U.S. patent application number 11/045856 was filed with the patent office on 2005-09-22 for packaging system, apparatus, and method with extruded force absorbing truss members.
Invention is credited to Carpenter, Gary, Powell, Robbie Rex.
Application Number | 20050204964 11/045856 |
Document ID | / |
Family ID | 46303799 |
Filed Date | 2005-09-22 |
United States Patent
Application |
20050204964 |
Kind Code |
A1 |
Carpenter, Gary ; et
al. |
September 22, 2005 |
Packaging system, apparatus, and method with extruded force
absorbing truss members
Abstract
A system, apparatus, and method for use in the packing of an
appliance containing a pallet, corner members, and truss members
are provided. The pallet comprises first and second support
members, a connecting cross member, and at least one truss member
for providing peripheral and oblique force absorption, wherein the
cross member is substantially perpendicular to the first and second
support members. The first and second support members include
attachment holes, wherein the attachment holes allow for the
attachment of the pallet to the appliance. The first and second
support members and the cross member are manufactured from a
synthetic substance and are substantially hollow. The system
further comprises an available plurality of articulable corner
support members, corner junction end caps with tenons, closed cell
design elements, and standoffs used to protect, support, separate
and/or stabilize the appliance in a container.
Inventors: |
Carpenter, Gary;
(Carrollton, TX) ; Powell, Robbie Rex; (Bonham,
TX) |
Correspondence
Address: |
Schultz & Associates, P.C.
One Lincoln Centre
Suite 1200
5400 LBJ Freeway
Dallas
TX
75240
US
|
Family ID: |
46303799 |
Appl. No.: |
11/045856 |
Filed: |
January 28, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11045856 |
Jan 28, 2005 |
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10860518 |
Jun 3, 2004 |
|
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10860518 |
Jun 3, 2004 |
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10637220 |
Aug 8, 2003 |
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Current U.S.
Class: |
108/51.11 |
Current CPC
Class: |
B65D 2519/00407
20130101; B65D 2519/00278 20130101; B65D 2519/00412 20130101; B65D
2519/00139 20130101; B65D 2519/00273 20130101; B65D 2519/00318
20130101; B65D 2519/00442 20130101; B65D 19/44 20130101; B65D
2519/00333 20130101; B65D 81/054 20130101; B65D 19/06 20130101;
B65D 2519/00034 20130101; B65D 81/053 20130101; B65D 85/64
20130101; B65D 2519/00283 20130101; B65D 2519/00815 20130101; B65D
2519/00069 20130101; B65D 2581/055 20130101; B65D 2519/00159
20130101; B65D 2519/00437 20130101 |
Class at
Publication: |
108/051.11 |
International
Class: |
B65D 019/00 |
Claims
1. A truss member apparatus for absorbing external forces within a
container, the truss member comprising: an elongated extruded
housing; and, wherein the housing comprises a plurality of extruded
socket portions for increasing the structural longitudinal
integrity of the housing.
2. The truss member of claim 1, wherein the extruded housing
comprises a top wall, a bottom wall, and two side walls.
3. The truss member of claim 2, wherein at least one extruded rib
member is interconnected between the top wall and the bottom
wall.
4. The truss member of claim 2, wherein an extruded socket portion
is spaced into the top wall.
5. The truss member of claim 2, wherein an extruded socket portion
is spaced into the bottom wall.
6. The truss member of claim 2 wherein extruded socket portions are
spaced into the top wall and the bottom wall.
7. The truss member of claim 6 wherein the extruded socket portions
are spaced into the center regions of the top wall and the bottom
wall.
8. The truss member of claim 1 wherein the truss member housing is
extruded from the group consisting of polyethylene and
polypropylene.
9. The truss member of claim 1 wherein a truss member of about 40
inches in length can sustain at least 2000 pounds of clamping
without decreasing in length more than about 1/4 inch at a
temperature range of about -20.degree. F. to +140.degree. F.
10. A truss member apparatus for absorbing external forces within a
container, the truss member comprising: an elongated extruded
housing; wherein the housing comprises a plurality of extruded
socket portions; and, at least one inner rib member positioned
within the housing for increasing the structural integrity of the
extruded housing.
11. The truss member of claim 10, wherein the extruded housing
comprises a top wall, a bottom wall, and two side walls.
12. The truss member of claim 11, wherein the at least one inner
rib member is interconnected between the top wall and the bottom
wall, wherein the at least one rib member is positioned
substantially perpendicular to the top and bottom walls and
positioned substantially parallel with the two side walls
13. The truss member of claim 11, wherein an extruded socket
portion is spaced into the top wall.
14. The truss member of claim 11 wherein an extruded socket portion
is spaced into the bottom wall.
15. The truss member of claim 11 wherein extruded socket portions
are spaced into the top wall and the bottom wall.
16. The truss member of claim 15 wherein extruded socket portions
are spaced into the center regions of the top wall and the bottom
wall.
17. The truss member of claim 10 wherein the at least one inner rib
member has a substantially planar cross section.
18. The truss member of claim 15 wherein the at least one inner rib
member is interconnected between the inner side of the socket
portion of the top wall and the inner side of the socket portion of
the bottom wall.
19. The truss member of claim 10 wherein the inner rib member has a
wave shaped cross section.
20. The truss member of claim 10 wherein two or more inner rib
members are interconnected between the inner side of the socket
portion of the top wall and the inner side of the socket portion of
the bottom wall.
21. The truss member of claim 10 wherein two or more inner rib
members are interconnected between the inner side of the top wall
and the inner side of the bottom wall.
22. A packaging support and protection system for an appliance in a
container comprising: a pallet; and, a plurality of extruded truss
members for providing peripheral and oblique absorption of external
forces wherein the truss members comprise a plurality of socket
portions in functional positional relationship with the pallet.
23. The system of claim 22 further comprising a plurality of
articulable corner/edge support members having interlocking
means.
24. A packaging support and protection system for an appliance in a
container comprising: a pallet; a plurality of extruded truss
members in a functional positional relationship with the pallet for
providing peripheral and oblique absorption of external forces
sustained wherein the extruded truss members comprise a plurality
of socket portions; and, at least one inner rib member for
increasing the structural integrity wherein the at least one inner
rib member is positioned inside the truss member interconnected
between the plurality of socket portions.
25. A method for packing an appliance, the method comprising:
providing a pallet; providing a container; positioning the pallet
with the container; providing an appliance; packing the appliance
in the container; providing a force absorption means; positioning
the force absorption means in functional positional agreement with
the container and the appliance.
26. The method of claim 25 wherein the force absorption means is an
extruded truss member.
27. The method of claim 26 wherein the truss member is extruded
substantially from polyethelene.
28. The method of claim 26 wherein the truss member is extruded
substantially from polypropylene.
29. The method of claim 26 wherein the truss member comprises a
plurality of socket regions extruded therein.
30. The method of claim 29 wherein the truss member further
comprises a supporting rib member.
31. The method of claim 30 wherein the supporting rib member is a
straight design.
32. The method of claim 30 wherein the supporting rib member is a
curved/wave design.
33. The method of claim 30 wherein the rib member is extrudedly
connected to the plurality of socket regions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of U.S.
application Ser. No. 10/860,518 filed Jun. 3, 2004, which is a
Continuation-in-Part of U.S. application Ser. No. 10/637,220, filed
Aug. 8, 2003.
BACKGROUND
[0002] The present invention is related to a packaging system, and
more particularly to a synthetic packaging system and apparatus for
supporting and protecting appliances. Even more particularly, the
present invention relates to an extruded plastic truss member for
protecting packaged products from peripheral and oblique
forces.
[0003] Packaging pallets are typically made of wood and are
commonly constructed using a box frame with deck boards attached to
form a flat surface. Wood pallets perform the desired function
however; the wood pallets add excessive weight and cost and are
environmentally wasteful. A manufacturer's goods are then placed
upon the flat surface of the pallet for transport. Pallets are
designed to allow for ease of transportation and allow for movement
through the use of mechanical means such as a forklift. However, a
manufacturer must account for the additional costs associated with
the additional delivery weight of a pallet and packaging.
[0004] Plastic pallets have been developed to meet some of the
shortcomings of wood pallets. An example of such a pallet is
described in U.S. Pat. No. 6,352,039 entitled "Plastic Pallet,"
issued to Woods, et al. The plastic pallet includes a frame and
deck boards attached to the frame without the use of mechanical
fasteners. A second example is shown in U.S. Pat. No. 3,581,681
entitled "Pallet," issued to Newton. In the Newton patent, a pallet
constructed of a thin-walled, resinous shell filled with a foam
core bonded to the inside surface of the shell. The shell of the
Newton pallet includes integral support beams spaced appropriately
to accommodate a forklift. The Newton pallet is constructed to meet
basic strength requirements at a low cost.
[0005] A benefit of transporting goods attached to pallets is that
the pallet can provide protection from external elements. An
example of such a system is shown in U.S. Pat. No. 4,244,471
entitled "Packaging System," issued to Plante. In the Plante
packaging system, top and bottom caps for packaging appliances are
shown. The top and bottom caps are attached via a plurality of
corner angles extending vertically between the top and bottom caps.
The corner angles have a length greater than the height of the
appliance so that a space exists between the appliance and the top
cap. The packaging system is rigid and thus allows multiple systems
to be placed upon each other.
[0006] Pallets are also used in the manufacture of appliances. The
base of the appliance is fixedly attached to the pallet before
construction. The pallet is moved down an assembly line via a
conveyor belt or other transportation system and the appliance is
constructed on the base. Once construction is completed, the
remaining packaging is attached to the pallet and the appliance is
then transported to its destination. The remaining packaging system
often includes a cardboard box that fits over the appliance. Often
the corners of the cardboard box are reinforced with a light metal,
Styrofoam, corrugated or paperwrap corners.
SUMMARY OF THE INVENTION
[0007] Generally, the present invention provides a packing system
for use with the transportation and manufacture of an appliance,
such as refrigerators, ranges and the like. The system comprises a
pallet, fixed corner and edge support members, articulable corner
and edge support members, spacing members, and truss members. In
the preferred embodiment, these members can be fitted into
corrugated or non-corrugated cardboard boxes or other containment
devices and can be used in combination or individually. The pallet
system comprises support members and connecting cross members,
wherein the cross members are substantially perpendicular to the
support members. The first and second support members include
attachment holes, wherein the attachment holes allow for the
attachment of the pallet to the appliance. The first and second
support members and cross members are manufactured from a synthetic
substance and are substantially hollow.
[0008] The corner support members, fixed and articulable, are used
for reinforcement of the corners of a cardboard box container, or
the like, and for protection of the corners and edges of the
appliance. The corner support members can be manufactured in a
plurality of various shapes, lengths, and sizes for specific
applications. In addition, the conformable corner support members
are provided to be user adapted to fit various corner shapes from
about 90 degrees to about 180 degrees in shape design. Also, the
articulable corner support members can be user adapted to form a
plurality of lengths and widths of numerous sizes and shapes of
products. The articulable members further allow for ease in storage
because of their ability to be stacked and stocked in a generally
flat configuration. The spacing members are used to exact proper
lateral positioning of the appliance in the cardboard box and to
protect various protrusions on the appliance from damage.
[0009] A system according to the preferred embodiment of the
invention reduces the weight, costs of the packaging and can be
recycled. Another advantage of the disclosed invention is the
reduction of damage to the system by outside elements. For
instance, pallets made according to the invention do not absorb
moisture and odors and do not disintegrate after exposure to such
elements.
[0010] The present invention's articulable corner/edge support
member apparatus comprises a plurality of substantially hollow
members formed through the extrusion of a plastic material, or the
like, having top, bottom, and side surfaces. It will be understood
by those skilled in the art that the apparatus can be formed in a
plurality of geometric shapes, including, but not limited to,
circles, octagons, triangles, squares, rectangles, and ovals
wherein a top, bottom, and side surface is merely a descriptive
reference point and is a relative description of any specific
portion which the designer chooses to reference as a top, bottom,
or side surface. For example, a circle can have a top, bottom, and
side as defined by the designer.
[0011] The apparatus is manufactured in a generally 3-D planar
fashion having a horizontal shaped channel portion that is formed
during the extrusion process along the longitudinal centerline of a
surface, preferably the top surface of the plastic material,
wherein the combination of the horizontal channel and a hingeable
base formed by the horizontal channel allows the plastic material
to conformably articulate along the hingeable base to adapt to a
plurality of acute and obtuse angles, while yet remaining
resiliently attached along the hingeable base axis. The articulable
corner/edge support member further comprises at least one
longitudinal interlocking groove along at least an upper portion of
a wall of the horizontal channel and in parallel relationship with
the hingeable base.
[0012] In addition to the interlocking groove is provided at least
one accompanying reciprocal longitudinal interlocking ridge hook
member along at least an upper portion of the opposite wall of the
horizontal V-shaped channel in a direct mirror positional
relationship to the female interlocking groove so as when the
articulable corner support member is articulated along the
hingeable base in an acute angle approaching 90 degrees the two
walls of the horizontal V-shaped channel come into contact. Upon a
slight applied pressure, the ridge hook and groove combination will
cause the articulable corner support member to interlock in an
approximate 90 degree position, therein causing the corner/edge
member to remain in the interlocked position until a force is
applied causing separation.
[0013] In another embodiment, the present invention further
comprises an articulable corner support member as in the previous
embodiment but further having at least one V-shaped notch cut and
removed entirely through the top, side, and bottom surfaces and
along a vertical axis and in perpendicular relationship to the
longitudinal horizontal V-shaped channel, wherein the base axis of
the vertically cut V-shaped notch is in close proximity to the
upper surface portion of at least one wall of the longitudinal
horizontal V-shaped channel. The articulable corner support member
of further having at least one V-shaped heat impression formed into
the top surface of the articulable corner support by heat
impression tool and die techniques, wherein the impression is
formed on the opposite top surface as compared to the vertically
cut V-shaped notch described above. The combination of the
vertically cut V-shaped notches and the V-shaped heat impressions
allow for a 3-D generally planar corner support member to be
articulated along the notches, channels, and impressions to thereby
form a plurality of 3-D corner support members with the ability to
further adaptively form a plurality of rectangle/square sizes.
[0014] In yet another embodiment of the present invention is
presented an articulable corner support member having at least two
substantially hollow rectangular pieces formed by extrusion process
of a plastic material, or the like, and having a linking plastic
portion extruded so as to hingeably attach the substantially hollow
pieces at opposing upper corner junction regions, thereby enabling
both support members to hinge at either or both hingeable junction
regions to conformably adapt to a plurality of corner/edge
surfaces.
[0015] In another embodiment, the present invention presents closed
cell design element members for use in a plurality of packaging
systems and configurations. The closed cell design element member
comprises at least two hollow geometric closed cell design elements
formed from a plastic material and connected by a plastic
connecting beam element. The closed cell elements comprise a
plurality of geometric shapes, lengths and sizes to accommodate
numerous packaging scenarios and various appliance shipping
configurations. Closed cell design elements of a particular member
can be formed having the same, different, or combination of
geometric shapes on each design element member. The plastic
connecting beam element provides stability and integrity of the
plurality of elements while positioned in the shipping container or
box. The closed cell element members can be formed to serve as
corner supporting members or to provide a plurality of partitioned
areas for safe separation and protection of a plurality of
appliances within a container.
[0016] In still another embodiment, the invention provides for a
joinable end cap extruded so as to removably unite the ends of the
fixed and articulable corner support members. The end caps are
formed to provide an interlocking frictional action imparted by
horizontal tenon-like extensions that protrude from the end cap's
exterior top surface and are inserted into the hollow ends of the
rigid and/or articulable corner support members. When four end caps
are used with the embodiments above a formed rectangle/square can
be rigidly and removably united. The use of the end caps ensures
structural integrity of the formed shape. The use of one end cap
with the third embodiment will provide rigid and removable union of
the opposing ends of the formed rectangle shape.
[0017] In another embodiment, the present invention provides a
force absorbing extruded truss member for preventing the crushing
of an appliance in a container during movement by a clamping style
forklift. In the industry, appliances are moved in various ways.
One example is through the use of forklifts that have been modified
to have large metal, vertically situated, clamping plates having a
rubber lining to increase the clamping resistance around a
corrugated box. These plates are utilized to clamp the packaged
appliance from two opposing sides. When utilizing this type of
forklift, the forklift must use approximately 2000 lbs. of clamping
pressure to lift and move an appliance weighing about 500 lbs. In
such a situation and under normal packing situations, the container
can collapse onto the appliance causing extensive damage due to the
external clamping pressure.
[0018] Accordingly, it is an object of the present invention to
provide a plurality of devices and methods of a packing system for
use with the transportation and manufacture of various appliances
and the like.
[0019] Another object is to reduce the weight and cost of appliance
packaging and to provide for a material that can be successfully
recycled.
[0020] Another object is to provide easily storable articulable
corner support members that allow the user to adapt the members
from a flat configuration into a 3-D corner adaptation and to
further allow the corner support members to be shaped into a
plurality of rectangular/square sizes to accommodate various
appliance sizes.
[0021] Another object of the present invention to provide a force
absorbing extruded truss member for preventing the crushing of an
appliance in a container during movement by a clamping style
forklift.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] For a more complete understanding of the present invention,
and for further details and advantages thereof, reference is now
made to the following Detailed Description taken in conjunction
with the following drawings, in which:
[0023] FIG. 1 is an isometric view of a pallet according to the
invention;
[0024] FIG. 2 is a plan view of a pallet according to the
invention;
[0025] FIG. 3 is a section view through line 3 of a pallet
according to the invention;
[0026] FIG. 4 is a section view through line 4 of a pallet
according to the invention;
[0027] FIG. 4A is a section view of a first embodiment of a truss
member according to the invention;
[0028] FIG. 4B is a side view of the first embodiment of a truss
member according to the invention;
[0029] FIG. 4C is a section view of a second embodiment of a truss
member having an internal straight rib member according to the
invention;
[0030] FIG. 4D is a section view of a fourth embodiment of a truss
member having an internal wave rib member according to the
invention;
[0031] FIG. 4E is an isometric view of an embodiment of a truss
member utilized in conjunction with a pallet, container, and
appliance according to the invention;
[0032] FIGS. 5A-D are section views of support members according to
alternate embodiments of the invention;
[0033] FIG. 6 is a plan view of a pallet according to an alternate
embodiment of the invention;
[0034] FIG. 7 is an isometric view of a pallet according to an
alternate embodiment of the invention;
[0035] FIGS. 8A-C are section views of corner support members
according to alternate embodiments of the invention; and
[0036] FIGS. 9A-B are section views of corner support members in
use; and
[0037] FIGS. 10A-D are section views of wall spacing members
according to alternate embodiments of the invention.
[0038] FIG. 11A is a section view of a 3-D articulable corner
support member in a flat unarticulated configuration depicting an
interlocking mechanism according to an embodiment of the
invention.
[0039] FIG. 11B is a section view of a 3-D articulable corner
support member of FIG. 11A in an articulated and locked
configuration according to an embodiment of the invention.
[0040] FIG. 11C is a close-up view of the locking interconnections
shown in FIG. 11B in a locked configuration of according to an
embodiment of the invention.
[0041] FIG. 11D is an isometric view of a 3-D articulable corner
support member in a flat unarticulated configuration according to
an embodiment the invention.
[0042] FIG. 12A is a plan view of a 3-D articulable corner support
member having vertical axis V-shaped notches and opposing
horizontal axis V-shaped heated impressions for forming
rectangles/squares.
[0043] FIG. 12B is an isometric view of the 3-D articulable corner
support member of FIG. 12A.
[0044] FIG. 12C is a plan view of FIGS. 12A & 12B after being
configured into a rectangle/square.
[0045] FIG. 13A is a section view of a multi-articulable corner
support member according to another embodiment of the
invention.
[0046] FIG. 13B is a section view of the multi-articulable corner
support member of FIG. 13A after being articulated to adapt to an
exemplary corner.
[0047] FIG. 14A is section view of an embodiment of a closed cell
design corner support element member according to an embodiment of
the invention.
[0048] FIG. 14B is section view of an embodiment of a closed cell
design interior partition support element member positioned within
a corrugated box according to another embodiment of the
invention.
[0049] FIG. 15 is an isometric view of a joinable corner end cap
with tenons in relation to the corner support members according to
the invention.
DETAILED DESCRIPTION
[0050] In the descriptions which follow, like parts may be marked
with the same numerals. The drawing figures are not necessarily
drawn to scale and certain figures may be shown in exaggerated or
generalized form in the interest of clarity and conciseness.
[0051] In accordance with a broad aspect of the invention, the
packing system and articulable corner support members of the
present invention are designed for multi-uses but are specifically
referred to herein as being used with the transportation and
manufacture of household type appliances. It is understood that the
spirit of the present invention provides for uses beyond just
household appliances. To accomplish the previous objectives, the
present invention contemplates the use of an appliance type pallet
formed of a plastic material and having support and cross members
for lateral support and stability. The invention allows for an
appliance to be attached to the pallet after the appliance has been
manufactured. Alternatively, the appliance can be built directly on
top of the disclosed pallet frame and disconnected and removed upon
delivery to the customer.
[0052] In addition to the pallet are provided corner support
members for further protecting the appliance during at least the
transportation phase. The present invention provides for pre-formed
rigid plastic corner support members that are formed into the
"corner shape" during the extrusion process. These rigid corner
support members are easily inserted at each corner between the
appliance and the box containing the appliance. Additionally
provided by the present invention are articulable corner support
members formed in a substantially flat configuration and having a
longitudinal V-shaped channel allowing the user to hingeably adapt
the articulable corner support members manually into a desired
corner angle before inserting into the shipping container. This
ability to adapt to a flat configuration when not in use provides
for ease of storage of large quantities of the articulable
members.
[0053] Each specific embodiment of the invention will now be
described in greater detail.
[0054] Referring now to FIGS. 1 and 2, an appliance pallet is
shown. An "H" shaped pallet 100 includes support members 102 and
104 connected by a cross member 106 which is substantially
perpendicular to the support members 102 and 104. The interior
sides 102a and 104a of support members 102 and 104 are connected to
the cross member 106. Pallet 100 can be manufactured as a single
piece or can be assembled from multiple, separate pieces. Pallet
100 can be cast or extruded or cast pieces can be assembled to form
the pallet. Assembly techniques for plastic elements are known to
those skilled in the art and can include adhesives, inductive
welding or physical connectors such as pop rivets or other methods
known in the art. In one disclosed embodiment the pallet is formed
from plastic, such as High Density Polyethylene (HDPE), however a
wide variety of materials may be used to form the pallet,
including, but not limited to, HIPS, LDPE, polypropylene,
polyethelene and Crosslink PE. The thickness of the walls of the
support members and cross members in the preferred embodiment is
between 0.010-0.100 of an inch in thickness.
[0055] Pallet 100 includes bolt holes 108. Bolt holes 108 are
designed to allow for various appliances to be directly attached to
the pallet. Retaining bolts are placed through the holes and into
an appliance to secure the pallet to the appliance. Adhesive
attachment can also be used as can removable straps. Also included
are feet holes 110 for placement of feet of appliance. Once the
appliance (not shown) is attached to pallet 100, which in one
disclosed embodiment includes bolts, the H shaped pallet 100 and
the appliance can be moved as a single piece. A wide variety of
attachment mechanisms can be implemented without detracting from
the spirit of the invention.
[0056] In another embodiment, the frame of the appliance (not
shown) can be attached to the pallet at the beginning stages of
manufacture of the appliance. The appliance frame and the pallet
are then moved along an assembly line allowing the appliance to be
completed while attached to the pallet. The appliance and the
pallet can then be packaged for shipment after completion of the
appliance. A wide variety of appliances can be attached to the
pallet, including as examples computers, ranges, washing machines,
refrigerators and dish washers.
[0057] In another embodiment (not shown), the pallet 100 extends
beyond the edges of the appliance and includes corners with extend
up the edges of the appliance. In this embodiment the pallet is not
necessarily attached to the appliance.
[0058] The interior views of the support members 102 and 104 are
shown in FIGS. 3 and 4. In FIG. 3, a cross sectional view through
line 3 of FIG. 2 is shown. In FIG. 4, a cross sectional view
through line 4 of FIG. 2 is shown. The support members 102 and 104
are shown forming hollow spaces 300 and 300a. The cross-sectional
shapes formed by the support members 102 and 104 are substantially
square. However, various cross-sectional shapes can be implemented
without detracting from spirit of the invention, including but not
limited to rectangular, oval, and circular. The hollow spaces 300
and 300a can remain hollow, can be filled with a rigid or flexible
plastic foam substance to enhance strength, or can include an
interior support, such as those shown in FIG. 4 and in FIGS. 5A-5D.
The wall thickness of the support members 102 and 104 can be varied
to allow for weight differences of the varying appliances. For
example, a greater wall thickness can be implemented for heavy cold
storage devices.
[0059] Cross member 106 is shown attached to support members 102
and 104. In one embodiment, the cross member 106 is manufactured
with a smaller cross-sectional area than either of the support
members 106. In this embodiment, the cross member 106 provides
support to the support members 102 and 104 but does not directly
bear the weight of the appliance. The cross member 106 increases
the stiffness of the pallet and reduces the level of deflection
under torsional loads. In another embodiment, the cross member 106
cross-sectional area is equal to the cross-sectional areas of the
support members 102 and 104. In this embodiment, the cross member
106 provides support to the support members 102 and 104 and can be
implemented to bear some of the weight of the appliance. In another
embodiment, cross member 106 is attached to support members 102 and
104 at interior sides 102a and 104a. In another embodiment, the
cross member 106 is attached to either the top or bottom surface of
the support members 102 and 104.
[0060] FIG. 4 shows a support member 102 with an offset channel rib
400. Offset channel rib 400 is offset from center and vertically
extends the length of support member 102. More than one offset
channel rib 400 can be located in support member 102 offset from
channel rib 400 to provide additional strength to the support
member 102 without incurring substantial increases in weight and
costs.
[0061] A force absorbing truss member 15 is shown in FIGS. 4A-4E.
The truss member of the present invention is formed by an extrusion
process in which melted plastic is discharged through a die
configured to produce a truss member having the desired cross
sectional shape. The truss member is primarily extruded from
polyethelene and polypropylene but can also contain a variety of
additives. Plastic extrusion is particularly well suited for making
truss members in varying lengths. In the preferred embodiment, the
truss member has dimensions of about 31/2 by 11/2 inches with
different lengths. But different dimensions can be used with equal
success. Plastic extrusion is also advantageous for making truss
members because different cross sectional shapes can be achieved by
using different extrusion dies.
[0062] The truss member of the present invention is an apparatus
used for absorbing clamping forces sustained during the handling
and storage of packaged appliances by clamping style forklifts. The
extruded truss member is particularly useful in protecting
appliances having thin metal walls affixed to a rigid structural
frame. The appliance frame usually has a structural area located
near the top and/or bottom of the vertical profile of the
appliance. This area, unlike the relatively weaker sidewalls, can
withstand larger lateral forces.
[0063] There is shown in FIG. 4A a hollow core elongated extruded
plastic truss member 410 for protecting a packaged product, such as
an appliance. Truss member 410 is designed to provide both oblique
and peripheral compression resistance without loss of structural
integrity, that is, without losing its force absorbing
characteristics. Truss member 410 comprises a top wall 415 with a
centrally located upper socket region 420a, a bottom wall 425 with
a centrally located lower socket region 420b, and two side walls
430, 435 which thereby forms the substantially hollow geometrical
truss member 410.
[0064] In the preferred embodiment, truss member 410 is generally
rectangular in cross section having side walls 430, 435 laterally
displaced from each other and substantially parallel to one
another. In addition, side wall 430 and side wall 435 are joined to
the top wall 415 and bottom wall 425 along the outer most edges
440a, 440b, 440c, and 440d of the juncture of the top and bottom
walls 415, 425 respectively, thereby forming the generally
rectangular cross-section shown in FIG. 4A. The juncture of the top
wall 415 and the bottom wall 425 to sidewalls 430, 435 can be
extruded to form a rounded corner, an approximate 90.degree. angle,
or any other desired geometric shape.
[0065] The top 415, bottom 425, and sidewalls 430, 435 in
combination form a single unitary housing having a thickness in the
preferred embodiment in the range of about 0.030 to 0.200 of an
inch. The distance between each wall 415, 425, 430, and 435, in
addition to the shape of the interconnection of the walls, may be
varied as required by design and manufacturing specifications.
Similarly, the thickness of the top 415, bottom 425, and side 430,
435 walls can be increased or decreased during the extrusion
process to achieve various desired force absorption characteristics
and criteria.
[0066] Referring to FIG. 4B, a profile view of the truss member 410
of FIG. 4A is shown for clarification. The truss member 410 can be
extruded in any length and then cut to desired lengths.
[0067] In a second embodiment, a hollow-core elongated plastic
truss member 445 with at least one supporting rib member 450 is
shown in FIG. 4C. This truss member 445 is also an extruded hollow
core. Truss member 445 further includes at least one or more
integrally formed extruded supporting rib members 450 extending
between opposing top and bottom walls 455, 460 respectively.
[0068] Preferably, rib member 450 is joined in a substantially
perpendicular relationship to top wall 455 and bottom wall 460 and
is aligned in a substantially parallel relationship to side wall
465 and side wall 470 as depicted in FIG. 4C. Support rib member
450 allows the truss member 445 to maintain cross sectional and
longitudinal stability and integrity when a container comprising an
appliance or the like is subjected to peripheral and oblique
forces, thereby preventing the container from collapsing inwardly
onto the appliance.
[0069] Rib member 450 is interconnected between interior side 475a
of top wall 455 at a central location of upper socket region 480a
of the top wall 455 and the interior side 475b of the bottom wall
460 at a central location of lower socket region 480b. The rib
member 450 operates to buttress the central region of the top 455
and bottom 460 walls of truss member 445 by distributing externally
imposed forces.
[0070] Rib member 450 can be longitudinally interconnected to the
top and bottom walls 455, 460, respectively, anywhere along
interior walls 475a and 475b of truss member 445. Any number of rib
members may be incorporated into the design of extruded truss
member 445. Preferably the ribs are substantially planar or
straight, have a substantially vertically cross section and are
located in various equally spaced positions between the interior
walls.
[0071] Alternatively, as shown in FIG. 4D, rib 500 may be extruded
in the shape of a curve or "wave" design. Rib 500 is primarily
perpendicular to the interior walls.
[0072] Referring now to FIG. 4E, when the extruded truss member is
used with pallet 100, the truss member directly absorbs external
peripheral and oblique forces. Absorbing forces protect the
relatively weaker sidewalls of the container and/or appliance from
damage. As a result, because the extruded truss member does not
collapse longitudinally, a safe zone distance 485 is maintained by
the truss member between the container and/or the appliance. Any
pallet can be utilized with disclosed truss member.
[0073] FIGS. 5A-5D show various internal support structures.
Support member 102 may be formed without support structures but may
also include them. FIG. 5A shows a cross-section of support member
102 including wave supports 500 and 500a. Wave supports 500 and
500a are located in the hollow space 300. The wave supports 500 and
500a provide additional strength without incurring substantial
increases in weight and costs.
[0074] In FIG. 5B, an alternate interior support structure is
shown. Support member 102 includes a rounded edge 504. The oval
hollow space 300 includes interior support structures 502 and 502a.
The interior support structures 502 and 502a of the preferred
embodiment are curved. The curved interior support structures 502
and 502a provide additional strength without incurring substantial
increases in weight and costs.
[0075] In FIG. 5C, the wave support structures 506 and 506a are
shown in an oval hollow space 300. In this embodiment, the wave
support structures 506 and 506a are located nearer the center of
the cross-sectional area of the support member 102. The location of
the support structures in the hollow space 300 can be varied to
accommodate different stiffness levels and to accommodate the
varying weights of different appliances, however, various other
locations are possible.
[0076] FIG. 5D shows an alternate cross-section of support member
102. The outside profile of support member 102 may have one or more
saddle regions 800 for lateral support. Support member 102 is shown
having three offset channel ribs 400. Other embodiments could have
more or fewer internal support structures of various shapes as
previously described.
[0077] In FIG. 6, an alternate embodiment of a pallet of the
invention is shown. Dual cross member pallet 600 includes support
members 602 and 606. The support members 602 and 606 are connected
with cross members 610 and 612. The cross members 610 and 612 are
attached at the interior sides 608 and 608a of the support members
602 and 606. Bolt holes 604 are shown in the support members 602
and 606 and can be used to attach the dual cross member pallet 600
to an appliance. In this embodiment two cross members 610 and 612
are shown, however, multiple cross members can be used.
[0078] In FIG. 7, an alternate embodiment of the pallet of the
invention is shown. A square pallet 700 includes support member 702
and 704. The support members 702 and 704 are connected with cross
members 706 and 708. Cross members 706 and 708 are attached at the
ends of support members 702 and 704. Cross members 706 and 708 and
support members 702 and 704 may have alternate cross-sections such
as those shown in FIGS. 5A-5D. Bolt holes 712 are shown in support
members 702 and 704 and can be used to attach square pallet 700 to
an appliance with retaining bolts. Also, appliance feet holes 710
may be located in support members 702 and 704 and cross members 706
and 708 to accommodate feet found on the appliance.
[0079] Once the appliance is fully constructed and ready to be
shipped, a cardboard box can be secured around the appliance to
protect the appliance during transport. The cardboard box can be
corrugated or non-corrugated. FIGS. 8A-C show alternate corner
support member structures designed to be inserted in or near the
corners of the cardboard box.
[0080] FIGS. 8A-C show cross-sections of the alternate corner
support member structures. The structures of the preferred
embodiment are extended to a predetermined length with a
constraining cross section. The cross section includes internal
support members 812. Curved internal support members 812 provide
additional strength to the corner support member during use without
incurring substantial increases in weight and expense. Also, during
manufacture after the corner support member has been extruded and
is cooling, internal support members 812 add support to the pliable
walls until the walls can cool and strengthen. The internal support
members 812 may be straight or have a curved profile. The corner
support members may not have any internal support members or may
have one or more internal support members depending on the type of
internal support desired.
[0081] The alternate corner support member structures are formed
from plastic, such as High Density Polyethylene (HDPE), however a
wide variety of manufacturing materials may be used to form the
support member structures without detracting from the spirit of the
invention, including, but not limited to, HIPS, LDPE,
polypropylene, polyethelene and Crosslink PE. The preferred
thickness of the walls of the corner support member structures,
such as internal support members 812, is between 0.010 and 0.100 of
an inch in thickness.
[0082] In FIG. 8A, corner support member 804 has an upper case "L"
profile having extensions 816 and corner 818. In use, corner 818
fits next to a corner edge of the appliance extending along and
overlapping the corner of the appliance to protect it from damage
and secure it during transport.
[0083] In FIGS. 8B and 8C, alternate embodiments of the corner
support members are shown. In FIG. 8B, corner support member 800
includes individual support lobes 806 connected by beam 514, loop
516 and beam 517. The support lobes are substantially tubular
members which are held at positions approximately perpendicular to
each other by beam 514, loop 516 and beam 517. Loop 516 provides
shock resistance to impact loads directed towards the corners of
the appliance. In FIG. 8C, corner support member 801 includes
support lobes 806 connected by beam 519, corner 520 and beam
521.
[0084] The various corner support structures shown in FIGS. 8A-C
can be contained within the walls of or proximate to an interior
wall of a cardboard box or packing container. For example, FIG. 9A
shows corner support member 800 inside the walls 902 of a packing
box 900. FIG. 9B shows the corner support member 801 proximate to
an interior wall 902 of a packing box 900. The corner support
member structures can vary in height, length, and dimensions and
can be positioned in the top corners, bottom corners, or side
corners of the shipping container depending on the desired cost,
stacking strength, horizontal cushioning, vertical cushioning and
corner cushioning desired.
[0085] In FIGS. 10A-D, alternate embodiments of a wall spacing
member are shown. The wall spacing member is a special type of
corner support structure which extends past an outside wall of the
appliance and contacts the inside wall of the container surrounding
the appliance. The purpose of the wall spacing members is to form a
standoff to distance the container from protrusions such as
handles, knobs or display panels that extend past the outside wall,
top or bottom of the appliance.
[0086] Referring to FIG. 10A, a wall spacing member 890 is shown
whose cross section includes a head section 810, a placement
surface 891, and a tail section 814. The tail section contains two
walls 816 separated by an internal support member 812. The length
of walls 816 extend to head section 810. Head section 810 includes
an internal support member 812 and is formed with a notch 520. In
use, notch 520 makes contact with the edge of an appliance while
placement surface 891 contacts the inside of the container. Head
section 810 forms a spacer for the protrusions of the appliance.
The distance the head section 810 extends past the wall of the
appliance depends on the profile of head section 810.
[0087] Referring to FIG. 10B, wall spacing member 892 is shown with
a cross section that has a head section 811 and a tail section 815.
The tail section contains two walls 816 separated by an internal
support member 812. Head section 811 includes an internal support
member 812 and is formed with a notch 520. Notch 520 makes contact
with the edge of an appliance, while placement surface 893 contacts
the inside of the packing box 900. Placement surface 893 is curved
to accommodate different types of packing containers. Head section
811 forms a spacer for the protrusions of the appliance.
[0088] Referring to FIG. 10C, a spacing member 894 is shown with a
cross section that has a triangular head section 813. Triangular
head section 813 accommodates different types of packing
containers.
[0089] Referring now to FIG. 10D, a wall spacing member 895 is
shown that has a head section 819. Head section 819 is formed in
the shape of a square in order to accommodate different types of
packing containers.
[0090] FIGS. 10A and 10B show a relatively small head profile
wherein head section 810 would extend a relatively short distance
from the walls of the appliance. The wall spacing members shown in
FIGS. 10A and 10B would be used for protrusions such as knobs or
dials. The wall spacing members shown in FIGS. 10C and 10D would be
used for larger protrusions such as handles.
[0091] Referring now to FIGS. 11A through 11D, an articulable
corner/edge support member is shown in both its un-articulated flat
configuration 1100 (FIG. 11A) and after being articulated and
snapped into an interlocking hinged 3-D configuration 1102 (FIG.
11B). The articulable corner/edge support member shown comprises at
least two substantially hollow support lobe members 1132, 1133
extruded from a plastic material in various lengths, or the like,
having top 1130, 1131, bottom 1135, 1135a, and side 1125, 1126
surfaces and formed in a generally planar fashion. It will be
understood by those skilled in the art that the articulable
apparatus can be formed in a plurality of geometric shapes,
including, but not limited to, circles, octagons, triangles,
squares, rectangles, and ovals wherein a top, bottom, and side
surface reference is merely a descriptive reference point and is a
relative description of any specific portion to which the designer
chooses to reference as the top, bottom, or side surface. For
example, a circle can have a top, bottom, and side as defined by
the designer for a specific purpose.
[0092] The hollow lobe members 1132, 1133 are provided internal
support by use of vertical supports 1150a, 1150b, 1150c, and 1150d
disposed within the hollow lobe members. The supports 1150a, 1150b,
1150c, and 1150d can be any shape including, but not limited to, a
straight or wave design. As depicted, supports 1150c and 1150d
attach in a linking relationship the inner-side of top surface 1130
to the inner-side of bottom surface 1135a. Similarly, supports
1150a and 1150b attach in a linking relationship the inner-side of
top surface 1131 to the inner-side of bottom surface 1135.
[0093] The hollow lobe members are designed for articulation about
an approximate center point of bottom surfaces 1135 and 1135a along
hingeable base center axis 1110 by fashioning a horizontal channel
portion 1104 with opposing sidewalls 1105, 1106. The channel
portion 1104 can be formed during the extraction process to be a
V-shaped channel, a contoured U-shaped channel, a square U-shaped
channel, or any other desirable shape. The sidewalls 1105, 1106 are
formed during extrusion along the longitudinal centerline of the
top surface of the plastic material. As can be seen in FIG. 11b,
the combination of the horizontal V-shape channel 1104 and the
hingeable base center axis 1110 allows the corner/edge support
member 1100, to conformably articulate along the hingeable base
1110 to adapt to a plurality of angles while yet remaining
resiliently attached along the hingeable base axis 1110.
[0094] In continued reference to FIGS. 11A through 11D, the
articulable corner/edge support member 1100 further comprises at
least one interlocking groove 1120 along at least a portion of at
least the longitudinal upper portion of one wall 1105 of the
horizontal channel 1104 and in approximate parallel relationship
with the hingeable base axis 1110. Further provided is at least one
accompanying and reciprocally positioned interlocking ridge hook
1115 that is disposed along at least an upper portion of the
opposite wall 1106 of the channel, in relation to the groove 1120,
so as when the corner/edge support member is articulated along the
hingeable base 1110 to form an acute angle approaching 90 degrees
the two walls of the horizontal channel come into interlocking
contact. It will be understood by those skilled in the art that
other interlocking ridge and groove combinations can be utilized
without departing from the present invention.
[0095] Specifically referring to FIG. 3C is shown a close-up view
of the locking interconnection of FIG. 11B. Upon application of a
slight pressure, the ridge hook 1115 and groove 1120 combination of
the corner support member will interlock in an approximate 90
degree position, as shown by 1102 of FIG. 11B, therein causing the
corner/edge member 1102 to remain in the interlocked position. The
corner/edge support member 1102 will remain in an interlocked
articulated position until a slight separation force is applied,
thereby causing disconnection of the two substantially hollow
support lobe members 1132, 1133 at the interlocking groove 1120 and
ridge 1115 interconnects.
[0096] FIGS. 12A-12C show another embodiment of an articulable
corner support member 1200 having at least two substantially hollow
support lobe members 1232, 1233 and wave supports 1150 and 1150a.
Articulable corner support member 1200 provides for articulation
about at least 3 separate axes 1206, 1220, and 1240. This
embodiment comprises an articulable corner support member as in
FIG. 11B but further comprising a plurality of V-shaped notches
1205 cut entirely through the top 1246, side 1225, and bottom 1226
surfaces along a vertical axis of substantially hollow support lobe
member 1232 and in perpendicular relationship to longitudinal
horizontal V-shaped channel 1204 having hingeable base axis 1240.
Once the V-shaped notches are cut as described the cutout remainder
is removed and discarded. Base axis 1206 of vertically cut V-shaped
notch 1205 is in close proximity to the upper surface portion of at
least one wall 1230 of the longitudinal horizontal V-shaped channel
1204 that separates substantially hollow support lobe members 1232,
1233.
[0097] FIG. 12B shows an isometric view of the articulable corner
support member 1200 of FIG. 12A. This embodiment further comprises
a plurality of V-shaped heat impression troughs 1220 pressed into
top surface 1235 of substantially hollow lobe 1233 of the corner
support 1200 by heat impression tool and die techniques. Heat
impression trough 1220 is formed in the opposite top surface 1235
and perpendicular to vertically cut V-shaped notch 1205 (cut
through surface 1246) described above. The combination of the
vertically cut V-shaped notches 1205, the V-shaped longitudinal
channel 1204 and base axis 1240, and the V-shaped heat impressions
1220 allow for a generally planar corner support member to be
articulated along the notches, channels, and impressions to thereby
form a plurality of 3-D corner support members with the ability to
further adaptively form a plurality of rectangle/square sizes as
shown in FIG. 12C.
[0098] The embodiment shown FIG. 12B further comprises at least one
female interlocking groove 1210 along at least a longitudinal upper
portion of one 1230 (in support lobe member 1232) of horizontal
V-shaped channel 1204 and in parallel relationship with a hingeable
base axis 1240. The embodiment depicted in FIG. 12B further
comprises at least one interlocking ridge 1215 that is disposed
along at least an upper portion of wall 1231 of V-shaped channel
1204 in direct a opposing mirror relationship to groove 1210 so as
when the corner support member 1200 is articulated along axis 1240
the two walls 1230, 1231 of the horizontal V-shaped channel 1204
come into contact. Upon a slight applied pressure, the ridge 1215
and groove 1210 combination will cause the articulable corner
support member 1200 to interlock in an approximate 90 degree
position, therein causing the corner/edge member 1102 to remain in
the interlocked position. The corner/edge support member 1200 will
remain in the interlocked articulated position until a separation
force is applied causing disconnection of the two substantially
hollow support lobe members 1232, 1233 at the interlocking
groove/ridge 1210, 1215.
[0099] Referring to FIG. 12C shows a square formed from the 3-D
corner support member of FIGS. 12A and 12B. It can be seen from
FIG. 12C how vertically cut V-shaped notch 1205, heat impression
trough 1220, and the V-shaped longitudinal channel 1204 with base
axis 1240 are cooperatively articulated to form a corner support
member with an approximate 45 degree angles 1251 at each corner to
form an approximate square 1250. In FIG. 12C it must be understood
that to create square 1250 as shown or a rectangle (not shown) at
least four vertically cut V-shaped notches 1205, four accompanying
heat impression channels 1220, and one V-shaped longitudinal
channel 1204 with base axis 1240 are needed. The physical
relationship of side 1225 of lobe support 1232, upper surface 1235
and side surface 1226 of lobe support 1233 are depicted for visual
clarity.
[0100] FIGS. 13A and 13B show an articulable corner support member
1300 in accordance with another embodiment of the present
invention. The articulable corner support member 1300 shown in FIG.
13A comprises at least two substantially hollow rectangular lobe
pieces 1305, 1310 formed by extrusion process of a plastic
material, or the like and supported internally by wave supports
1150 and 1150a. The lobes 1305, 1310 comprise a linking plastic
beam portion 1315 extruded so as to hingeably and resiliently
attach the substantially hollow lobe pieces 1305, 1310 at opposing
upper corner junction regions 1301, 1302. The intersection of
corner junction region 1301 to lobe piece 1305 and corner junction
region 1302 to lobe piece 1310 enable both support lobe pieces to
articulate at either or both hingeable upper corner junction
regions 1301, 1302 to conformably adapt to a plurality of corner
and or edge surfaces.
[0101] FIG. 13B shows the corner support member 1300 of FIG. 13A
after being articulated into one possible configuration. FIG. 13B
depicts hollow lobe piece 1310 as having been articulated into
position via hingeable upper corner junction region 1302. In this
articulated position side wall 1320 of lobe 1310 will rest in
hinged relation adjacent to linking plastic beam portion 1315 until
re-positioned into an unarticulated position. Similarly, lobe piece
1305 can articulate at hingeable upper corner junction region 1301
so as to rest side wall 1321 adjacent to linking plastic beam
portion 1315. It must be understood that lobe pieces 1305 or 1310
can be articulated in either direction (up or down) to accommodate
the particular packing/shipping configuration desired. In addition,
corner support member 1300 can be used in either configuration
described or can be used in a multiple of different configurations
as so described.
[0102] Now referring to FIGS. 14A and 14B is depicted a section
view of closed cell design element members for use in a plurality
of packaging systems and configurations. The closed cell design
element member 1400 of FIG. 14A comprises at least two hollow
geometric shaped closed cell design elements 1460a, 1460b formed
from a plastic material. The closed cells 1460 are provided
internal support by wave support 1150 or the like. The closed cell
design elements 1460a, 1460b are resiliently connected by rigid
plastic connecting beam element 1410 and forms an approximate 90
degree angle 1411. The plastic connecting beam element 1410
provides stability and integrity of a plurality of closed cell
elements 1460 while positioned in a shipping container or box.
[0103] The closed cell elements 1460a, 1460b comprise a plurality
of geometric shapes, lengths and sizes to accommodate numerous
packaging scenarios and various appliance shipping configurations.
The generally tubular shaped closed cell design 1460 shown in FIG.
14A is not meat to delimit closed cell design shapes to that as so
depicted. Closed cell design elements 1460 of a particular member
can be formed having the same, different, or combination of
geometric shapes on each design element member.
[0104] The closed cell element member 1450 embodiment of FIG. 14B
provides a plurality of partitioned areas for safe separation and
protection of a plurality of appliances 1454 while within a
container or box 1452. Closed cell element member 1450 shown
comprises at least four substantially hollow closed cell tubular
pieces 1460a, 1460b, 1460c, and 1460c and can be provided in a
plurality of lengths depending on the desired configuration (e.g.,
appliance/box height and/or width). The closed cell tubular pieces
1460a-d can be formed in a plurality of diameters, which are once
again dependent on the desired packaging/shipping configuration.
Each closed cell tubular design piece 1460a-d is attached via a
rigid plastic connecting beam element 1465. The connecting beam
1465, as shown, forms four approximate 90 degree angles at their
intersection 1466. The beam element 1465 configuration of FIG. 14B
forms at least four partitioned areas wherein a plurality of
objects can be placed for shipment or storage.
[0105] In further reference to FIG. 14B, for exemplary purposes,
the articulable corner support member 1100 of FIG. 11B is shown
used in combination with closed cell design element 1450. It must
be understood that the formed embodiment shown in FIG. 12C can also
be utilized to frame the bottom and top of appliance 1454 for
farther support during shipment.
[0106] Referring now to FIG. 15 is depicted an isometric view of a
joinable corner end cap 1500 according to an embodiment of the
invention. The corner end cap 1500 is shown in combination use with
the articulable corner/edge support 1102 after being articulated
and snapped into a locked hinged 3-D configuration 1102 (as shown
in FIG. 11A). Joinable corner end cap 1500 comprises outer surfacer
510 having a plurality of tenons 1520, 1540, 1550, and 1560 rigidly
extruded in at least horizontal and vertical planes and extending
therefrom.
[0107] The joinable end cap 1500 is extruded so as to removably
unite the ends of fixed 816 (FIG. 8A) and articulable corner
support members 1102. The end caps are formed to provide an
interlocking frictional action imparted by horizontal tenon-like
1520, 1540, 1550, and 1560 extensions that protrude in planes
horizontally and vertically from the end cap's exterior top surface
1510. These tenon extensions 1520, 1540, 1550, and 1560 are
inserted into the hollow ends of the rigid 816 and/or articulable
1102 corner support members. When four end caps 1500 are used with
support members 812 and/or 1102 a formed rectangle/square 1250 (as
shown in FIG. 12C) can be rigidly and removably united. The use of
the end caps 1250 ensures structural integrity of the desired
formed shape 1250. The use of only one end cap 1500 with the
embodiment of FIGS. 12A, 12B will provide a rigid and removable
union of the remaining opposing ends of the formed rectangle/square
shape 1250.
[0108] Other embodiments of the invention will be apparent to those
skilled in the art after considering this specification or
practicing the disclosed invention. The specification and examples
above are exemplary only, with the true scope of the invention
being indicated by the following claims.
* * * * *