U.S. patent application number 10/714223 was filed with the patent office on 2004-07-08 for shipping container and support dunnage.
Invention is credited to Denton, Adam, Tucker, Matthew W..
Application Number | 20040129589 10/714223 |
Document ID | / |
Family ID | 32684713 |
Filed Date | 2004-07-08 |
United States Patent
Application |
20040129589 |
Kind Code |
A1 |
Tucker, Matthew W. ; et
al. |
July 8, 2004 |
Shipping container and support dunnage
Abstract
A shipping container and dunnage supports includes at least one
first support and at least one second support which are disposed
within a shell and are engagable with a peripheral edge of an
article disposed within the shell. The first and second dunnage
supports may include an insert block positioned in the support to
increase the structural and shock absorption characteristics of the
support.
Inventors: |
Tucker, Matthew W.;
(Brighton, MI) ; Denton, Adam; (Howell,
MI) |
Correspondence
Address: |
YOUNG & BASILE, P.C.
Suite 624
3001 West Big Beaver Road
Troy
MI
48084-3107
US
|
Family ID: |
32684713 |
Appl. No.: |
10/714223 |
Filed: |
November 14, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10714223 |
Nov 14, 2003 |
|
|
|
10340054 |
Jan 10, 2003 |
|
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|
60347432 |
Jan 10, 2002 |
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Current U.S.
Class: |
206/335 |
Current CPC
Class: |
B65D 2585/6877 20130101;
B65D 5/6632 20130101; B65D 5/509 20130101 |
Class at
Publication: |
206/335 |
International
Class: |
B65D 085/68 |
Claims
What is claimed is:
1. A shipping container for an article having a peripheral edge,
the shipping container comprising: a shell including a plurality of
panels, including at least a base panel, a top panel and opposed
side panels; at least one first support adapted to mount over a
peripheral edge of an article disposable within the shell, the
first support having a generally C-shape formed of a first leg and
a second leg resiliently extending from an end leg; and at least
one second support mounted within the shell, the second support
having an inner channel opening through the support, the channel
configured for mounting over a portion of a peripheral edge of an
article.
2. The shipping container of claim 1 wherein: the second support is
mounted in an inverted position on the shell.
3. The shipping container of claim 1 further comprising: means for
fixedly mounting the second support on at least one of the foldable
panels in the shell.
4. The shipping container of claim 3 wherein the mounting means
comprises: adhesive applied to at least one of two opposed surfaces
of the second support.
5. The shipping container of claim 1 wherein the first support
further comprises: enlarged ends formed on each of the first and
the second side legs.
6. The shipping container of claim 1 wherein: the at least one of
the first supports comprises a pair of first supports each having a
surface disposed adjacent to one of the side panels of the shell;
and a chamfered edge formed on a portion of the surface of the at
least one of the first pair of supports.
7. The shipping container of claim 6 wherein: the chamfered surface
is formed at a juncture of one of the side legs and the end
leg.
8. The shipping container of claim 1 wherein: the at least one of
the second supports comprises a pair of second supports each having
a surface disposed adjacent to one of the side panels of the shell;
and a chamfered edge formed on the surface of the at least one of
the second pair of supports.
9. The shipping container of claim 8 wherein: the chamfered surface
is formed on at least a portion of the surface facing the side
panel of the shell.
10. The shipping container of claim 1 wherein: the first and second
supports are formed of expanded polypropylene.
11. The shipping container of claim 1 wherein: the first support is
movably disposed within the shell when engaged with an article
disposed within the shell.
12. The shipping container of claim 1 further comprising: foldable
flaps disposed in cutouts on the base panel and the top panel
between the opposed side panels; and indicia means, carried on an
exterior surface on at least one of the top and bottom panels of
the shell, for indicating a mounting location for a securing strap
over the flaps and the top and bottom panels of the shell.
13. A shipping container for an article having a peripheral edge,
the shipping container comprising: a shell having at least a bottom
panel, opposed side panels each contiguous with the bottom panel
along a foldable edge, and opposed top panels each contiguous with
one of the side panels about a foldable edge, the top panels
foldable into overlapping relationship; a first pair of supports
adapted to mount over a peripheral edge of an article disposable
within the shell, the first pair of supports having a generally
C-shape formed of a first leg and a second leg resiliently
extending from one end leg; and a second pair of supports mounted
within the shell, each of the second pair of supports having an
inner channel opening through the support, the channel configured
for mounting over a portion of a peripheral edge of an article.
14. The shipping container of claim 13 wherein: the first pair of
supports are movably mounted with respect to the base panel of the
shell; and the second pair of supports are fixedly mounted to the
base panel of the shell.
15. The shipping container of claim 13 wherein: the first pair of
supports are movably disposed adjacent one edge of the base panel
of the shell; and the second pair of supports are fixed to the base
panel adjacent a different edge of the base panel.
16. The shipping container of claim 13 further comprising: each of
the first pair of supports having a surface facing one of the side
panels of the shell; and a chamfered surface formed on a portion of
the surface of each of the first pair of supports and disposed
adjacent to one of the foldable edges between the side panels, the
top panel and the bottom panel of the shell.
17. The shipping container of claim 13 further comprising: each of
the second pair of supports having a surface facing one of the side
panels of the shell; and a chamfered surface formed on a portion of
the surface of each of the second pair of supports and disposed
adjacent to one of the foldable edges between the side panels, the
top panel and the bottom panel of the shell.
18. The shipping container of claim 13 further comprising: means
for fixing the second. pair of supports to the bottom panel of the
shell; and fastening means, carried on a surface of at least one of
the second pair of supports opposite from a surface of the second
pair of supports fixed to the bottom panel of the shell, the
fastening means engagable with one of the top panels when the top
panels are overlapped over the second pair of supports.
19. Support dunnage for use with an article having a peripheral
edge disposable in a shell, the support dunnage comprising: at
least one first support positioned in a shell having a first leg
and a second leg extending from an end leg forming a first open
channel configured for mounting over a portion of a peripheral edge
of an article; and at least one second support positioned in the
shell distant from the first support and having an inner channel
opening configured for mounting over a portion of the peripheral
edge of the article.
20. The support dunnage of claim 19 wherein the at least one first
support comprises a single first support.
21. The support dunnage of claim 22 wherein the first support
further comprises a panel mounted to the first support to position
the first support in the shell.
22. The support dunnage of claim 19 wherein at least one of the
first and the second supports includes an insert block positioned
in the support.
23. The support dunnage of claim 25 wherein the first support
includes a first insert block and the second support includes a
second insert block.
24. Support dunnage for use with an article having a peripheral
edge disposable in a shell, the support dunnage comprising: a first
support positioned in a shell having a first leg and second leg
extending from an end leg forming a first open channel configured
for mounting over a portion of a peripheral edge of an article
disposable within the shell, the first open channel having an
angled first top portion intersecting a second portion having a
step adjacent the intersection, the first support further having at
least one first insert block positioned in the first support; and a
pair of opposing second supports positioned in the shell distant
from one another and from the first support, each second support
having an inner channel opening configured for mounting over a
portion of the peripheral edge of the article and each second
support having a second insert block positioned in the second
support.
25. The support dunnage of claim 24 wherein the first support
comprises a single first support positioned between the second
supports and distant therefrom.
26. The support dunnage of claim 25 wherein the first support
includes a panel mounted to the first support to position the
support in the shell.
27. The support dunnage of claim 24 wherein at least one of the
first and second supports is made from polyurethane having a
density of about 1.5 lbs/ft.sup.3 to about 3.0 lbs/ft.sup.3.
28. The support dunnage of claim 24 wherein at least one of the
first and second insert blocks is made from polypropylene having a
density of about 1.8 lbs./ft.sup.3 to about 3.2 lbs./ft.sup.3.
29. A dunnage block for use in supporting and protecting an
automobile hood having a peripheral edge positioned in a shell, the
dunnage block comprising: a support having a top surface, a bottom
surface, an inner surface and an outer surface, the support having
a channel configured for mounting over a portion of a peripheral
edge of an automobile hood.
30. The dunnage block of claim 29 wherein the support further
comprises a first leg and a second leg extending from an end leg
and wherein the channel is a first open channel.
31. The dunnage block of claim 30 further comprising an enlarged
end distant from the end leg on at least one of the first leg and
the second leg.
32. The dunnage block of claim 30 wherein the first open channel
further comprises an angled first channel portion and a second
channel portion intersecting the first portion defining the first
open channel.
33. The dunnage block of claim 32 wherein the second channel
portion further comprises a step adjacent the intersection of the
second channel portion and the first channel portion.
34. The dunnage block of claim 30 further comprising a first insert
block positioned in the support.
35. The dunnage block of claim 30 further comprising a panel
mounted to the support to position the support in the shell.
36. The dunnage block of claim 30 wherein the support further
comprises a first groove positioned on an inner surface of at least
one of the first and the second legs.
37. The dunnage block of claim 29 further comprising a front side
and an opposing rear side and wherein the channel is an inner
channel opening in the front side and inner surface of the
support.
38. The dunnage block of claim 37 wherein the inner open channel
further comprises an undercut portion extending toward the rear
side of the support.
39. The dunnage block of claim 37 further comprising a second
insert block positioned in the support.
40. The dunnage block of claim 29 further comprising a chamfer on
the outer surface of the support adjacent at least one of the top
surface and the bottom surface.
41. The dunnage block of claim 29 further comprising an insert
block positioned in the support, the support having a first
composition and the insert having a second composition.
42. The dunnage block of claim 41 wherein the first composition is
selected from the group consisting of polyurethane and
polypropylene.
43. The dunnage block of claim 42 wherein the first composition is
polyurethane having a density of from about 1.5 lbs/ft.sup.3 to
about 3.0 lbs/ft.sup.3.
44. The dunnage block of claim 42 wherein the first composition is
polypropylene having a density of from about 1.8 lbs/ft.sup.3 to
about 3.2 lbs/ft.sup.3.
45. The dunnage block of claim 41 wherein the second composition is
selected from the group consisting of polypropylene and
polyethylene.
46. The dunnage block of claim 45 wherein the second composition is
polypropylene having a density of from about 1.8 lbs/ft.sup.3 to
about 3.2 lbs/ft.sup.3.
47. The dunnage block of claim 45 wherein the second composition is
polyethylene having a density of from about 2 lbs/ft.sup.3 to about
9 lbs/ft.sup.3.
48. The dunnage block of claim 41 wherein the first composition and
the second composition are of polypropylene having a density of
from about 1.8 lbs/ft.sup.3. to about 3.2 lbs/ft.sup.3.
Description
CROSS-REFERENCE TO CO-PENDING APPLICATION
[0001] This application is a continuation-in-part application of
co-pending application Ser. No. 10/340,054 filed Jan. 10, 2003
which claims the benefit of priority of the Jan. 10, 2002 filing
date of U.S. provisional patent application serial No. 60/347,432,
the contents of which are incorporated herein in their
entirety.
BACKGROUND
[0002] Shipping containers for articles, workpieces, auto parts,
etc., take a variety of shapes and configurations based on the size
and shape of the article or part to be transported. For example,
automotive parts, such as vehicle sheet metal parts, i.e., hoods,
deck lids, fenders, door panels, widow glass, etc., come in
numerous shapes.
[0003] One type of shipping container for transporting single
articles, such as automotive parts, is a corrugated cardboard box
having folded over panels which are taped or otherwise secured in a
closed position.
[0004] As many automotive parts have a Class A surface finish,
extra protection is required to prevent damage to the Class A
finish on one or more surfaces of the part by protecting the Class
A finish surface of the part from contact with the shipping
container itself.
[0005] In the shipping container field, it is known to utilize
dunnage to protect articles or parts in shipping containers from
movement as well as from contact with the container. Such dunnage
typically takes the form of foamed plastic blocks or members which
are configured with openings for mounting on one edge of the
article or part. The dunnage is designed for a snug fit within the
shipping container or is fixed in place by means of adhesive,
fasteners, etc., to prevent dislodgement and to prevent movement of
the article during shipping.
[0006] Although in certain applications, the dunnage, after the
part is removed from the shipping container, is returned to the
manufacturing facility for reuse. More frequent, the dunnage is
removed from the shipping container after the part is removed and
then discarded. In this situation, the dunnage represents an added
cost to the article or workpiece since new dunnage is required for
each article or part.
[0007] It would be desirable to provide a shipping container and
support dunnage which adequately supports and protects an article
or workpiece disposed within the shell during storage and shipping,
enables easy closure of the shipping container after the article or
workpiece is inserted into the container, reduces the number of
dunnage pieces which come in contact with or are needed to support
the article, increases the structural characteristics, impact
strength or shock absorption properties of the dunnage, simplifies
the shell of the container and requires a minimal amount of
disposable dunnage to reduce the total article manufacturing cost.
It would further be desirable to provide dunnage having the above
benefits which satisfies the rigorous testing requirements of
industrial manufacturers including automobile manufacturers.
SUMMARY
[0008] The present invention is a shipping container and dunnage
which provides advantages over prior article shipping containers
and dunnage.
[0009] In one aspect of the invention, the shipping container
includes a shell including a plurality of panels which can include
a base panel, a top panel and opposed side panels. At least one
first support is adapted to mount over a peripheral edge of an
article to support the article within the shell. The first support
has a generally C-shape formed of two spaced side legs resiliently
extending from one end leg. At least one second support is mounted
or positioned within the shell in engagement over a peripheral edge
of the particle. The second support has an inner channel opening.
The channel is configured for mounting over a corner of a
peripheral edge of the article.
[0010] In another aspect, the first support is movably disposed
within the shell. The second pair of supports are fixedly mounted
within the shell.
[0011] In another aspect, indicia means are provided on the
exterior surface of the shell to facilitate to optimum positioning
of a banding strap about the shell.
[0012] In another aspect, the shipping container includes a shell
having a bottom panel, opposed side panels, each contiguous with
one of the bottom panel along a foldable edge, and opposed top
panels contiguous with the side panels about a foldable edge. The
top panels are foldable into overlapping relationship. A first pair
of supports is adapted to mount over a peripheral edge of an
article to support the article within the shell. The first pair of
supports have a generally C-shape formed of two side legs
resiliently extending from one end leg. A second pair of supports
is fixedly mounted within the shell. Each of the second pairs of
supports has an inner channel opening through one side of the
support. The channel is configured for mounting over a corner
formed in a peripheral edge of the article.
[0013] In another aspect, the invention is a support block
engagable with an article for supporting the article in a shipping
container. The block can be the above described C-shaped block, or
the block with an inner recess or any combination thereof.
[0014] In one aspect, the at least one first support includes a
single first support and the at least one second support includes a
pair of second supports. In another aspect, the shipping container
and dunnage blocks are configured to support and protect and
automobile hood.
[0015] In another aspect, the invention is at least one support or
dunnage block having an insert block positioned in the dunnage
block to increase the structural integrity and impact absorption
properties of the dunnage block. In another aspect, the dunnage
block is made from polyurethane, polypropylene, polyethylene or any
combination thereof In another aspect, the support or dunnage block
is made from polyurethane and the insert block is made from
polypropylene.
[0016] The present shipping container and dunnage support provides
optimum protection for an article disposed within the container,
enables easy closure of the container after the article is inserted
into the container and, further, utilizes a minimal amount of
disposable dunnage to reduce the total article manufacturing
cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The description herein makes reference to the accompanying
drawings wherein like reference numerals refer to like parts
throughout the several views, and wherein:
[0018] FIG. 1 is a partial perspective view of one aspect of the
shipping container showing an automotive hood positioned in the
container;
[0019] FIG. 2 is a top view of the shipping container in FIG. 1 in
a partially assembled position;
[0020] FIG. 3 is a perspective view of a first support shown in
FIG. 1;
[0021] FIG. 4 is a perspective view of a second support shown in
FIG. 1;
[0022] FIG. 5 is a front view of the partially assembled shipping
container in FIG. 1 showing the side panels and the first and
second top panels in an angularly displaced orientation to the
bottom panel;
[0023] FIG. 6 is a perspective view of the shipping container in
FIG. 1 in an assembled position;
[0024] FIG. 7 is a perspective view of an alternate shipping
container having support dunnage and an automotive hood positioned
therein;
[0025] FIG. 8 is a partially cut-away perspective view of an
alternate first support shown in FIG. 7 including a single first
support showing one of the preferred insert blocks;
[0026] FIG. 9 is a left side view of the single first support in
FIG. 8;
[0027] FIG. 10 is a rotated, partially cut-away perspective view of
the single first support in FIG. 8 showing the preferred dual
insert blocks;
[0028] FIG. 11 is a rotated perspective view of the single first
support in FIG. 8 including a panel attached thereto;
[0029] FIG. 12 is a perspective view of an alternate second support
shown in FIG. 7;
[0030] FIG. 13 is a perspective view of a preferred insert block
for the second support shown in FIG. 12;
[0031] FIG. 14 is a schematic perspective view showing the insert
block of FIG. 13 positioned in the second support of FIG. 12;
and
[0032] FIG. 15 is a partial top view of the shipping container
shown in FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring to FIGS. 1-6, one aspect of a shipping container
10 of the present invention is illustrated. Referring specifically
to FIGS. 1 and 2, shipping container 10 includes, by example, a
shell 12, a pair of first or front supports or dunnage blocks 14
and a pair of second or rear supports or dunnage blocks 16. First
14 and second 16 supports are shown supporting an article, for
example, an automotive hood 18 as best seen in FIG. 1.
[0034] Referring to FIGS. 2 and 5, shell 12 includes a substrate 20
including a front edge 24, a rear edge 26, a first side edge 27 and
a second side edge 28. The substrate 20 is divided into five
sections including a bottom panel 29, two side panels 44, a first
top panel 52 and a second top panel 54. The substrate 20 is
generally rectangular in shape in an unfolded or unassembled
position as shown in FIG. 2 and is made from die-cut, heavy-duty
corrugated cardboard material. It is understood that substrate 20
may alternately be any polygonal shape to fit an application and
intended contents and may comprise multiple, non-connected pieces.
The substrate 20 may alternately be made from other materials which
include similar physical properties to rigidly contain articles. As
shown in FIGS. 1 and 5, shipping container 10 is designed and
proportioned to securely support and retain an automotive hood 18.
It is understood that the shipping container 10 is adaptable for
other contents or goods without deviating from the present
invention.
[0035] Referring to FIGS. 2 and 5, bottom panel 29 is generally of
square shape and is defined by front edge 24 and rear edge 26 of
substrate 20. Bottom panel 29 includes a cutout 30 along both the
front edge 24 and rear edge 26 at the approximate center of bottom
panel 29 as seen in FIG. 2. Bottom panel 29 includes a pair of
bottom flanges 32 that are integral with bottom panel 29 and
separated from inner edges 38 defining cutouts 30. Bottom flanges
32 include a flange edge 36 defining a length of flange 32 which
does not extend beyond the front 24 or rear 26 edge of substrate 20
and is preferably distant therefrom. Bottom panel 29 further
includes a first crease 34 at the intersection of both bottom
flanges 32 and bottom panel 29. First crease 34 is formed by a
slight deforming compression of substrate 20 along a linear path to
facilitate folding or rotating bottom flanges 32 along first crease
34 in an angular orientation to bottom panel 29 as best seen in
FIG. 5 and described in detail hereinafter.
[0036] The pair of side panels 44 which are separated by and
integral with bottom panel 29. Sides panels 44 are defined by a
first side crease 46 and second side crease 48 formed in substrate
20 as previously described. First 46 and second 48 side creases are
separated by a distance sufficient to accommodate the height of the
desired contents and supports described below positioned in
shipping container 10.
[0037] Substrate 20 further includes a first top panel 52 and a
second top panel 54 which are integral with the respective side
panels 44 as best seen in FIGS. 2 and 5. The first 52 and second 54
top panels include a second cutout 56 along the front edge 24 and
rear edge 26 as best seen in FIG. 2. First top panel 52 includes a
first front flange 58 and a first rear flange 59 which are both
integral with first top panel 52. In a similar fashion to the
bottom panel, first top panel 52 includes a second crease 62 at the
intersections of first front 58 and first rear 59 flanges and first
top panel 52. The first front 58 and the first rear 59 flanges are
also separated from an outer edge 64 to permit the respective
flanges to fold or rotate in an angular orientation to first top
panel 52 as best seen in FIG. 5. First front 58 and first rear 59
flanges include a flange edge 66 which is positioned such that the
respective flanges do not extend beyond the front edge 24 and rear
edge 26 as previously described for bottom flanges 32.
[0038] In a similar fashion to first top panel 52, second top panel
54 includes a second front flange 60 and a second rear flange 61
which are integral with second top panel 54. Second top panel 54
similarly includes a second crease 62 along the linear
intersections of second front flange 60 and second rear flange 61
with second top panel 54. Second front 60 and second rear 61
flanges are separated from outer edge 64 and include a flange edge
66 similar to that of the first front 58 and first rear 59 flanges
as previously described. First 52 and second 54 top panels are
separated from the respective side panels 44 by second side creases
48 which permit first 52 and second 54 top panels to fold or rotate
along second crease lines 48 to angularly displace first 52 and
second 54 top panels from the respective side panels 44 as best
seen in FIGS. 5 and 6.
[0039] It will be understood that the above-described container 10
is by way of example only. The present invention is also usable
with other container constructions including a regular slotted
carton, a folded-over lap carton or a telescopic carton.
[0040] Referring to FIGS. 1-3 and 5, shipping container 10
preferably includes a pair of first supports 14. As best seen in
FIG. 3, each front support 14 includes a top surface 80, a bottom
surface 82, an outer surface 84, an inner surface 86 and a first or
open channel 88. Each first support 14 further includes opposing
rounded portions 90 which partially obstruct first channel 88
adjacent to inner surface 86. Each first support 14, when used on
the side of the component 18, further includes a 45 degree chamfer
at the intersections of the top surface 80 and bottom surface 82
with the outer surface 84 as best seen in FIG. 3. It is understood
that chamfers 92 may be at an alternate angle from 45 degrees or
may take a rounded or radiused form as opposed to a substantially
flat chamfer as shown.
[0041] First supports 14 may also be positioned on the component or
hood 18 closer to the center of the front edge of the hood 18. This
would move each front support 14 inward toward the opposed front
support 14 from the side located position shown in FIG. 1. In these
so called "front edge" mounted positions of first supports 14, the
chamfer 92 will not be required but may still be used to reduce
weight and the amount of material needed to form the supports.
[0042] It will also be understood that the chamfer 92 for side edge
mounted first supports 14 is optional. According to one aspect of
the invention, first supports 14 are formed of a lower density
material than the rear support 16 described hereafter. This lower
density material allows front supports 14 to absorb external forces
better without transferring a substantial portion of such forces to
the hood 18.
[0043] As best seen in FIGS. 1, 2 and 5, first supports 14 are
positioned on bottom panel 29 adjacent respective first side
creases 46 and are distant from front edge 24 in an approximate
position as shown to accommodate an automotive hood 18. In
alternate aspects of the invention, additional front supports 14
may be used where desired to support, for example, less rigid
components where needed to further support and protect the
contents. First supports 14 are preferably made from expanded
polyurethane or polypropylene cut or molded to the desired shape
which, in the described configuration, provides both rigidity to
support hood 18 as well as flexibility to separate rounded portions
90 to accept hood 18 and provide a cushion to protect hood 18.
Alternate materials include molded or cut expanded polystyrene and
other materials that provide rigidity in a block form and
substantial cushioning or shock absorption properties while
permitting flexibility to insert and remove, for example, an
automotive hood 18 into and out of first channel 88 as described
and illustrated in FIG. 1.
[0044] Referring to FIGS. 1, 2 and 4, shipping container 10
preferably includes, for example, a pair of second supports 16.
Referring to FIG. 4, each rear support 16 has a top surface 102, a
bottom surface 104, an outer surface 106, an inner surface 108, a
front side 110 and a rear side 112. Each second support 16 further
includes an inner channel opening 114 which is partially open to
inner surface 108 and includes an undercut 116 substantially as
shown. As illustrated, inner channel opening 114 is positioned and
oriented in second support 16 to accept and partially retain a rear
corner of an automotive hood 18 as best seen in FIG. 1. Second
support 16 further includes a 45 degree chamfer at the
intersections of top surface 102 and bottom surface 104 with outer
surface 106 and extend the entire length between the front 110 and
rear 112 sides. It is understood that chamfers 118 may be at an
alternate angle from 45 degrees or may take a rounded or radiused
form as opposed to a substantially flat chamfer as shown. The
second support 16 is preferably made from expanded polypropylene or
polyurethane cut or molded to the desired shape as substantially
shown in FIG. 4. Alternate materials for second support 16 include
those previously described for first support 14. As best seen in
FIGS. 1 and 2, second supports 16 are positioned on bottom panel 29
adjacent to the respective first side creases 46 and rear edge 26
as substantially shown.
[0045] Referring to the shipping container 10 in FIGS. 1-6, The
second supports 16 are preferably secured to the shell 12 by a hot
melt-type adhesive 124 which is pre-applied in one or two strips or
beads or other patterns to surface 104 of the second supports 16
respectively. The second supports 16 are then placed in contact
with and disposed on bottom panel 29. Alternate methods to secure
second supports 16 to the container 10 include adhesives other than
a hot melt-type, double-sided adhesive tapes and films, or
mechanical fasteners such as staples through substrate 20 into the
supports 14 and 16.
[0046] Referring to FIGS. 7 and 15, second supports 200 are not
mounted to shell 250 but are moveable within shell 250. In an
installed position in shell two, and on installation of the
article, for example hood 18, second supports abut opposing side
panels 264 and end panel 266 of the shell lower portion 260
[0047] Referring to FIGS. 1, 2 and 5, an automotive hood 18 is
mounted in the first supports 14 and second supports 16. The rear
corners of hood 18 are positioned in inner channel 114 and more
particularly in undercut 116, and the forward, outer edges of hood
18 are positioned in open channel 88 in first supports 14 and are
preferably in contact with rounded portions 90 to positively locate
and retain hood 18 from lateral movement relative to bottom panel
29. Following installation of hood 18 in shipping container 10,
bottom flanges 32 on bottom panel 29 are folded or rotated about
first creases 34 to angularly displace bottom flanges 32 with
respect to bottom panel 29 to an approximately perpendicular
orientation as best seen in FIG. 5. The first front 58 and first
rear 59 flanges on first top panel 52 are similarly displaced in a
perpendicular orientation along second creases 62. Second front 60
and second rear 61 flanges of second top panel 58 are also
displaced at an angular orientation of approximately 90 degrees to
second top panel 54 in a similar manner. At this stage of assembly,
the two beads of adhesive 124 that were pre-applied on top surface
102 of rear supports 16, are revealed through removal of contact or
release paper, not shown, to expose the adhesive as shown in FIGS.
1-4.
[0048] As best seen in FIGS. 5 and 6, side panel 44 adjacent to
second top panel 54 is rotated about first side crease 46 until
side panel 44 is approximately 90 degrees with respect to bottom
panel 29. In this position, side panel 44 is directly adjacent to
or in slight contact with outer surfaces 84 and 106 of front
supports 14 and rear supports 16 supports. Second top panel 54 is
then rotated or folded along second side crease 48 to angularly
displace second top panel 54 at approximately 90 degrees with
respect to side panel 44 thereby placing second top panel 54 in
opposing and substantially parallel orientation to bottom panel 29
as best seen in FIG. 6. In this position, second front 60 and
second rear 61 flanges are positioned toward the inside of the
container with respect to bottom flanges 32 of bottom panel 29. In
this position, adhesive 124 on rear supports 16 adjacent to second
top panel 54 is compressed against second top panel 54 thereby
securing second top panel 54 to the rear supports 16 and bottom
panel 29. To facilitate easy angular rotation of side panel 44 and
second top panel 54 with respect to bottom panel 29, chamfers 92
(optional) and 118 of front 14 and rear supports 16 respectively
are utilized to accommodate variances in substrate 20 and variances
in first 46 and second 48 side creases both in position of the
creases and radii of the creases when folded. Chamfers 92
(optional) and 118 further accommodate variances with respect to
the variable positioning or the supports 14 and 16.
[0049] First top panel 52 and side panel 44 are similarly displaced
in angular orientation to bottom panel 29 along first 46 and second
48 side creases at approximately 90 degree angles to position first
top panel 52 in overlapping relation to second top panel 54 and in
opposing and parallel orientation to bottom panel 29 as best seen
in FIG. 6. In this position, adhesive 124 on the exposed top
surfaces 102 of and rear supports 16 adjacent to first top panel 52
is compressed against first top panel 52 thereby securing first top
panel 52 in this position similar to second top panel 54 as
previously described. In this position, first front 58 and first
rear 59 flanges are positioned between bottom flanges 32 of bottom
panel 29 and second front 60 and second rear 61 flanges forming
three thicknesses of substrate 20 in overlapping orientation to
deter movement of automotive hood 18 along open 88 and inner 114
channels.
[0050] Referring to FIG. 6, shell 12 optionally further includes
markings or text 128 (shown in phantom) on the outer surface of
substrate 20 to guide a user in applying strapping bands
circumferentially around shipping container 10 to maintain the
flanges 32, 58, 59, 60 and 61 in an approximately 90 degree
orientation to the top and bottom panels to prevent unwanted
longitudinal movement of automotive hood 18 with respect to bottom
panel 29 and to prevent further angular disposition of side panels
44 or matchboxing of the assembled shipping container 10. As shown
in FIG. 6, in a fully assembled position, through openings 126
exist which provide a free flow of air and circulation in shipping
container 10 and around the contents, for example, automotive hood
18. Adhesive 124 on the front and rear supports 14 and 16 prevent
the supports 14 and 16 from dislodging from the hood 18 and
inadvertently exiting the shipping container 10.
[0051] Referring to FIGS. 7-15, an alternative shipping container
10 and support or dunnage blocks 140 and 200 of the present
invention are illustrated.
[0052] FIG. 7 shows a shipping container 10 including a single
first support or dunnage block 140, a pair of second supports or
dunnage blocks 200 and an alternate shell 250 having a bottom
portion 260 and a cover portion 270.
[0053] Referring to FIGS. 7 and 15, an alternate shell 250 is
illustrated. Shell 250 includes a bottom portion 260 having a
generally rectangular bottom panel 262, opposing side panels 264
and an end panel 266 continuous with bottom panel 262. Shell 250
further includes a top cover portion 270 having a complimentary top
panel 272, opposing side panels 274 and an end panel 276 continuous
with top panel 272.
[0054] Top cover portion 270 is sized and configured such that when
rotated about end panel 266 and positioned over bottom portion 250,
down-folded side panels 274 and end panel 266 overlappingly engage
upturned bottom portion side panels 264 thereby enclosing article
18 within shell 250. The cover portion 270 is secured in place by
flange 278 attaching to the underside of bottom panel 262 (not
shown). As with shell 12, shell 250 is exemplary only and can be
any polygonal shape, configuration and material suitable for the
desired article and dunnage supports to be used therewith to be
shipped or stored.
[0055] Referring to FIGS. 7-11, an alternate first support or
dunnage block 14 may comprise a single first support 140. Single
first support 140 is preferably positioned along the front
peripheral edge of the article, for example, hood 18, at the
approximate center of the hood as shown in FIG. 7. As best seen in
FIGS. 8 and 9, first support 140 includes a top surface 142, bottom
surface 144, an inner surface 146, outer surface 148 , and opposing
sides 150. First support 140 includes a first leg 154 and second
leg 156 both extending from an end leg 158 as best seen in FIG.
8.
[0056] First leg 154 and second leg 156 define an open channel 162
including an angled first portion 164 and second portion 166 which
intersect as shown in FIGS. 8 and 9.
[0057] Second portion 166 preferably includes a step 168 adjacent
the intersection. Open channel 162, angled first portion 164,
second portion 166 and step 168 are configured to mount over a
portion of a peripheral edge of, for example, hood 18 as shown in
FIG. 7.
[0058] Referring to FIG. 8, first support 140 preferably includes a
first groove 172 positioned on inner surface 146 of second leg 156.
First groove 172 includes 45.degree. slanted surfaces 175
intersecting an inner face 176. In use with an automotive hood 18,
first groove 176 is configured and positioned to accept the hood
latch (not shown) of hood 18 and further function to deter lateral
movement of the hood 18 with respect to center support 140. It is
understood that first groove 172 may take different shapes, forms
suitable for acceptance of latches, hardware and other features of
the article disposed in shell 250.
[0059] First support 140 preferably includes a second groove 180
including 45.degree. slanted surfaces 182 intersecting an inner
surface 184 as well as 45.degree. chamfers 186 as best seen FIG. 8.
These features are primarily for reductions in weight and in the
material needed to manufacture the support while maintaining the
desired structural and impact absorption properties. It is
understood that second groove 180 and chamfers 186 may take other
shapes and forms suitable for the application or may be eliminated
altogether.
[0060] Referring to FIG. 11, first support 140 preferably includes
a panel 194 mounted to the outer surface 148 of first support 140.
Panel 194 is configured to assist in the positioning of first
support 140 in shell 250 and deters lateral movement of support 140
in shell 250. Panel 194 is made from corrugated cardboard and has a
crease 196 providing for controlled bending or distortion of the
panel 194 for positioning and stability purposes. Panel 194 may be
mounted to first support 140 by gluing, taping, stapling, staking
or other suitable means.
[0061] First support 140 is preferably made from expanded
polyurethane cut or molded to the desired shape having a density in
the range from about 1.5 lbs/ft.sup.3 to 3.0 lbs/ft.sup.3. In a
most preferred aspect, the polyurethane density is from about 2.1
lbs/ft.sup.3 to about 2.8 lbs/ft.sup.3. A suitable but exemplary
polyurethane foam for first support 140 is INSTPAK G-FLEX foam
manufactured by Sealed Air Corporation. In an alternate aspect,
first support 140 can be made from expanded polypropylene cut or
molded to the desired shape having a density in a range from about
1.8 lbs/ft.sup.3 to 3.2 lbs/ft.sup.3. When polypropylene is used
for support 140, the most preferred density is from about 2.5
lbs/ft.sup.3 to about 3.1 lbs/ft.sup.3. A suitable but exemplary
polypropylene for support 140 is manufactured by BASF under the
trademark NEOPOLEN P in the densities described above.
[0062] Referring to FIGS. 8-10, first support 140 includes two
first insert blocks 192 positioned in end leg 158 as shown. First
insert blocks 192 are, for example, polygonal in shape and are made
from expanded polypropylene cut or molded to the desired shape
having a density in a range from about 1.8 lbs/ft.sup.3 to 3.2
lbs/ft.sup.3. In a most preferred aspect, the polypropylene has a
density from about 2.5 lbs/ft.sup.3 to about 3.1 lbs/ft.sup.3.
First insert blocks 192 are insert molded into first support 140 in
the approximate locations in end leg 158 as shown. A suitable
polypropylene for insert block 192 is manufactured by BASF under
the trademark NEOPOLEN P in the densities described above. In an
alternate aspect, insert blocks 192 are made from polytheylene
having a density in a range from about 2 lbs/ft.sup.3 to about 9
lbs/ft.sup.3
[0063] In a most preferred aspect, support 140 is made from
polyurethane and insert blocks 192 are made from polypropylene in
the most preferred density ranges described above.
[0064] It is understood that one or more supports 140 may be used
to support an article and the placement on the article and the
position in shell 250 may vary depending on the application. It is
further understood that a single or additional insert blocks 192
may be used and their size, shape and configuration may vary to
suit center support 140 or first support 14 to suit the
application. Referring to FIGS. 7 and 12-14, alternate second
supports or dunnage blocks 200 are shown. Second support 200
include a top surface 202, bottom surface 204, inner surface 206,
outer surface 208, a front side 209 and a rear side 210. Second
supports 200 have an inner channel opening 212, a chamfer 214 and
an undercut (not shown) as previously described and illustrated for
alternate second support 16. Second support 200 preferably includes
third grooves 216 and chamfers 222 on top 202 and bottom 204
surfaces having slanted surfaces 218 and inner surfaces 220 similar
to second groove 180 and chamfers 186 in center support 140.
[0065] It is understood that third grooves 216 and chamfers 222 may
be of different shapes, sizes and orientation then that as shown to
suit the application or eliminated altogether without deviating
from the present invention. It is also understood that inner
channel 212 may also vary in size, shape and orientation to suit
the application. It is further understood that a single or
additional second supports 200 may be used to suit the particular
application.
[0066] Each second support 200 preferably includes a second insert
block 224 as shown in FIGS. 13 and 14. Second insert block 224
includes a top surface 226, bottom surface 228, inner surface 230,
outer surface 232 and opposing sides 234. Second insert block 224
preferably includes an inner slot 236 which is positioned and
configured to accommodate inner channel 212 of the second support
200 as best seen as assembled in FIG. 14. Second insert 224 is
preferably made from expanded polypropylene or polyethylene cut or
molded to the desired shape as previously described for first
insert 192 and is insert molded into second support 200 as shown in
FIG. 14. When second insert 224 is used in second support 200,
second support 200 is preferably made from polyurethane as
previously described for first support 140.
[0067] It is understood that one or more second inserts 224 may be
used in second support 200 to suit the application or desired
characteristics, or as shown in the alternate second support 16,
not used at all. It is further understood that different materials
other than polyurethane, polypropylene or polyethylene and in
different densities than those described above for the dunnage
supports and insert blocks may be used to provide the desired
characteristics described herein without deviating from the present
invention.
[0068] In a preferred aspect, first center support 140 having the
first inserts 192 is used together with second supports 200 having
second insert 224 and shell 250 to comprise a shipping container
10.
[0069] Referring to FIGS. 7 and 15, in an alternate aspect, the
article, for example, an automobile hood 18 is positioned in bottom
shell portion 260 and into inner channels 212 in second supports or
dunnage blocks 200 and in the open channel 162 in first support or
dunnage block 140 as substantially described above. Shell cover
portion 270 is positioned over bottom portion 250 to enclose hood
18 in shipping container 10. Cover portion 270 is secured to bottom
portion 250 by strapping, taping, gluing, stapling or other
suitable means for shipment and storage.
[0070] In summary, there has been disclosed a unique shipping
container and dunnage supports which are designed for easy closure,
optimum article support and protection and minimal disposable
dunnage for a low article manufacturing cost.
* * * * *