U.S. patent application number 11/566754 was filed with the patent office on 2007-06-14 for package handling system.
Invention is credited to Tom Brubaker, Gary McLaughlin, Jeff Myers, Tom Walton.
Application Number | 20070131147 11/566754 |
Document ID | / |
Family ID | 40941332 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070131147 |
Kind Code |
A1 |
Brubaker; Tom ; et
al. |
June 14, 2007 |
PACKAGE HANDLING SYSTEM
Abstract
A package handling system for handling and transporting a load
comprises two spaced apart skid runners molded from an expandable
polystyrene or other polyolefin expanded bead, and a high impact
polystyrene film. Each runner has a first surface designed to
contact a load supporting surface and second surface contoured to
accommodate a specific load, and a polystyrene skid applied
coextensive with the first side. Optionally, the length of the
first side has a plurality of grooves. The system can be used in
combination with corner post supports and/or one or more top
pieces. A method of packaging a load is also disclosed.
Inventors: |
Brubaker; Tom; (Perkasie,
PA) ; McLaughlin; Gary; (Coraopolis, PA) ;
Myers; Jeff; (Seneca, SC) ; Walton; Tom;
(Marco Island, FL) |
Correspondence
Address: |
COHEN & GRIGSBY, P.C.
11 STANWIX STREET
15TH FLOOR
PITTSBURGH
PA
15222
US
|
Family ID: |
40941332 |
Appl. No.: |
11/566754 |
Filed: |
December 5, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60748865 |
Dec 9, 2005 |
|
|
|
Current U.S.
Class: |
108/56.1 ;
206/320 |
Current CPC
Class: |
B65D 85/68 20130101;
B65D 2585/6817 20130101 |
Class at
Publication: |
108/056.1 ;
206/320 |
International
Class: |
B65D 19/16 20060101
B65D019/16 |
Claims
1. A package handling system for a load comprising at least two
spaced apart skid runners for supporting a load to be carried by
said skid runners, each of said skid runners being comprised of an
expanded polystyrene molded to have at least a first and second
surface, said first surface being substantially coextensive the
length and width of said skid runner for contact with a supporting
surface, said second surface being configured to support said load,
and a polystyrene film laminated substantially coextensive with
said first surface.
2. A package handling system as set forth in claim 1 wherein at
least one of said runners is located at least at a supporting
position of said load.
3. A packaging handling system as set forth in claim 1 wherein said
system includes a third skid runner positioned between and
substantially parallel with said at least two spaced apart skid
runners.
4. A package handling system as set forth in claim 1 wherein said
skid runners have at least a pair of sides and ends positioned
between said first and second surfaces and wherein at least a
portion of said sides and ends includes said polystyrene film
bonded thereto at least adjacent to an intersection with said first
surface.
5. A packaging handling system as set forth in claim 1 wherein said
first surface comprises a plurality of grooves.
6. A packaging handling system as set forth in claim 4 wherein said
first surface comprises a chamfered edge extending along one end or
both of said pair of ends.
7. A package handling system as set forth in claim 4 wherein said
first surfaces comprises a chamfered edge extending along one side
or both of said pair of sides.
8. A package handling system as set forth in claim 4 further
comprising a side wall generally aligned with and extending from
one of said sides and protruding from said second surface.
9. A package handling system as set forth in claim 4 wherein said
second surface further comprises at least one bearing area
generally aligned with and extending along one of said sides and
being positioned between said ends.
10. A package handling system as set forth in claim 1 wherein said
second surface further includes one or more openings or indents
having the general shape of a square, circle or rectangle suitable
to accommodate protruding contact surfaces on said load.
11. A package handling system as set forth in claim 1 wherein said
skid runners are spaced apart a distance less than the relative
dimension of said load to be supported on said second surface.
12. A package handling system as set forth in claim 1 wherein said
skid runners comprise of an expanded polystyrene having a density
of from about 1.25 to 3.5 pounds per cubic foot.
13. A package handling system as set forth in claim 1 wherein said
polystyrene film is a high impact film and is located over at least
said first surface.
14. A package handling system as set forth in claim 13 wherein said
high impact film is located by lamination.
15. A package handling system as set forth in claim 14 wherein said
lamination is prepared substantially simultaneously with molding
said skid runner.
16. A package handling system as set forth in claim 4 wherein said
polystyrene film is located over at least a portion of said sides
and ends.
17. A packaging system for a load comprising a plurality of spaced
apart expanded polystyrene skid runners, each of said skid runners
comprising a first surface for contact with a load supporting
surface and second surface for contacting support of said load,
each of said skid runners having a polystyrene film substantially
coextensively bonded to said first surface, and a plurality of
corner supports configured to support a corner of said load, each
of said corner supports extending at least from an outer edge of
said second surface to a point adjacent the extent of said
load.
18. A packaging system for a load as set forth in claim 17 wherein
said system further includes one or more top pieces each said top
piece being removably attached to an end of said corner
support.
19. A method of packaging a load, said method comprising the steps
of: a. molding expanded polystyrene to form at least two elongated
generally rectangular skid runners, each of said runners having
first and second surfaces and at least two side walls and two ends;
b. bonding a polystyrene film substantially coextensive with said
first surface and a portion of said sides and ends adjacent to an
intersection with said first surface; and c. placing the supporting
position of said load on said second surfaces of said at least two
skids runners.
20. A method of packaging a load, further comprising the step of:
d. positioning a first end of each of at least two corner posts
into one of said at least two skid runners, and positioning each
second end of each of at least two corner posts into opposite ends
of a top piece.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of U.S. Provisional
Application Ser. No. 60/748,865, filed on Dec. 9, 2005, the entire
contents of which are incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a package handling system
and, in particular, to a package handling system comprising of an
expanded polystyrene molded shape having a polystyrene sheet formed
and applied to the contours of the molded shape, such as on at
least bearing portions or the surfaces having contact with support
surfaces such as a floor.
BACKGROUND OF THE INVENTION
[0003] Package handling systems comprising of skid runners are
known in the art. Skid runners are used to support loads and as
spacers to protect the loads. They facilitate handling the loads
for transportation using common handling equipment such as fork
lifts and hand trucks. Skids can be made in many shapes to support
various types of load configurations and weights. For example, U.S.
Pat. No. 4,317,515 shows a skid runner made from laminated paper to
support sheets of wall board, lumber and the like. U.S. Pat. No.
4,050,664 discloses a skid runner formed from kraft paper conduit
and includes integrated strapping means for stabilizing loads on
the runners.
[0004] Skid runners have been made from many different types of
material. The most common material is wood where the runner is
integrated into a pallet for transporting various products. Metal
such as steel channels has been used to support heavy loads for
transportation and storage. These runners can also be designed to
be integrated into rack storage systems and to act as part of the
rack system itself. Various shipping containers have been
fabricated from aluminum or steel or plastics such as polyethylene
or polypropylene with integrated skid runners. Most tend to be
cumbersome and heavy, adding bulk and weight to the system thereby
increasing cost.
[0005] Traditionally, skids have been designed to support their
intended loads using two or more skids that would extend the length
of the loads and have a height that enables the tongs of a fork
lift, or other lifting apparatus, to extend between the skids. In
many applications, pallets are used instead of containers to handle
large loads of individual items. These loads can vary from stacks
of beer cases to individual appliances or machines. Typically,
loads of cases or products are stacked on a pallet in a palletizer
and then wrapped with a thin film wrapping material instead of
using a traditional container or cardboard shipping box. Large
loads are also shipped on pallets which are wrapped in a film in
lieu of a shipping carton. In both of these examples, it is not
unusual to include cardboard edges at the corners of the stacked
cases prior to wrapping to stabilize the loads so that multiple
pallets of products can be stacked for shipping or warehousing.
[0006] Notwithstanding these advances in package handling systems
and methods, none of the prior systems or methods provide for a
convenient, light weight and inexpensive system useable with
stackable and/or heavy loads. Thus, there is a need for a packaging
system that facilitates stackable loads, is inexpensive to produce
and is light in weight to reduce shipping charges. In addition, it
would be highly desirable to have a packaging system that is
customizable for the various product shapes to be packaged, shipped
and stored plus be of a material that can absorb shock typically
encountered in shipping environments.
SUMMARY OF THE INVENTION
[0007] Generally, the present invention comprises a packaging
system for a load such as a container, for example, a cardboard box
or an appliance such as a refrigerator, stove, washer or the like
designed to overcome the prior shortcomings. Thus, it is an object
of the invention to provide a lightweight, customizable skid runner
for use with packaging and a method of packaging a load that does
not require or obviates the requirement for package handling
palletization. An objective of the runner absorbs shock typically
encountered in shipping environments. It is a further object in an
example of the invention to provide a novel skid runner that can
include integrated corner posts or novel corner posts for
packaging, particularly posts having ends that include at least one
portion that interlocks into a skid runner. In another embodiment,
it is an object of the invention to provide a packaging system that
includes an integrated skid runner and corner posts that increase
safe stacking and handling of appliances and like products.
[0008] One embodiment of the invention comprises at least two
spaced apart skid runners having a polystyrene skin applied to at
least portions of each of the runners for supporting the load. Each
of the skid runners is preferably made from an expandable polymeric
moldable material, and more preferably shape molded from expanded
polystyrene to have at least first and second surfaces. The first
surface in this embodiment is substantially coextensive with the
length and width of the skid runner for contact with a supporting
surface for the load such as a warehouse floor, truck or another
packaging system. The second surface, on the other hand, can be
configured to support a load. For example, the second surface can
be specially designed to engage mating parts of a load to be
packaged such as the support feet or legs of an appliance.
[0009] A polystyrene film is laminated, fused or bonded
substantially coextensive with the first surface. The film is
preferably a high impact polystyrene film. The unique combination
of applying the film to the expanded polystyrene material provides
enhanced wear and durability characteristics plus substantially
increases the tensile and flexural strength of the skid runner
without adding excess weight.
[0010] In preferred embodiments of the invention, the film is
bonded to the expanded bead skid runner in the molding process so
as to be an integral component of the skid runner.
[0011] In an embodiment of the invention, the packaging system
comprises a plurality of spaced apart skid runners. At least one of
the runners is located at a supporting position of a load, such as
along an edge extending generally from corner to corner. The runner
has a first surface for contact with a supporting surface for the
package handling system, such as warehouse floor, transport vehicle
or vessel or another packaging system. A second surface is provided
for contacting the load at a supporting position on the load. Each
of these skid runners is preferably molded from, but not limited
to, expandable polystyrene and includes polystyrene film fused or
laminated substantially coextensively to the first surface.
Typically, in this embodiment, there are three, or possibly four,
skid runners. In an example using three runners, the runners are
positioned in parallel substantially in parallel with one another,
the third skid runner being generally centered between the other
two. In an example with four skid runners, each runner is
configured to be located at a respective corner of the load. In
some applications this may comprise an extension of the supporting
leg of an appliance such as refrigerator. In this embodiment the
size and weight of the skid runners is almost immaterial to the
size and weight of the load, thus reducing the shipping charges of
the load compared to containers or palletized loads. In addition,
the expanded polystyrene skid runners of the present invention
provide substantially enhanced impact resistance to the load from
dropping by a careless forklift driver, for example.
[0012] The skid runners further have a pair of outer sides between
the first and second surfaces. The outer sides include at least a
portion of the polystyrene film laminated or fused thereto at least
adjacent to an intersection with the first surface. In a preferred
embodiment of the invention, the polystyrene film is laminated or
fused to associated expanded polystyrene part during the molding
process to provide a cohesive coextensive bond with the associated
part.
[0013] Other advantages of the present invention will become
apparent from a perusal of the following detailed description of
presently preferred embodiments taken together with the
accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an isometric view of a skid runner according to an
embodiment of the present invention.
[0015] FIG. 2 is a plan view of a skid runner according to an
embodiment of the present invention.
[0016] FIG. 3 is an elevation view of the skid runner shown in FIG.
1.
[0017] FIG. 4 is a sectional elevation of the skid runner along
line A-A shown in FIG. 2.
[0018] FIG. 5 is a bottom view of the skid runner according to an
embodiment of the present invention.
[0019] FIG. 6 is an end view of the skid runner according to an
embodiment of the present invention.
[0020] FIG. 7 is an isometric view generally showing surface 12 of
the skid runner according to an embodiment of the present
invention.
[0021] FIG. 8 is an isometric view generally showing surface 11 of
the skid runner according to an embodiment of the present
invention.
[0022] FIG. 9 shows an embodiment of the present invention in
combination with corner post supports and a carrying load.
PRESENTLY PREFERRED EMBODIMENTS OF THE INVENTION
[0023] With reference to FIGS. 1-6, a skid runner 10 is shown
molded from expandable polystyrene having a density of, but not
limited to, from about 1.5 to about 3.5 pounds per cubic foot. The
overall weight of skid 10 is from about 2.60 to about 5.30 ounces.
Generally, the weight and density vary depending upon the load
weight design required, and the shock absorbency desired. For a
small but fairly heavy load, the load contacting surface area of
the skid will be relatively small and have a density high enough to
support the weight of the load. The greater the density the greater
the skid weight. The size of the runner will vary to accommodate
the size and shape of the load it is to support. Size will also
affect the weight. Skid 10 includes a first surface 11 designed to
contact a load supporting surface, and a second surface 12
configured to accommodate portions of a load, as shown in FIGS. 1
and 2. Skid 10 includes ends 13 and 14 and a pair of outer sides 16
and 17 positioned between first and second surfaces 16 and 17. Film
20 covers first surface 11 and portions of sides 16 and 17, as
illustrated for example in FIGS. 1 and 3. Film 20 is a high impact
polystyrene film that is fused substantially coextensive with first
surface 11 during the molding process. Preferably the polystyrene
film 20 is laminated or fused to the first surface after molding of
the expanded skid 10 but when it is still in the mold. The load
supporting surface includes any surface on which the skids may be
used such as a warehouse floor, transport vehicle or vessel or
like. The second surface 12 of skid 10 is uniquely configured to
custom fit the specific load contact surfaces as needed for
support. As can be seen from the above data, the weight of the
skids imparts little weight to the package, provides an economical
and impact resistant skid for transporting loads such as appliances
safely.
[0024] The height of ends 13 and 14 and sides 16 and 17 can be made
to accommodate the height necessary for the tongs of a forklift if
required for the application. Common edges between first surface 11
and ends 13, 14 and side surface 16, as an option, can be chamfered
to accommodate and ease transition over various surfaces. Chamfered
ends and side surfaces can ease conveyer roller transaction such as
rollers on a conveyor line. In an example, chamfered edge 28 is
provided along one of ends 13 or 14, or both ends 13, 14. Sides 16,
17 can also be chamfered, providing chamfered side 29 shown, for an
example, in FIG. 8. The height of chamfered edge 28 and side 29 is
generally the same. The chamfer height typically is a variable that
is determined by the specific application and need.
[0025] In an embodiment, a generally central portion along side 16
extends opposite surface 11 creating sidewall 26 that protrudes
from surface 12 as illustrated in FIG. 3. Sidewall 26 provides
further support and protection from side force impact to the load.
Sidewall 26 can be designed to accommodate the dimensions of the
specific load contacting surfaces.
[0026] Additionally, as shown for example in FIG. 4, skid 10 can
have specific openings such as 22a and 22b that can be used to
incorporate other packaging components such as a corner post 51.
Locations such as indents or openings 18 and 19 on second surface
12 of skid 10 can be made to accommodate specific or recurring
loads. Openings 18 and 19 give clearance for wheels of a load for
example.
[0027] In an embodiment, skid runner 10 has a plurality of grooves
25 provided on first surface 11 as shown in FIGS. 5 and 6. Grooves
25 provide a ribbed texture to first surface 11 that increases
flexural strength. Grooves 25 generally extend the length of
surface 11 from end 13 to end 14, or to a position just inward
thereof. Film 20 contours the form of the grooves 25 along surface
11. In this way, grooves 25 reduce contact with the load supporting
surface area and reduce friction thereby minimizing the effort
required to slide loads across supporting surfaces such as a floor
or truck bed. Generally grooves 25 are each of a similar shape and
located equidistant to one another parallel or substantially
parallel along first surface 11. Shape and position of grooves 25
can vary from application to application. The width of the grooves
25 is minimized, as measured from side 16 to side 17, if greater
contact with the load supporting surface area is desired, for
instance to increase stiffness and decrease friction. If increased
skid flex is desired, such as to adsorb more shock, the width of
grooves 25 could be increased in size or even eliminated The
grooves 25 also enhance the flexual strength of the invention.
[0028] Optionally, second surface 12 has a projecting support 23
specially molded to adapt or configure the second surface to engage
the load bearing members of the load, such as the legs of an
appliance, e.g. a refrigerator, washing machine or like legs, by
fitting between portions of inner faces of those legs. In an
example shown in FIG. 7, a product bearing area 23 extends opposite
surface 11 from a central portion of surface 12. Bearing area 23 in
combination with side 17 measures about 2.0 to 3.0 from first
surface 11, or, preferably, about 2.4 to 2.6 inches high, and, more
preferably, about 2.52 inches in height. Bearing area 23 has a
length that is generally one-third the length of the skid. Bearing
area 23 or similar configuration, is typically used with second
surface 12 as the main load bearing surfaces. The ability to custom
mold the second surface 12 of skid 10 by use of bearing area 23 and
sidewall 26, for example, to accommodate specific loads provides a
cost efficient system for placing a skid to the load at the point
of manufacture and retaining the skid to the final destination.
[0029] In an example of the invention as shown in FIG. 8, first
surface 11 also has one or more recesses 33a and 33b also referred
to as mechanical attachment locations. Recesses 33 provide an
indent to grooves 25. Regardless of whether grooves 25 are used,
recesses 33 have the general form of a circle, square or rectangle,
and enable mechanical attachment of skid runners to the product
being supported.
[0030] An illustration of a typical application of an embodiment of
the present invention is shown in FIG. 9. FIG. 9 shows a
combination of two runners 10 supporting a refrigerator load in
combination with corner post supports 51 and top pieces 30. In this
embodiment of the packaging system, skid runner 10 is optionally
used in combination with vertical corner post supports 51 as
illustrated in FIG. 9. Corner post supports 51 are located along
each corner or edge of the load, such as an appliance,
coextensively with the height thereof. A male feature on post
support 51 removeably engages with corresponding locking feature
22. Optionally, expanded polystyrene corner posts 51 can be used
with skid runners 10 and top pads 30 to form a complete protective
system for a typical load as shown in FIG. 9. In this embodiment of
the packaging system, corner post 51 locks into skid runner 10 and
top pad 30. A conventional stretch wrap or other material of
exterior containment can be applied to complete the packaging
system.
[0031] The invention also provides a method of packaging a load.
First, expanded polystyrene is molded to form at least two
elongated generally rectangular skid runners. Each of the runners
has first and second surfaces and at least two side walls and two
ends. Next, during the molding process, a polystyrene film is
bonded substantially coextensive with the first surface and
portions of the sides and ends that are adjacent to an intersection
with the first surface. The film becomes an integral part of the
final molded skid. At least two skids are placed in the supporting
position of a load, generally the bottom part, on the second
surfaces of are skid. Optionally, one or more corner post supports
and/or one or more top pieces are positioned in the skid, as in the
former case, or adjoined by contouring to the corners or edges of
the load. Optionally, the combined skids and load are wrapped with
plastic, paper, tape or other packaging material for further
protection.
[0032] While the presently preferred embodiment of the invention
has been shown and described in particularity, the invention maybe
otherwise embodied within the scope of the appended claims.
* * * * *