U.S. patent application number 10/446546 was filed with the patent office on 2004-02-05 for packaging system for vertically packaged rolls.
Invention is credited to Garvin, William J., Simonsen, Steven H..
Application Number | 20040020168 10/446546 |
Document ID | / |
Family ID | 31191398 |
Filed Date | 2004-02-05 |
United States Patent
Application |
20040020168 |
Kind Code |
A1 |
Simonsen, Steven H. ; et
al. |
February 5, 2004 |
Packaging system for vertically packaged rolls
Abstract
A packaging and stabilizing system and method for creating a
pallet of vertically aligned rolls of material. The packaging
system includes a plurality of individual interlocking devices that
each extend between the cores of a pair of rolls on the pallet. The
interlocking devices are installed to create a lattice pattern
between the rolls on the pallet such that the rolls are stabilized
and prevented from tipping. Each individual roll of the pallet can
be removed by first removing the interlocking devices connecting
the roll to the remaining rolls in the pallet. Once the
interlocking devices are removed, the roll can be removed without
compromising the stability of the remaining rolls on the
pallet.
Inventors: |
Simonsen, Steven H.;
(Shiocton, WI) ; Garvin, William J.; (Appleton,
WI) |
Correspondence
Address: |
ALCOA INC
ALCOA TECHNICAL CENTER
100 TECHNICAL DRIVE
ALCOA CENTER
PA
15069-0001
US
|
Family ID: |
31191398 |
Appl. No.: |
10/446546 |
Filed: |
May 27, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60400653 |
Aug 1, 2002 |
|
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Current U.S.
Class: |
53/448 |
Current CPC
Class: |
B65D 71/0096 20130101;
B65D 67/02 20130101; B65D 2571/00043 20130101 |
Class at
Publication: |
53/448 |
International
Class: |
B65B 035/30 |
Claims
What is claimed is:
1. A method of stabilizing a plurality of rolls on a pallet, each
roll being vertically-oriented and having a core extending
therethrough, the method comprising the steps of: positioning a
plurality of rolls on the pallet, each roll being
vertically-oriented; providing a plurality of independent
interlocking devices; inserting each of the interlocking devices
between the cores of a pair of adjacent rolls on the pallet;
arranging the plurality of interlocking devices in a lattice
pattern to stabilize the plurality of rolls on the pallet; wherein
each of the interlocking devices are separate from the remaining
interlocking devices and can be inserted and removed
individually.
2. The method of claim I wherein the plurality of rolls are
positioned in a plurality of rows, wherein at least one
interlocking device extends between the rolls of adjacent rows.
3. The method of claim 1 wherein the interlocking devices are
positioned between the rolls as the rolls are sequentially
positioned on the pallet.
4. The method of claim 1 wherein the lattice pattern of the
interlocking devices is arranged such that each roll is coupled to
at least two other rolls on the pallet.
5. The method of claim 1 wherein the interlocking devices each
include a spanning section extending between two spaced vertical
legs, wherein the vertical legs are inserted into the cores of the
rolls.
6. The method of claim 5 further comprising the step of modifying
the length of the spanning section prior to insertion of the
interlocking device into the core of the rolls.
7. The method of claim 5 wherein the step of modifying the length
of the spanning section includes bending the spanning section along
a fold line to modify the length of the spanning section.
8. A method of stacking and unstacking a plurality of rolls on a
pallet, each roll being vertically-oriented and having a core
extending therethrough, the method comprising the steps of:
sequentially placing the plurality of rolls on the pallet to define
a plurality of rows; inserting an interlocking device between each
roll and at least one other of the plurality of rolls as each roll
is placed onto the pallet, such that each roll is stabilized prior
to additional rolls being placed on the pallet; arranging the
plurality of interlocking devices in a lattice pattern among the
plurality of rolls to stabilize the plurality of rolls on the
pallet, wherein the lattice pattern is arranged such that each roll
is coupled to at least two other rolls on the pallet and at least
one interlocking device extends between rolls of adjacent rows; and
removing all of the interlocking devices from the core of the roll
to be removed from the pallet, wherein the interlocking devices of
the lattice pattern remain between the rolls remaining on the
pallet to stabilize the rolls.
9. The method of claim 8 wherein each of the interlocking devices
are independent from the remaining interlocking devices such that
each of the interlocking devices can be individually inserted and
removed between the plurality of rolls on the pallet.
10. The method of claim 8 wherein the interlocking devices each
include a spanning section extending between two spaced vertical
legs, wherein the vertical legs are inserted into the cores of the
rolls.
11. The method of claim 10 further comprising the step of modifying
the length of the spanning section prior to insertion of the
interlocking device into the core of the roll.
12. The method of claim 11 wherein the step of modifying the length
of the spanning section includes bending the spanning section along
a fold line.
13. An interlocking device for stabilizing a plurality of rolls on
a pallet, each roll being vertically-oriented and having a core
extending therethrough, the interlocking device comprising: a
spanning section extending between a first end and a second end; a
first vertical leg connected to the first end of the spanning
section; a second vertical leg connected to the second end of the
spanning section, wherein the first vertical leg and the second
vertical leg are configured to be received within the core of one
of the plurality of rolls, wherein the spanning section, the first
vertical leg and the second vertical leg are coplanar with each
other in a stacking condition and wherein the first vertical leg
and the second vertical leg are perpendicular to the spanning
section in an operating condition.
14. The interlocking device of claim 13 wherein the spanning
section includes at least one fold line such that the length of the
spanning section can be modified by folding the spanning section
along the fold line.
15. The interlocking device of claim 13 further comprising a pair
of wings each coupled to one of the first and second vertical legs,
wherein the wings are generally coplanar with the spanning section
in the storage condition.
16. The interlocking device of claim 13 wherein the spanning
section, first vertical leg and the second vertical leg are
integrally formed from cardboard.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is based on and claims priority to
U.S. Provisional Patent Application Serial No. 60/400,653 filed on
Aug. 1, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a packaging system for use
in packaging vertically-oriented rolls of material. More
specifically, the present invention relates to a packaging system
for interlocking vertically-oriented rolls of material on a pallet
such that the rolls of material can be individually stacked and
later removed while the remainder of the rolls on the pallet are
stabilized.
BACKGROUND OF THE INVENTION
[0003] Many types of materials required by industry are supplied in
large quantities by rolling the material about a hollow,
substantially cylindrical core. Depending on the type of goods, the
core may be formed from cardboard, plastic, metal or some other
type of material. Alternatively, rolls of material can also be
formed without a core. After the material has been wound onto a
roll during manufacture, a desired number of individual rolls are
packaged together and sent to the consumer.
[0004] When packaging rolled goods for shipment, warehouse handling
or storage, it is a conventional practice to stack the individual
rolls on a pallet such that the rolls are vertically-oriented
relative to their longitudinal axis. In a typical pallet system,
the rolls may be packaged in a number of individual rows with each
row having a number of rolls. Depending upon the length of the
rolls, multiple layers may be stacked onto a single pallet.
Typically, once a pallet is formed, packaging material, such as
stretch wrap or shrink-wrap and paperboard end protectors, are used
to secure the pallet and prevent the rolls from tipping during
storage and shipment.
[0005] Presently, a packaging system exists that includes a top
cardboard or paperboard template that includes multiple die cut
openings positioned to receive a core extension of each roll when
the rolls are stacked on a pallet. The template interlocks the
individual rolls by utilizing a plastic plug that passes through an
opening in the template and into the core extension. When the
template is installed on the rolls assembled on a pallet, the
template prevents the rolls from tipping. However, this type of
packaging system has a significant drawback in that once the
template is removed, the individual rolls are no longer interlocked
and can tip. Typically, the entire interlocking template must be
removed from the top of a pallet of rolls prior to the rolls being
unstacked. Additionally, when the rolls are initially stacked at
the manufacturer, the template is not positioned on the pallet
until the entire pallet has been formed.
[0006] When such a pallet is delivered to a consumer, the consumer
removes the outer packaging material, including the top template,
and removes the individual rolls of material one at a time. During
the unloading of a pallet after the outer packaging material has
been removed, it is possible for the rolls to be bumped and fall
onto the floor from the pallet. Since some pallets are stacked such
that the rolls are between six inches and four feet above the
floor, a falling roll of material could be severely damaged upon
contact with the floor. The damage to a roll could be so severe
that the entire roll would need to be scrapped.
[0007] In addition to the problems identified above, currently
available packaging system typically require many separate,
individual components to provide an interlock between the plurality
of stacked, vertical rolls. The numerous parts required increases
the packaging costs of the rolls of material. Further, once the
rolls have been unloaded, the numerous packaging materials required
to interlock the rolls of vertically aligned material creates a
significant amount of scrap material that must be disposed of by
the consumer.
[0008] Therefore, a need exists for a packaging system that allows
vertical stacked rolls of material to be interlocked with each
other to prevent tipping of the individual rolls during either the
stacking or unstacking process. Further, a need exists for a
packaging system that allows individual rolls from the pallet to be
removed while allowing the remaining rolls in the pallet to be
stabilized. Further, a need exists for a packaging system that is
inexpensive and easy to install.
SUMMARY OF THE INVENTION
[0009] The present invention generally relates to a packaging
system for stabilizing a plurality of vertically-oriented rolls on
a pallet. The packaging system of the present invention allows the
rolls to be removed from the pallet individually while maintaining
the stability of the remaining rolls on the pallet.
[0010] The packaging system of the present invention includes a
plurality of individual interlocking devices that can be configured
based on the application such that one size will fill most
applications by bending or folding in the appropriate position.
Once the interlocking device has been properly sized, the
interlocking devices are positioned between a pair of rolls on the
pallet. The interlocking devices extend between the open cores of a
pair of rolls and interlock a pair of rolls to each other. The
interlocking devices are positioned between the rolls on the pallet
to create a lattice extending between the roll cores such that the
rolls are adequately stabilized.
[0011] During the initial formation of the pallet, an interlocking
device is positioned between each roll and another roll on the
pallet as each roll is added to the pallet. In this manner, the
pallet is stabilized during the entire time it is being
constructed, unlike the packaging system of the prior art.
Likewise, when the pallet of vertically-oriented rolls is
disassembled, the individual interlocking devices are sequentially
removed only as individual rolls are removed to allow the pallet to
maintain its stabilization while allowing the individual rolls to
be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The drawings illustrate the best mode presently contemplated
of carrying out the invention.
[0013] In the drawings:
[0014] FIG. 1 is a perspective view of a pallet including a
plurality of vertical rolls supported utilizing the packaging and
stabilizing system of the prior art;
[0015] FIG. 2 is a section view taken along line 2-2 of FIG. 1
illustrating the interaction between the packaging system of the
prior art and one of the vertical rolls of material;
[0016] FIG. 3 is a partial perspective view illustrating the
insertion of one of the interlocking devices of the packaging and
stabilizing system of the present invention between a pair of
vertical rolls;
[0017] FIG. 4 is a top view illustrating a first configuration for
a plurality of the interlocking devices of the packaging and
stabilizing system of the present invention;
[0018] FIG. 5 is a magnified view taken along line 5-5 of FIG. 4
illustrating the interaction between three of the interlocking
devices within a single vertical roll;
[0019] FIG. 6 is front view of the interlocking device in its
stacking condition;
[0020] FIG. 7 is a top view illustrating a second configuration for
the interlocking devices of the packaging and stabilizing system of
the present invention;
[0021] FIG. 8 is a perspective view illustrating an alternate
packaging and stabilizing system in accordance with the present
invention;
[0022] FIG. 9 is a section view taken along line 9-9 of FIG. 8;
and
[0023] FIG. 10 is a perspective view of a backing member used with
the alternate embodiment of the packaging and stabilizing system of
the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] Referring first to FIG. 1, thereshown is a prior art
packaging and stabilizing system 10. The prior art packaging system
10 is utilized to stabilize a pallet of closely spaced rolls 12 for
shipping. Each of the rolls 12 is vertically-oriented for
shipment.
[0025] As illustrated in FIG. 1, each of the rolls 12 is supported
at its lower end by a bottom template 14 having a series of die cut
openings 16. The die cut openings 16 are each sized to receive a
core extension that extends past the lower edge of the film wound
upon each of the rolls 12. The bottom template 14, in turn, is
supported upon the pallet 18 for shipping.
[0026] Once the pallet of rolls 12 has been assembled onto the
bottom template 14, a top template 20 is positioned on the top end
of each roll 12 to secure the rolls in an ordered, packaged
condition. As illustrated in FIG. 1, the top template 20 includes a
series of die cut openings 22 each sized to receive an upper core
extension 23 formed on each of the rolls 12. As illustrated in FIG.
2, once the top template 20 has been positioned as shown, an
individual backing member 24 and end plug 26 are inserted into each
of the core extensions 23 to secure the top template 20 in the
position as shown. In the preferred embodiment of the invention,
the bottom template 14, the top template 20 and the backing members
24 are all formed from cardboard or paperboard, while the end plug
26 is formed from a plastic material.
[0027] Although the packaging system 10 shown in FIG. 1 is
effective for stabilizing a pallet of vertically-oriented rolls
during shipment, significant drawbacks exist during the assembly
and disassembly of the pallet. As can be understood in FIG. 1, when
a roll 12 is to be removed from the pallet, all of the individual
end plugs 26 and backing members 24 must first be removed from the
cores of the plurality of rolls 12. Once all of the end plugs 26
and backing members 24 have been removed, the top template 20 can
be lifted from the pallet and the rolls 12 removed
individually.
[0028] As can be understood in FIG. 1, once the top template 20 has
been removed, the rolls of material are no longer stabilized and
are thus subject to tipping. This condition exists both during the
initial stacking and subsequent unstacking of the rolls to form a
pallet for shipment. Additionally, the packaging system 10 of the
prior art includes many individual components, including the top
template 20, the plurality of individual backing members 24, and
end plugs 26 that must be stored prior to assembly and disposed of
once the pallet has been unstacked.
[0029] Referring now to FIG. 3, thereshown is a first embodiment of
the packaging and stabilizing system 30 of the present invention.
The packaging system 30 provides a system for stabilizing a
plurality of individual rolls 12 loaded onto a pallet while
allowing the individual rolls 12 to be removed from the pallet one
at a time while simultaneously maintaining stability for the
remaining rolls on the pallet. Additionally, the packaging system
30 of the present invention allows the loaded rolls to be
stabilized during the formation of the pallet as each individual
roll is added to the pallet.
[0030] As illustrated in FIG. 3, each individual roll 12 includes a
core extension 32 that extends above the top edge surface 34 of the
roll. The core extension 32 in the preferred embodiment of the
invention extends approximately 1/4 to one inch above the top edge
surface 34 and defines an open center 36 that extends along the
entire longitudinal length of the roll 12. Alternatively, the core
may be flush with the top edge surface 34.
[0031] In accordance with the present invention, the packaging
system 30 includes a plurality of individual interlocking devices
38 that each extend between the core of a pair of adjacent rolls.
Each interlocking device 38 secures a pair of interlocking rolls to
each other such that the plurality of interlocking devices 38
create a lattice pattern to provide stability for the pallet of
rolls during assembly, packaging, shipment and disassembly of the
pallet.
[0032] As can be seen in FIG. 5, more than one interlocking device
38 can be positioned in a core 32 of an individual roll 12. Thus,
an individual roll can be interlocked with more than one adjacent
roll such that the series of interlocking devices 38 create a
stabilized pallet of rolls.
[0033] Referring now to FIGS. 3 and 6, thereshown is the preferred
embodiment of the interlocking device 38 in accordance with the
present invention. The interlocking device 38 is formed from a
single sheet of die-cut cardboard or paperboard material. The
devices 38 include a spanning section 40 sized to extend between a
pair of adjacent cores when the outer diameters of the rolls 12 are
positioned in contact with each other.
[0034] As shown in FIG. 3, the spanning section 40 is connected
between a pair of vertical legs 42 and 44. The vertical legs 42 and
44 each extend into the core of one of the rolls to support the
spanning section 40 between a pair of rolls. In the preferred
embodiment of the invention, each of the vertical legs 42, 44
includes a pair of wings 46 and 48 that engage the inner surface of
the core of one of the rolls to help in retaining the vertical legs
42, 44 within the respective hollow core. In the preferred
embodiment of the invention illustrated in FIG. 6, the spanning
section 40 has a length of approximately {fraction (7 3/8)} inches
as measured between the first end 52 and the second end 54 of the
spanning section 40.
[0035] Referring back to FIG. 6, the interlocking device 38
includes an intermediate fold line 50 that allows the length of the
spanning section 40 to be adjusted. In the embodiment of the
invention illustrated in FIG. 6, the fold line 50 is {fraction (5
3/4)} inches from the first end. However, it should be understood
that the position of the fold line 50 can be modified depending
upon the preferred distance between the cores of the rolls to be
stacked on a pallet.
[0036] Referring back to FIG. 6, each of the vertical legs 42, 44
has a length of approximately 6 inches, while the wings 46 and 48
have a width of approximately {fraction (1 5/8)} inches from the
fold lines 56, 58 to the outer edges 59, 61, respectively. Each
wing includes a tapered corner 63 to aid in guiding the vertical
legs 42, 44 into the roll core. The width of the spanning section
40 is approximately two inches in the preferred embodiment of the
invention. Although specific measurements for the sections of the
interlocking device 38 are presented, it should be understood that
the physical dimensions of the interlocking device 38 can be
modified depending upon the roll size and the configuration of the
rolls on a pallet. The measurements given are not meant to be
limiting but are merely presented for illustrative purposes.
[0037] As can be understood in a comparison of FIGS. 3 and 6, the
interlocking device 38 is die-cut from a single sheet of cardboard
and is created in a flat, storage condition shown in FIG. 6. In the
storage condition shown in FIG. 6, multiple interlocking devices 38
can be stacked on top of each other and thus occupy a small space.
Thus, before the interlocking devices 38 are used, the interlocking
devices can be compactly stacked and stored.
[0038] When the interlocking device 38 is to be used, the
interlocking device 38 is folded along the first end 52 and the
second end 54 to define the vertical legs 42 and 44, as shown in
FIG. 3. Next, the wings 46 and 48 are folded along their respective
fold lines 56 and 58 (FIG. 6) such that the interlocking device 38
is in the operating condition shown in FIG. 3. As discussed
previously, the interlocking device 38 can be folded along line 50,
depending upon the diameter of rolls being stacked utilizing the
system of the present invention.
[0039] Referring back to FIGS. 3 and 4, assembly of a pallet of
vertically-oriented rolls utilizing the packaging system 30 of the
present invention will now be described. Initially, one of the
rolls 12a is positioned on a pallet in a vertical orientation.
After the first roll 12a has been positioned, a second roll 12b is
placed adjacent to the first roll 12a and an interlocking device
38a is positioned between the two adjacent rolls to secure the
rolls to each other. Another roll 12c is then placed on the pallet
and yet another individual interlocking device 38b is used to
secure the newly placed roll 12c to the prior placed roll 12a. This
process continues until the interlocking devices 38 are arranged in
a lattice pattern and the entire pallet of vertically-oriented
rolls are assembled, as shown in FIG. 4.
[0040] Referring now to FIG. 5, once the entire pallet of
vertically-oriented rolls are assembled, several of the rolls, such
as roll 12c, receive multiple interlocking devices 38. As shown in
FIG. 5, roll 12c includes three interlocking devices 38 such that
the roll 12c aids in stabilizing more than one row of the rolls
assembled on the pallet. As can be seen in FIG. 5, the wings 46, 48
of each of the interlocking devices 38 are received within the open
center 36 to hold the interlocking device 38 in place. In the
pallet configuration shown in FIG. 4, the pallet includes four rows
each including five rows of material. Alternatively, as illustrated
in FIG. 7, the pallet can be arranged such that the pallet includes
five rows of rolls where each row includes five rolls. In the
packaging arrangement shown in FIG. 7, the rolls are closely spaced
and provide an alternate method of packaging rolls on a pallet. In
the packaging arrangement shown in FIG. 7, the interlocking devices
38 are utilized in a lattice pattern to stabilize the rows and thus
illustrate the flexibility of the packaging system of the present
invention.
[0041] Once the pallet of rolls is assembled, as shown in FIGS. 4
and 7, the series of individual interlocking devices 38 provide
stability for the entire pallet such that the pallet can be shipped
without fear of tipping of any of the individual rolls.
[0042] Once the pallet of rolls is at its desired location, each of
the rolls 12 can be removed without disrupting the stability of the
remaining rolls on the pallet. For example, to remove individual
roll 12d (FIG. 4), the interlocking devices 38c and 38d are removed
such that the lattice of interlocking devices to the roll 12d is
only partially broken. Once the interlocking devices 38c and 38d
are removed from the roll core of the roll 12d, the roll 12d can be
lifted from the pallet while the lattice pattern between the
remaining rolls on the pallet continues to stabilize the pallet to
prevent tipping. This process is repeated for each of the rolls on
the pallet until the pallet has been completely unloaded.
[0043] Referring now to FIGS. 8-10, thereshown is a second
embodiment of the packaging system of the present invention. In the
second embodiment of the packaging system 60, an alternate type of
interlocking device is utilized to stabilize the rolls on the
pallet. In the second embodiment of the packaging system 60, a
sheet of plastic 62 is draped over the top ends of each roll 12 as
the rolls are added to the pallet. As illustrated in FIG. 9, after
the sheet of plastic material 62 has been installed, a backing
member 64, having a plurality of extending tabs 66 extending from a
flat face 67, is inserted into the core 68 of the roll 12. As
illustrated in FIG. 10, the tabs 66 include end points 70 that
pierce the plastic sheet 62. Once the backing member 64 is in
place, an end plug 66 is inserted into the core to lock the core in
place relative to the sheet of plastic material 62.
[0044] Referring back to FIG. 8, once the pallet has been
assembled, the sheet of plastic material 62 acts as an interlocking
device between the individual rolls of material.
[0045] Once the pallet of rolls has been delivered to a desired
location, each of the individual rolls can be removed from the
pallet by cutting the plastic sheet 62 around the roll being
removed or by simply folding back the plastic sheet after the core
plug 66 and backing member 64 have been removed. Once the plastic
sheet 62 has been cut or folded, the individual roll can be removed
and the backing member 64 and end plug 66 discarded.
[0046] As can be understood in FIG. 8, when an individual roll is
removed, the remaining portion of the plastic sheet 62 maintains
the stability of the remaining rolls to prevent the rolls from
tipping. In the preferred embodiment of the invention, the plastic
sheet 62 is formed from a clear material such that the plastic
material can be cut or folded without damaging the rolls.
[0047] Although not illustrated in the Figures, another alternate
embodiment of the invention is contemplated in which individual
rubber band-type elements can be used between the core extensions
of adjacent rolls. The rubber band elements would replace the
individual interlocking devices 38 shown in FIG. 3. It is
contemplated that a rubber band device would extend between
adjacent rolls and that several rolls in the pallet may have more
than one rubber band extending around its core extension. Like the
interlocking devices 38 shown in FIG. 3, rubber bands would allow
each individual roll to be removed separately while maintaining the
stability of the entire pallet.
[0048] In addition, it is contemplated by the inventor that the
cardboard or paperboard interlocking devices 38 shown in FIG. 3
could be replaced by a plastic U-clip having a pair of vertical
legs and a spanning section. A plastic U-clip would function
identically to the interlocking devices 38 shown in FIG. 3 and
would provide the required stability and individual removability of
the rolls of material.
[0049] Although several embodiments of the invention are described
in the present disclosure, it is contemplated by the inventor that
other interlocking devices are within the scope of the present
invention. The interlocking devices of the present invention
provide stability for a pallet of vertically-oriented rolls while
allowing the rolls to be individually removed without disrupting
the overall stability of the remaining rolls. Further, the
packaging system of the present invention reduces the number of
discarded components as compared to the prior art packaging system
10 illustrated in FIG. 1.
[0050] Having described the presently preferred embodiments, it is
to be understood that the invention may be otherwise embodied
within the scope of the appended claims.
* * * * *