably a double-coated 0.5 mm polyester, permanent
adhesive #603XL. The adhesive is available from
Converter/Specialties, 245 Route 130, Burlington, N..J. 08016 in
the form of a tape, including a layer of adhesive on a release
liner. The edges of adhesive strip 66 are indicated at 70 and 72.
Adhesive strip 68 has similar edges. The moisture-resistant barrier
on the flaps is located between the paper layer and the adhesive
strips.
[0043] As will be apparent from FIG. 1, the moisture-resistant
polyethylene layer on the inwardly folded parts of the central
section is in face-to-face relationship with the adhesive strips,
serving as a release layer, to which the adhesive strips adhere
weakly. As shown in FIG. 1, the outer ends of the flaps are
preferably unglued and project beyond creases 18 and 20, so that
they can be grasped and pulled outward. The release layer allows
the sheet to be unfolded, in the manner depicted in FIG. 2, by
pulling on the flaps.
[0044] A hole 74 is punched in the central section of the sheet
near edge 16. This hole is used for hanging the sheet along with
others in a stack from which individual sheets can be readily
removed. As shown in FIG. 1, the tapering of the tapered sections
ensures that hole 74 is exposed when the sheet is folded, in the
manner depicted in FIG. 1, with creases 40 and 42 in close
proximity to each other. The manner in which a stack of sheets is
hung will be described with reference to FIGS. 5 and 6.
[0045] FIG. 3 shows sheet 10 in its unfolded condition above a flat
75, to which it is about to be attached. The flat is a cardboard
box having a bottom (not shown), four sides, two of which (end wall
76 and side wall 78) are visible in FIG. 3, and a top which is
partly open. Flanges 80 and 82, extend inwardly toward each other
from the end walls, providing reinforcement allowing similar flats
to be stacked one on top of another, for storage and transport.
Tabs 84 project upward from the end walls, and slots 86 are
provided at the lower parts of the end walls. The tabs of one flat
extend into the slots of a next flat in a stack in order to prevent
relative sliding movement of the flats in a stack.
[0046] As mentioned previously, the top of a flat is ordinarily
open except between the flanges 80 and 82. Moreover, top opening
may extend partially into the side walls in order to save material
and to provide easier access to the contents of the flat. For
example, wall 78 has a large notch 88 which serves as an extension
of the top opening.
[0047] The contents of the flat shown in FIG. 3 consist of plural
individual plastics containers 90, containing produce, for example,
blueberries, cherry tomatoes, or the like. These containers may be
arranged in the flat in one or more layers.
[0048] As shown in FIG. 4, the protective sheet 10 is stretched
over the top opening of the flat 75, with its coated bottom facing
the interior of the flat, and with the side edges 14 and 16 of its
central section parallel to the end walls, of the flat. The flaps
extend downward over the outer faces of the side walls and are
secured to the side walls of the flat by the self-sticking adhesive
strips. Thus, as seen in FIG. 4, the flap 58 of protective sheet 10
is secured to side wall 78 of the flat 75. The central part of the
protective sheet preferably, but not necessarily, fits into the
notch 88 and the corresponding notch in the opposite side wall so
that it firmly engages the containers in the flat. The central part
of the protective sheet should be sufficiently wide to engage at
least partially all of the containers in the upper layer of
containers within the flat.
[0049] In a preferred embodiment of the protective cover, the
central section is approximately 33 cm. long (measured in the
longitudinal direction, i.e. the direction of elongation of the
cover when stretched flat) and 27 cm wide. The rectangular parts of
the flaps measure approximately 12 cm in the longitudinal direction
and 19 cm. in width. The tapered sections measure approximately 8
cm. in the longitudinal direction of cover. The adhesive strips are
about 5 cm wide and are spaced from the ends of the flaps by about
5 cm.
[0050] In another, smaller, embodiment, the central section is
approximately 27 cm. long (measured in the longitudinal direction,
i.e. the direction of elongation of the cover when stretched flat)
and 19 cm wide. The rectangular parts of the flaps measure
approximately 7.5 cm in the longitudinal direction and are about 19
cm. in width The tapered sections measure approximately 2.5 cm. in
the longitudinal direction of cover. The adhesive strips are about
3 cm wide and are spaced from the ends of the flaps by about 3
cm.
[0051] Protective covers in these two sizes are capable of
accommodating most of the produce flats presently in use.
[0052] Flats being transported by truck or trailer, are generally
stacked one on top of another on a skid. Flats containing berries,
cherry tomatoes and other small items are usually stacked on top of
other items on a flat. At least the uppermost flat on each skid has
a protective cover affixed to it. Thus, if an uppermost flat in a
stack is dislodged, for example by inertia when the vehicle travels
over a bump in the road, its protective cover will maintain its
contents intact, even if it falls through a considerable distance
and even if it is overturned. If an uppermost flat falls off a
stack, it exposes the next flat as the uppermost flat, which may
also have a protective cover on it. The protective cover on each
exposed uppermost flat protects its contents.
[0053] In the warehouse, the protective covers in their folded
condition as shown in FIG. 1, are preferably supplied in stacks
hung on rods projecting from storage racks. As shown in FIGS. 5 and
6, a storage rack post 90, which is a component of a typical
warehouse storage rack, is provided with a vertically aligned
series of holes 92 on one side and a series of corresponding holes
on the opposite side (not shown). A bolt 94 is located in a
selected pair of corresponding holes, as shown in FIG. 6, and
secured in place with a nut 96, using washers 98. The length of the
bolt should be such that a substantial part of the length of the
bolt projects from the post 90, serving as a mounting rod for the
stack of protective sheets. A wing nut 100, threaded onto the
projecting end 102 of the bolt, holds a stack 104 of folded
protective sheets 10 on the bolt, the bolt extending through
punched holes 74 in the sheet.
[0054] In the process of preparing a flat for shipment, the
warehouseman grasps the frontmost protective cover on the hanging
stack of FIGS. 5 and 6, and pulls it to separate it from the stack,
tearing the hole 74 in the process. He then pulls the flaps, as
shown in FIG. 2, to unfold the protective cover, and places it on
the flat in the manner shown in FIG. 4.
[0055] In the alternative embodiment illustrated in FIGS. 7, 8 and
9, the protective sheet 106 is supplied in flat, unfolded
condition. The coated bottom face of the sheet can be identical to
the coated bottom face of sheet 10 (FIG. 1). Thus, the entire
bottom face of sheet 106 is coated, and self-sticking adhesive
strips 108 and 110 are provided over the coating on flaps 112 and
114.
[0056] On the top face, separate release layers 116 and 118 are
provided on the flaps. These release layers are made slightly wider
than the adhesive strips so that, when the protective sheets 106
are provided in a stack 120 as depicted in FIG. 9, the adhesive
strips of each sheet are engaged with release layers on the next
adjacent sheet. The weak adhesion of the adhesive strips with the
release layers keeps the stack intact so that it can be hung easily
on a warehouse rack post 122, but allows the individual sheets to
be removed easily from the stack for use. In the case of sheets
provided in an unfolded condition, the punched mounting holes 124
are preferably provided adjacent to the center of an end edge of a
flap, so that the stack of sheets will hang in a vertically
elongated condition. A frontmost protective cover is removed from
the hanging stack by pulling on its lower flap, tearing the hole
124 in the upper flap. The protective cover is then affixed to a
flat in the manner shown in FIG. 4.
[0057] In the embodiment depicted in FIGS. 7, 8 and 9, all of the
protective covers in the stack are substantially identical to one
another. To facilitate handling of the stack, it is desirable not
to expose adhesive on an end sheet in the stack, e.g., the rearmost
sheet in FIG. 9. To avoid exposure of the adhesive, an additional
sheet (not shown) having a release layer, but no adhesive strips,
may be positioned against the end sheet and in contact with the
adhesive strips thereon which would otherwise be exposed.
Alternatively, the additional sheet may be a front sheet if the
adhesive strips face forward. Of course, in instances where
exposure of adhesive is not a problem, the additional sheet is not
needed. In either case, in the preferred version of the embodiment
of FIGS. 7, 8 and 9 an additional sheet may or may not be present.
In other words, in the stack, each adhesive strip on all but one of
protective covers is in contact with a release layer section on an
adjacent protective cover.
[0058] In the embodiment illustrated in FIGS. 10 and 11, the
protective cover 126 is primarily parchment, preferably the
parchment known as 39 Lb. Original Plain Parchment, approved by the
U.S. Food and Drug Administration. Here as in the embodiments
described previously, the protective cover has flaps 128 and 130,
the rectangular parts of which are narrower than the central
section 132, and connected to the central section by tapered
sections. The upper flap 128 is longer than its lower flap 130 in
the longitudinal direction of the cover, and includes a perforation
line 134 parallel to, and spaced about 2.5 cm from, the upper edge
136. A punched hole 138 is provided within the area between the
perforation line 134 and upper edge 136. Both flaps have strips of
self-sticking adhesive covered by peelable release liners. As shown
in FIG. 10, adhesive strip 140 on lower flap 130 is protected by a
release liner 142, shown partially peeled away. A similar adhesive
strip (not shown) on flap 128 is protected by peelable release
liner 144. In a larger version of the protective cover, in which
the width of the central section is 27 cm. wide, the adhesive strip
is preferably about 2.5 cm. wide, while the release liner is about
7.5 cm. wide. In the smaller version, in which the width of the
central section is 19 cm., the adhesive strip is preferably about 2
cm. wide, while the release liner is about 5 cm. wide. In both
cases, the excess width of the release liner facilitates removal of
the release liner by a warehouse worker wearing gloves.
[0059] The protective covers in accordance with FIG. 10 are
preferably supplied in a stack as shown in FIG. 11. The sheets in
the stack are held together by a layer 146 of glue which contacts
the upper edges of the upper flaps of the sheets. Optionally, the
glue layer 146 may be reinforced by a layer of fabric (not shown).
The glue layer holds the sheets of the stack together, maintaining
the punched mounting holes in alignment with one another,
eliminating the need for bands, shrink wrap, or other
packaging.
[0060] In use, the stack of protective covers is mounted on a
threaded pin 148 extending laterally from a rack element 150, and
held in place by a wing nut 152. When an individual cover is
needed, the warehouseman pulls the frontmost cover in the stack,
tearing it off at perforation line 134. He than peels the release
liners 142 and 144 away, exposing the adhesive strips, and places
the protective cover on a flat in the manner depicted in FIG.
4.
[0061] All of the above versions of the protective cover eliminate,
or at least substantially reduce, losses due to spillage of
packaged produce, and increase profit at both the distribution and
retail levels. The covers are inexpensive to produce, and the
saving achieved by the elimination of spillage far exceeds the cost
of the protective covers. Moreover, they are easy to use, and their
implementation does not require extensive training.
[0062] Although the protective covers are intended primarily for
use in the warehouse in preparing flats for shipment. A supply of
protective covers may be kept on hand by the retailer for the
purpose of protecting goods being returned, and thereby avoiding
losses in return shipments, which as mentioned previously, are
borne by the retailer.
[0063] The protective covers of the invention may be modified in
several respects. For example, their shapes and dimensions may be
changed, and various alternative moisture-resistant layers and
self-sticking adhesives may be used. In the embodiment of FIGS.
1-6, the adhesive strips can overlie the moisture-resistant layer,
or alternatively, the adhesive strips may be situated in gaps in
the moisture-resistant layer and in direct contact with the paper
layer.
[0064] Still other modifications may be made to the apparatus and
method described above without departing from the scope of the
invention as defined in the following claims.
* * * * *