U.S. patent application number 10/856407 was filed with the patent office on 2005-08-25 for shipping package system for fragile panels.
Invention is credited to Carroll, Arch W. JR., Christensen, D. Carl, Nelson, Mark A..
Application Number | 20050183978 10/856407 |
Document ID | / |
Family ID | 34861366 |
Filed Date | 2005-08-25 |
United States Patent
Application |
20050183978 |
Kind Code |
A1 |
Christensen, D. Carl ; et
al. |
August 25, 2005 |
Shipping package system for fragile panels
Abstract
A product vulnerable to damage during shipping, such as an
automobile windshield glass, for example, is mounted on a support
pad and fixed onto the pad by wrapping a stretch wrapping film
around the combination of the pad and glass. The borders of the pad
extend beyond the borders of the glass so the package containing
the glass can be stood on edge, but the edge of the glass is spaced
away from the surface on which the package is stood. Thus the
glass, secured to the pad, is suspended away from that surface.
Multiple packages can be packed into a shipping container and the
loaded container can be lifted and transported by a lift truck with
lifting forks received in passageways formed in the container by
notches in the bottom edges of the support pads. The pads and
containers are made of die-cut. corrugated fiberboard material
although other material might also be used in the practice of the
invention.
Inventors: |
Christensen, D. Carl; (Peru,
IN) ; Nelson, Mark A.; (Marion, IN) ; Carroll,
Arch W. JR.; (Marion, IN) |
Correspondence
Address: |
BAKER & DANIELS LLP
300 NORTH MERIDIAN STREET
SUITE 2700
INDIANAPOLIS
IN
46204
US
|
Family ID: |
34861366 |
Appl. No.: |
10/856407 |
Filed: |
May 28, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10856407 |
May 28, 2004 |
|
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|
10783914 |
Feb 20, 2004 |
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Current U.S.
Class: |
206/448 ;
206/449; 206/454 |
Current CPC
Class: |
B65D 85/48 20130101;
B65D 57/00 20130101 |
Class at
Publication: |
206/448 ;
206/449; 206/454 |
International
Class: |
B65D 085/00 |
Claims
What is claimed is:
1. Product packaging apparatus comprising: a support having a front
face and a rear face and having top and bottom edges and left and
right side edges; the support having at least one recess in the
bottom edge and at least one recess in the top edge; the support
having forwardly projecting extensions at said side edges thereby
providing forwardly projecting panels for resistance of said
support to bending about axes parallel to a line containing said
bottom edge; and wrapping film received in said recesses and
stretched around said support between said recesses for enveloping
a portion of the product to be packaged and a portion of the
support and for securing the product to the support in a position
of the product within the perimeter of the support.
2. A package comprising: a product to be protected and having a
perimeter edge and a front surface and having some exterior
corners, the product having dimensions in x-axis and y-axis and
z-axis directions, and the maximum x-axis dimension and the maximum
y-axis dimension each being greater than the maximum z-axis
dimension; a support pad having a perimeter edge, top and bottom
edges and left and right side edges and having sufficient vertical
column strength from top to bottom to support the product without
deforming, the bottom edge of the support pad having at least two
points on a straight line for stable mounting of the bottom edge of
the support on the bottom of a shipping container, the support pad
having means for locating the product on the front face of the
support pad, the entire perimeter edge of the product lying within
said means for locating and within the perimeter edge of the
support pad, the support pad having edge extension panels
projecting forward from the pad a distance at least as great as the
maximum z-axis dimension of the product; and a stretch wrapping
film wrapped around the support and the product and securing the
product to the support pad to prevent movement of the product
relative to the support pad.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to packaging for
shipment of products whose configurations have length and width
that are large relative to depth, and more particularly to
packaging such products which are made of materials or have
construction features which are easy to break or otherwise damage
in shipping operations.
[0002] Current bulk packaging of windshields for the automotive
after-market trade is predominantly configured to hold twenty-five
or more windshields. Such packaging involves construction of wooden
frame with corrugated fiberboard attached around the framing, along
with several other packaging components to protect various fragile
contact points of the individual windshields. A considerable amount
of labor is required to configure the packaging for use by the
manufacturer of the glass. The containers are required to be
"pre-erected" and they present difficulties in the shipping and
storage of empty containers.
SUMMARY OF THE INVENTION
[0003] One aspect of the invention provides means and method for
protection of products individually during storage and
shipment.
[0004] Another aspect is facilitating the standing of individual
product containing packages on edge on a floor, a table, a "bulk
pack" container bottom, or other supporting surface, but suspending
the product spaced away from the supporting surface.
[0005] Another aspect of the invention provides a support pad
shaped to facilitate placement of the product to be shipped, within
the perimeter of the pad, and stretch wraps the product onto the
pad with commercially available stretch film using the stretch and
holding properties of the film and thereby secures the product in
place on the pad within the perimeter of the pad.
[0006] Another aspect of the invention is that a single
wrapped-product package can be placed in a container and shipped to
a customer.
[0007] Another aspect is packaging a product so that a number of
packages of individual products can be "collated" into a shipping
container.
[0008] Another aspect of the invention is that shipping containers
filled with a number of packages of individual products can be
provided, using cohesive properties of stretch wrap film to add
stability to such "bulk packs" without separators between the
individual packages.
[0009] Another aspect of the invention is that a support pad and
shipping container can be made of materials "Knocked down flat",
and stored flat until the product to be shipped is manufactured and
ready to pack out. At that time the pad and container materials can
be erected for packaging the product.
[0010] Another aspect of the invention is provision of holes in
shipping containers for entry of forks of lift trucks enabling the
lifting, transportation and storage of loaded containers without
separate pallets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front perspective view of a windshield package
according to one embodiment of the present invention.
[0012] FIG. 2 is a rear perspective view of the package of FIG.
1.
[0013] FIG. 3 is a front view of a pattern for a two-tab corrugated
fiberboard blank for a windshield suspension pad according to
another embodiment of the invention.
[0014] FIG. 4 is a schematic diagram showing a windshield about to
be installed on a fiberboard blank according to the pattern of FIG.
3.
[0015] FIG. 5 is a view showing the windshield installed on the
blank.
[0016] FIG. 6 shows the tabs folded up over the bottom edge of the
windshield.
[0017] FIG. 7 shows the windshield and pad wrapped with stretch
wrap film suspending the windshield on the pad and thus forming a
windshield package.
[0018] FIG. 8 shows a corrugated fiberboard blank for a shipping
container bottom tray according to one aspect of the invention.
[0019] FIG. 9 shows the blank of FIG. 8 erected to form a bottom
tray, and a similar blank erected to form a top tray or lid of the
shipping container to be filled with the windshield packages.
[0020] FIG. 10 is a view of the back of a package suspending a
windshield therein and being carried conveniently by a worker.
[0021] FIG. 11 is a top view of a plurality of such packages
arranged in an X-shaped configuration in a container bottom
tray.
[0022] FIG. 12 is a perspective view showing the packages in a
shipping container ready for installation of the top.
[0023] FIG. 13 shows the container closed and strapped closed.
[0024] FIG. 14 is similar to FIG. 13 but with a portion broken out
of the corner to show the pads mounted directly on the floor of the
container and with the bottom notches in the pad oriented for
access by the lifting forks of a lift truck.
[0025] FIG. 15 is a front perspective view of a cabinet door
package prepared according to an embodiment of the present
invention.
DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0026] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended, such alterations and further modifications in the
illustrated device, and such further applications of the principles
of the invention as illustrated therein being contemplated as would
normally occur to one skilled in the art to which the invention
relates.
[0027] Referring now to FIGS. 1 and 2, a package according to one
embodiment of the present invention is shown. It includes a
corrugated fiberboard pad 11 cut to provide three tabs 12 at the
bottom edge 13 and which have been turned upward to produce notches
14. Similarly, three notches 16 have been provided in the upper
edge 17. In these instances, instead of forming tabs at the
notches, the material has been completely blanked out of the
board.
[0028] A curved windshield 18 is mounted to the pad 11 and is
secured to the pad by film stretch wrapped around the pad and the
windshield as at 19. the wrapping material can be wrapped by
machine or by hand, and the pattern can be random as long as there
is control of location of the windshield on the pad so that the
entire perimeter 21 of the windshield is well within the bottom and
top edges 13 and 17 of the pad and the side edges 22 and 23 of the
pad. The film wrapping through the notches and around the edge of
the windshield at the top and around the tabs at the bottom is
important. It is preferable that the wrapping from top to bottom is
performed across the majority of the width of the windshield. While
the wrapping from top to bottom notches can be parallel on either
the front as shown in FIG. 1, or the back, it is preferable that
there be continuous wrap from notches in the upper edge diagonally
to notches in the lower edge on at least the front or the back and,
preferably, on both front and back of the package. A combination of
this angled wrapping with straight wrapping from top notch to
bottom notch and from portions of the top edge other than notches,
to portions of the bottom edge both notched and without notches, is
shown on the backside of the pad in FIG. 2. So the stretch wrapping
of the windshield is adequate to suspend the windshield on the pad
with all features of the windshield edges well within the area
defined by the perimeter of the pad. The upturned tabs 12 held in
place by the wrapping may assist in supporting the weight of the
windshield during the wrapping and subsequent handling and
transportation.
[0029] Referring now to FIG. 3, there is shown a drawing pattern
for a die-cut pad 26 of 275 pound double-walled corrugated
fiberboard material. Dimensions in inches are shown as an example.
In the resulting die-cut pad, the top edge 27 has two notches 28
punched completely out. The side edges 29 and 31 are straight. The
bottom edge 32 is notched at four places to form two tabs 33 and 34
with light score lines such as 36 to facilitate folding them
forward. A hand hole 35 is blanked out of the middle. The printed
outline of the windshield to be suspended on this pad is printed on
the pad as shown at 37, 38, 39 and 41. This outline provides
appropriate guidelines for the placement location of the windshield
on the pad for stretch wrapping. Various other ways for proper
product placement can be used. Another example is die cuts to
produces holes, marks or tabs for orientation points. Of course
such cuts can be provided at the same time that the pad is cut from
stock.
[0030] Referring now to FIG. 4, the blank 26 is shown ready for
mounting the windshield 42 on it The windshield is placed on the
pad as shown in FIG. 5, and the tabs 33 and 34 are turned upward
and forward in the direction of arrows 43 so that they overlap the
front face of the windshield at the bottom edge as shown in FIG. 6.
The score lines such as 36 on the pad 26 assure that when the tabs
are bent forward and upward the windshield will be properly located
with its lower edge overlying the pattern drawn or otherwise placed
on the front of the pad 26.
[0031] When the windshield has been positioned such that it matches
the pattern of lines, the stretch wrap film 44 is stretch wrapped
around the pad and the windshield, with the film being wrapped
through notches 28 at the top and around and covering the tabs 33
and 34 at the bottom, securely locating the windshield on the pad.
Stretch wrap is continued as needed or desired around the front of
the windshield and the back of the pad. When the amount of stretch
wrapping ahs been completed to provide the degree of attachment and
protection desired, the wrap film can be cut, and the end portion
of the film adhered to the portion already wrapped, using the
benefit of the cohesive nature of the wrapping film. If desired,
the amount of warp shown on the front of the windshield at FIG. 7,
can be more than necessary to simply suspend the windshield
securely on the pad, and/or can be spread out the whole width of
the windshield, to serve additional useful purpose as will be
described later herein.
[0032] Referring now to FIG. 8, a die-cut blank 46 of double wall.
275# corrugated fiberboard or any other appropriate strength
material is shown for the bottom "tray" of a shipping container. It
has the usual bottom panel 47 with sidewalls 48, end walls 51 and
flaps 52 on the end walls. The sidewalls have holes punched at 53.
This blank can be erected as shown in FIG. 9, gluing or otherwise
securing the flaps 52 to the side walls in conventional fashion. A
top 56 can be made according to the same form or pattern blank as
for the bottom tray, but omitting holes 53, and made slightly
larger than the bottom tray, to slide down on it in the direction
of arrows 57 to close the shipper.
[0033] Prior to closing the shipper, it is filled with window
packages such as described above with reference to FIGS. 3-7. After
wrapping the window, the wrapped window package 45 (FIG. 7) can be
picked up and conveniently carried by the worker standing at either
the front of the wrapped windshield and pad, or at the rear, and
inserting a hand in the hand hole 35 as shown in FIG. 10, and
picking up and carrying the windshield to the shipper tray 46 and
placing the windshield in the tray with the bottom edge 32 of the
pad resting on the bottom 47 of the tray. Since the windshield is
curved, the rapping with stretch wrap imparts a curve to the pad.
Such curve is shown in FIGS. 1, 2, 11 and 12. Therefore, the
windshields will be placed in the tray in an "X" configuration as
shown in FIGS. 11 and 12. By placing them in this configuration,
instead of nesting all windshield packages in one orientation, half
of them are oriented in one direction and the other half in the
other direction. Therefore the convex front surfaces of all of the
packages face inwardly toward the center plane 61 (FIGS. 8 and 11)
of the container. The two windshield packages 45L and 45R at the
center of the container, could have their convex front faces in
abutting relationship. Therefore, it may be desirable that the
wrapping for these two packages be extra thick to prevent any left
to right (FIG. 11) shifting of the packages. Alternatively, and
more likely than extra wrapping on center packages, some packing
material can be placed between these facing windshield packages 45L
and 45R. An example is one double wall panel 50 of corrugated
fiberboard. The rest of the packages nest. The side edges 29 and 31
of the pads are close enough to the end walls 51 of the tray that
there is no shifting sideways of the windshields within the
tray.
[0034] Bottom notches 14 were mentioned with reference to the
embodiment of FIGS. 1 and 2. Similarly, there are the bottom
notches 30 in the pads of the illustrations of the two-notch
embodiment of the FIGS. 3-7 and 10-14. According to another feature
of the invention mentioned with reference to FIG. 8, there are four
holes 53 in the sidewall 48 of the bottom tray 46 of the container.
As best shown in FIG. 14, the bottom edges 32 of the pads rest on
the floor 47 of the tray 46. the top of each of the notches 30 is
spaced above the tray bottom 47. The holes 53 are aligned with the
notches in the pads, all of which are aligned in two rows 35 (FIG.
11) when the containers have been packed with the packages 45. The
holes 53 provides access to the lifting forks 40 of a fork lift
truck. Thus, it is possible to use the packed containers according
to the present invention, without pallets, because the forks of the
lift truck can enter the access holes 53 and pass through notches
30 under the windshields and lift the whole shipper and transport
it as needed. The upturned tabs 34, and stretch wrapping around
them, provide protection for the pads and the suspended windshield
glasses. If further protection is desired to assure prevention of
edge crush of the pads by lifting forks at notches 30, some tubes
or downwardly opening channels made of corrugated fiberboard or
other material can be placed from the access holes 53 in one tray
wall and extend through the passageways formed by the bottom
notches 30 of the pads to the access holes in the opposite wall of
the tray. An example of such channel is shown in FIG. 12 where two
such channels 55 are shown partially inserted into the two
passageways 35 (FIG. 11) formed by the two notches 30 each, of all
of the pads in a filled container bottom tray. This is a way that,
if needed or desired, additional protection can be provided in the
tops of the passageways formed by the notches 30 in all of the
window packages from one of the walls 48 through the container to
the other wall 48. After a container is filled, the lid 56 can be
installed and can rest on the upper edges 27 of the suspension pads
and strapped closed by poly strapping 64 in two places, running
through the access holes 53, and under the pads through the notches
30. If desired to preclude any edge crush by the strapping 64, some
tabs 66 of fiberboard or other material can be folded around the
upper edges of the holes 53 as shown in FIG. 13. Similar protection
can be provided at other locations such as 67.
[0035] Packaging according to the present invention may be done by
performing the stretch wrapping by hand. But various stretch
wrapping machines are known. Examples are referenced in U.S. Pat.
Nos. 6,564,532 and 6,550,222, and the references cited therein.
Another is the "Yellow Jacket 110" which is a horizontal stretch
wrapping machine by Wiley Metal, of Marion Ind., U.S.A. So the
product and pad can be stretch wrapped by machine, if desired.
[0036] The packaging of automotive window products individually and
"collating" a number of the packages into a shipping container can
have real advantages over conventional practices. It allows safer
and easier handling of individual glass components, as the stretch
wrapping can be extensive enough, if desired, to cover the entire
perimeter of the glass and thereby preclude encounter of any edge
of glass by a worker while loading the packages into a shipping
container. Additionally, the cohesive properties of the stretch
wrap film, as one package nests against another, can lend stability
to the bulk packs of multiple packages, by virtually eliminating
the tendency of windshields to "shingle", i.e. slide out of the
bottom of current conventional packaging. It can also reduce the
incidence of damage in transit.
[0037] In the foregoing description, the illustrated embodiments
show forwardly and upwardly turned bottom tabs on the pad. The
weight and application of the product to the pad can have a bearing
on whether it is desirable or necessary to sue tabs at the bottom
or at the top (at the location of the notches 28) or both bottom
and top, or not at all. If the glass or other product to be
suspended to a pad according to the invention is relatively flat,
it may be desirable to have notches in the side edges of the pad as
well as in the top and bottom, and stretch wrap film around the
product, not only in and through the notches in the top and bottom
edges, but also in and through notches in the side edges.
[0038] It should be understood that the invention can be employed
using suspension pad materials other than 350 pound, double walled
corrugated fiberboard. It depends on the nature and weight of the
product to be suspended. Since the space requirement of the
suspended product is usually significantly greater in length and
width, than in thickness, it is usually suspended such that the
package will be packed on edge in the shipper. Therefore the
fiberboard will be oriented with the flutes running vertically to
provide the needed vertical column strength. It is conceivable that
a pad with only one facing secured to the corrugated media, might
be sufficient in some applications.
[0039] It is also conceivable that the pad be made of material
other than corrugated fiberboard. A plastic or metal might also be
used. Desirability and height of stacking containers in warehouses
or vehicles, weight and nature of the packaged product, and other
considerations could dictate features of pads made of other
materials, to provide the necessary column or top-to-bottom
stacking strength of the pad. For example, if plastic were used, it
might be necessary to have a corrugated component. Another
consideration is the condition of the surface of the pad material,
which is contacted by the product to be suspended. It cannot be
abrasive, if abrasion of the product portion in contact would be
detrimental to the needed appearance or performance of the product.
Otherwise, it may be necessary to stretch wrap portions of the pad
before placing the product on the pad, so that the stretch wrap
film will protect the pad-engaging portions of the product from
abrasion, and then wrap the product onto the pad. Alternatively, a
non-abrasive coating can be provided on the front of the pad where
the product will contact it.
[0040] The thickness of the wrap film used depends on what is
necessary to get a snug covering of the product on the pad. Where
the product will be machine-wrapped onto the pad, film selected
will be dictated largely by optimum effectiveness of performance of
the wrapping machine.
[0041] If, instead of bulk shipping of ten to thirty or more
packages, only one package is to be shipped, a simple container can
be employed. If the product is curved, as for a windshield or
backlight (back window), the corners may appear to be more
vulnerable than inboard portions of the window. Dunnage can be
placed in the container if desired so that the corners of the pad
remain properly situated in the corners of the container. the
corners of the glass, being well inboard from the corners of the
container, are well protected. If desired, instead of adding
dunnage, pad extension panels or "wings" 26W (FIG. 3) can be
provided by scoring or creasing the pad at locations 29 and 31.
This will allow the panels to be folded forward at a ninety-degree
angle from the plane of the face of the pad and extend across the
width or short dimension of the shipping container. The short
dimension will be relatively small, as the container is containing
only one product package. Therefore the extension panels locate the
pad in the container not only side-to-side, but also front-to-rear
and, with the back of the pad located against the back of the
container, and corners of the product touching or near the front of
the pad, the edges and corners of the product are kept away from
the front of the container.
[0042] In the description above, the packaged product has been made
of glass. The invention is useful for the packaging and shipping of
a variety of other products, where the product is three dimensional
but the x-axis and y-axis dimensions are significantly greater than
the z-axis dimension. Frequently, for various reasons such as, for
example, convenience is removal of a certain package from a group,
or to avoid warp, it is preferred to pack, store and ship the
products oriented on an edge, like books in a bookcase. In the
above examples, the side-to-side (x-axis) and top-to-bottom
(y-axis) dimensions are significantly greater for the curved
windshield than is the maximum dimension on the front-to-back
(z-axis) i.e. the distance between imaginary parallel planes, one
of which touches the most forward point of the glass and the other
of which touches the most backward point of the glass.
[0043] Another product having such high and wide relative to
front-to-rear dimensional relationship is shown in FIG. 15. It is a
furniture cabinet door, with a glass window in it. Although the
door without the window, might not be considered fragile, it is
desirable it not be damaged in packaging or shipping. The present
invention avoids risk of damage that could occur on the bottom edge
if the door were resting on that edge. So referring to FIG. 15, the
pad 71 of corrugated fiberboard has top, bottom, left and right
edges 72, 73, 74 and 76, respectively. Each of these edges has a
notch in it. The cabinet door 77 is suspended on the pad by stretch
wrapping stretch wrap film 78 from top to bottom edge notches and
side to side edge notches as shown. The wrapping in the front
envelops the door and pad at the front, and crosses in the front
and back in whatever is found most convenient for the wrapping
personnel or wrapping machinery used. Since a single continuous
length of film 78 can be used in this example as in the
above-described examples, portions of the wrap can be at angles
between notches as at 78A in front or in back or both, whatever is
convenient and sufficient to hold the door snugly against the pad
and within the perimeter of the pad. In any case, the entire
perimeter of the door is within the entire perimeter of the support
pad, even considering the notch contour as part of the perimeter of
the pad. Pad and wrapping technique can be tailored to the
particular product to be suspended. In any case, the weight of the
product is not transmitted directly from a portion of the product
to any portion of the container in which it is shipped. The product
is suspended on the pad, and the weight is transmitted through the
pad to the container, thus protecting the product from damage. Of
course the window 79 in the door is amply protected.
[0044] The pad for the package of FIG. 15, with the single notch in
each edge, results in a sort of clover shaped pad. Multiple side
edge notches and top and bottom edge notches can be provided if
desire for best product suspension, depending on the nature of the
product packaged.
[0045] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the preferred embodiment has been shown
and described and that all changes and modifications that come
within the spirit of the invention are desired to be protected. It
should be understood that while the use of the word preferable,
preferably or preferred in the description above indicates that the
feature so described may be more desirable, if nonetheless may not
be necessary and embodiments lacking the same may be contemplated
as within the scope of the invention, that scope being defined by
the claims that follow.
* * * * *