U.S. patent application number 11/806538 was filed with the patent office on 2007-10-11 for stackable packaged soft-wall containers.
Invention is credited to Douglas W. Eggins, Michael G. Whiteside.
Application Number | 20070235363 11/806538 |
Document ID | / |
Family ID | 38574024 |
Filed Date | 2007-10-11 |
United States Patent
Application |
20070235363 |
Kind Code |
A1 |
Whiteside; Michael G. ; et
al. |
October 11, 2007 |
Stackable packaged soft-wall containers
Abstract
A packaging system for soft-walled plastic containers of tapered
or other non-cylindrical shapes has a supporting base to which the
containers are secured, with a superposed positioning means
engaging the upper portions of the containers; and load transfer
spacer sheets extending upwardly in substantially coplanar relation
with the tops of the containers, to support a superposed similar
package, for palletizing. The package may be strapped, horizontally
or vertically and used in plasti-wrapped multi-tier pallet loads.
The supporting base may be a tray, which can be of the nesting
variety. Formed or die-cut top sheets can be used in combination
with the load-transfer spacer sheets
Inventors: |
Whiteside; Michael G.;
(Barrie, CA) ; Eggins; Douglas W.; (Barrie,
CA) |
Correspondence
Address: |
D.W. EGGINS
18 DOWNSVIEW DRIVE
BARRIE
ON
L4M 4P8
CA
|
Family ID: |
38574024 |
Appl. No.: |
11/806538 |
Filed: |
June 1, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11082984 |
Mar 18, 2005 |
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11806538 |
Jun 1, 2007 |
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11594187 |
Nov 8, 2006 |
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11806538 |
Jun 1, 2007 |
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Current U.S.
Class: |
206/509 |
Current CPC
Class: |
B65D 2571/0029 20130101;
B65D 71/38 20130101; B65D 2571/00895 20130101; B65D 2571/00327
20130101; B65D 71/70 20130101; B65D 21/0233 20130101; B65D
2571/00419 20130101; B65D 2571/00666 20130101; B65D 2571/0079
20130101; B65D 2571/0024 20130101 |
Class at
Publication: |
206/509 |
International
Class: |
B65D 21/00 20060101
B65D021/00 |
Claims
1. A composite package containing a plurality of substantially
identical containers of goods, for transportation, storage and
display, said package having a lower portion to receive said goods
containers in assembled, mutually organized relation thereon; first
positioning means to immobilize said containers in relation to said
package lower portion; divider means interposed in spacing relation
between predetermined ones of said containers, second positioning
means to secure the upper portions of said containers in mutually
fixed relation, said second positioning means having upper portions
of predetermined load-bearing capacity extending upwardly to be
substantially coplanar with the tops of said containers, and
retaining means securing the elements of said package in mutually
secured relation to form a stable, load-bearing structural unit for
stacking in a plurality of self-supporting layers.
2. The composite package as set forth in claim 1, said first
positioning means consisting of an adhesive securing individual
ones of said containers to said package lower portion.
3. The composite package as set forth in claim 1, said first
positioning means consisting of raised surface portions of said
package lower portion, located to contact lower edge portions of at
least some of said containers in positioning engagement
therewith.
4. The composite package as set forth in claim 1, having a securing
strap attached in compressive, positioning relation with selected
portions of said package.
5. The composite package as set forth in claim 1, said retaining
means comprising an upper tray member engaging upper portions of
said containers in predetermined positioned relation, said upper
tray member having load bearing upper support surface portions, in
use to receive a further package in supported relation thereon.
6. The composite package as set forth in claim 1, said containers
each having an upper, closure cap, said divider means having at
least one portion of corrugated board extending in supported
relation from said package lower portion to a position
substantially coplanar with the tops of said containers, said
corrugated board divider means having the corrugations thereof
positioned edgewise to the anticipated direction of applied
downward compressive loading.
7. The composite package as set forth in claim 5, said upper tray
member having laterally and longitudinally extending hollow ribs,
and corrugated board divider means extending from said package
lower portion to engage said ribs in load-transfer relation between
said package lower portion and said upper tray member.
8. The composite package as set forth in claim 7, said element
securing retaining means comprising a plurality of mutually spaced
apertures to receive respective cap portions of said containers in
entered, engaged relation therein.
9. The composite package as set forth in claim 1, said retaining
means comprising an upper sheet member having apertures to receive
closure cap members of said containers in secured penetrating
relation therethrough; said upper sheet member having a plurality
of slots in predetermined positioned relation to receive upwardly
extending tab portions of said divider means in penetrating
relation therethrough.
10. The composite package set forth in claim 9, said closure cap
members and said upwardly extending tab portions having their
uppermost surfaces in substantially co-planar relation, to provide
load bearing upper support surfaces, in use to receive a further
package in supported relation thereon.
11. The composite package as set forth in claim 6, said package
lower portion consisting of a tray having side walls and a bottom,
said side walls being outwardly tapered to form a nesting draw,
whereby said tray may be nested with other like trays, to form a
compact package for ready shipment.
12. The composite package as set forth in claim 11, said second
positioning means consisting of a planar cover sheet sized to fit
within said side walls, upon said tray bottom, said cover sheet
having apertures to receive projecting upper portions of said
container in secured penetrating relation therethrough; said cover
sheet having a plurality of slots in predetermined positioned
relation to receive upwardly extending tab portions of said divider
means in penetrating relation therethrough.
13. The composite package as set forth in claim 12, said tray side
walls being of predetermined height to accommodate a predetermined
number of said cover sheets in flush-fitting relation within a said
tray.
14. A composite package for secure shipping, having a plurality of
walled tray members in mutually nested relation, the uppermost said
tray member containing a plurality of substantially planar sheets
in mutually stacked relation within said tray; said substantially
planar sheets each having apertures extending therethrough,
arranged in predetermined mutually spaced relation, in use to
receive load transfer members in projecting relation through said
planar sheet.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] CIP of applications Nos.: Ser. No. 11/082,984 filed Mar. 18,
2005 and Ser. No. 11/594,187 filed Nov. 8, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO MICROFICHE APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. This invention is directed to a packaging system for
multi-pack stackable structured packaging for shaped
containers.
[0005] 2. There exists a large family of taper-shaped containers,
differing both in shapes and sizes, used for pourable or pumpable
fluids, most of which containers are soft, thin-walled plastic
bottles. Owing to the thin-ness of their soft, flexible walls these
containers are subject, when loaded externally, to deformation with
consequent stress cracking, so that they presently are transported
in a substantially loose-packed condition within substantially
rigid, fully enclosed cardboard cartons.
[0006] Cardboard packaging is used extensively in the Western world
for an extremely wide range of goods. This "board", primarily of
the three-layer type having a corrugated core, is frequently used
in a `once-off` manner, and then either scrapped, or recycled. The
adverse ecological burden that this represents is little
recognised. The production, use and re-cycling of the vast
quantities of material involved requires the ongoing destruction of
forests and requires vast quantities of fuel (for transportation),
water and power for initial production, and for recycling, when
that is practiced.
[0007] In the present matter of global warming, vast quantities of
green-house gas are generated in the manufacture and subsequent
disposal or re-utilization of cardboard (board) packaging. Any
effective diminution in the quantity of board required for
packaging, or increase in its utilization by way of re-use
represents a significant reduction in the generation of green-house
gases, and can provide a highly desirable reduction in the rates of
world-wide de-forestation.
[0008] A brief review of the background concerning the usage of
corrugated cardboard (CC) establishes the following facts:
[0009] In the United States CC-fibre is re-cycled twice on average:
in Europe it is recycled four times. [source--Barbara
Crowell--Pack3 conference Brussels May 3-4, 1993]
[0010] In Asia CC is recycled so many times as to be significantly
weaker and less water-resistant than US recycled fibre, so as to be
unacceptable for further recycling.
The reduction by one Tonne of Corrugated Board can lead to
representative cost savings:
[0011] Municipal Solid waste Management--$176; Municipal Wastewater
management--$7; [0012] Value of reduced Greenhouse Gas
emissions--$19. Totalling Direct Savings $183. [0013] A further
indirect saving of $19 may also accrue. The present invention, in
common with the above-referred to Applications, aims at providing
integrated structural packaging that particularly lends itself to
being multi-tier stacked on a pallet for purposes of handling,
shipping, storage and display, while minimizing the quantity of
packaging material required to achieve the desired structural
characteristics.
[0014] In the above-referred patent applications the goods
containers are primarily of substantially rigid, cylindrical form
(including rectangular cylindrical sections), with the packaging
having D-cut and other separators positioned between the respective
containers, to provide mutual separation, combined with integration
of the containers with the package, under the compressive effects
of tensioned wrapping strap or straps.
[0015] In the subject family of thin-walled plastic containers,
most such containers are non-cylindrical, being shaped generally
with an upwardly modified cross section, both for aesthetic and for
hand-held purposes, and also to facilitate their withdrawal from
their moulds. This tapered formation, allied with the thin-walled
flexible structure of the containers militates against their
satisfactory immobilization within, and integration with the
containing package, under the compressive influence of external
strapping, as taught in the forementioned Applications.
BRIEF SUMMARY OF THE INVENTION
[0016] The present invention provides a packaging system for the
bulk packaging of flexible walled containers of non-uniform
section, wherein a plurality of the containers are mounted upon a
tray, in secured relation thereto to form a package, having at
least one integrating collar engaging at least some of the
containers in secured, mutually spaced relation; and upwardly
extending load transfer means to promote the load carrying
capability of the package in the support of a superimposed like
package or packages in stable, stacked relation therewith, usually
for transportation by way of wooden pallets, which loads may be
plasti-wrapped for transportation.
[0017] The subject containers may have upwardly tapering walls to
provide a portion of the container with an upwardly diminishing
cross section.
[0018] The subject containers may have screw cap closures; the
subject integrating collar having a plurality of apertures in
mutually spaced relation to receive a corresponding plurality of
the cap closures extending in penetrating relation through the
collar.
[0019] The subject collar apertures may have flexible edge portions
to enter undercut portions of the container located below the caps,
to thereby engage the caps and secure the integrating collar to the
containers. The collar may be of corrugated board or paperboard.
The load transfer means may be in the form of board separators
extending between the containers and having upwardly extending
portions projecting substantially coplanar with the tops of the
containers, to provide co-planar load-receiving means as support
for a superimposed package. The board separators are preferably of
vertically oriented corrugated board.
[0020] The subject containers may be glued to the tray.
[0021] The subject containers may be positioned on the tray by way
of upturned board portions of the tray engaging edge portions of
the lower extremity of respective ones of the containers.
[0022] Selected adjoining ones of the subject containers may be
joined by way of a low-tension adhesive.
[0023] The subject load transfer means may comprise upwardly
extending partition means having the lower end portion thereof
secured to the tray, and extending upwardly between adjacent ones
of the subject containers, with an upper edge portion of the
partition means located substantially coplanar (flush) with the
tops of the container caps, in load sharing relation therewith.
[0024] The subject partition means may be convoluted when seen in
plan view, with adjoining portions respectively extending laterally
and longitudinally of the subject tray, in mutual stiffening
relation.
[0025] The subject partition means may have first and second
portions in mutually inclined, normal relation, each portion
extending in interdigitated stiffening relation with an adjoining,
normally extending portion.
[0026] The subject package may include low tension (frangible) glue
as an attachment agent between package components and containers,
and between adjoining containers, at their mutual contact
areas.
[0027] One embodiment may have a planar die-cut top sheet, having a
series of die-cut apertures having radiating cut-lines, for
penetration and capture of the caps of the respective containers. A
further series, of laterally and of longitudinally extending cut
lines or slots receive upwardly projecting tab portions of the
convoluted ("Z") dividers. The shoulder portions of the separators
adjoining the tabs support the undersurface of the top sheet, and
the tabs project through the cut slots and extend above the top
sheet, to be substantially coplanar with the top surfaces of the
projecting caps of the containers.
[0028] A further embodiment provides a tray having slightly tapered
walls, such that the trays may be nested. The top sheet may be
dimensioned to fit into the base of the tray, enabling a number of
trays and their associated top sheets to be packaged into a "solid"
block for return shipping to the goods Supplier, for re-use. The
tray wall height may be selected to match a predetermined number of
top sheets, such as the five of a pallet stack.
The Z-spacers may pack flat with the trays and top sheets.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0029] Certain embodiments of the invention are described by way of
illustration, without limitation thereto other than as set forth in
the accompanying claims, reference being made to the accompanying
drawings, wherein:
[0030] FIG. 1 shows a first group of five containers A through E,
of non-uniform section;
[0031] FIG. 2 shows a second group of containers A through D of
non-uniform section;
[0032] FIG. 3 shows a third group of containers A through C of less
usual shape;
[0033] FIG. 4 is a plan view of a first embodiment package of
containers, packaged in accordance with the present invention, and
incorporating a load-bearing spacer;
[0034] FIG. 5 is a side elevation of the FIG. 4 package
embodiment;
[0035] FIG. 6 is a perspective view of the spacer of FIGS. 4 and
5;
[0036] FIG. 7 is a plan view of a second embodiment package of
containers incorporating a top locator/load transfer cover;
[0037] FIG. 8 is a perspective view of a further embodiment of a
top locator/load transfer cover in an inverted position;
[0038] FIG. 9 is a plan view of a loaded tray, before application
of the transfer cover of FIG. 8, with four partition members shown
in their assembled condition;
[0039] FIG. 10 is a partial top perspective view of portions of a
package having a planar die-cut top sheet, showing projecting
container caps and upstanding spacer tabs;
[0040] FIG. 11 is a plan view of the FIG. 10 arrangement;
[0041] FIG. 12 is a perspective view of a nestable tray;
[0042] FIG. 13 is a perspective view of a top sheet matched to the
FIG. 12 tray; and,
[0043] FIG. 14 is a perspective view of a portion of a store's
trolley for use with nestable package components
DETAILED DESCRIPTION OF THE INVENTION
[0044] It will be understood by those skilled in the art that the
above disclosure is directed primarily to specific embodiments of
the present invention, and that the subject invention is
susceptible of reduction to practice in other embodiments that fall
within the scope of the appended claims.
[0045] Referring to the drawings, FIGS. 1, 2 and 3 illustrate a
very small portion of an almost limitless assortment of plastic
container `bottles`, many of which are "soft-walled", and are
suited for packaging in the presently disclosed high efficiency
packaging, characterized by its integration of packaging components
with the structure of the container, to form structural packages
that are well adapted for multi-layer palletizing. It will be
understood that `hard-walled` containers, including other than
plastic may also be susceptible of use within the present
invention.
[0046] FIG. 4 shows a package 10 including six shaped containers 12
mounted in a tray base 14 and having a spacer 16 of corrugated
board secured by way of insert tabs 18 to the bottom 20 and wall 21
of the tray base 14 (see also FIG. 6). The containers 12 are each
secured by way of low-tension adhesive (not shown) to the package
bottom 20. The abutting side surfaces of containers 12 may also be
mutually adhered by way of small patches of `low-tensile`
(strength) adhesive (not shown).
[0047] A strap 17 may be used, which is positioned by corner slots
19 to engage and retain the `corner` containers 12.
[0048] The top edge of the spacer 16 is substantially coplanar with
the tops of the caps 24 of the containers 12 (see FIG. 5), to
supplement the load-bearing capacity of the containers 12.
[0049] Referring to FIG. 7, in this package embodiment 25, a spacer
such as 16 may be supplemented or replaced by a spacer/platform 26
shown in overlaid (but non-applied) relation with the base 14 and
the containers 12. The spacer/platform 26 has a die-cut sheet
portion 28 with score-cut holes 30 that are sized to receive and
engage beneath the lower edges of the caps 24, so as to locate the
top portions of the containers 12, when the spacer/platform 26 is
pushed down over the underlying caps 24.
[0050] The spacer platform 26 has an upstanding peripheral rim 32
that projects upwardly to be flush with the tops of the container
caps 24, so as to provide a supporting base for a superposed like
package 10 or 25, which would overly the rim 32.
[0051] It will be understood that for the package embodiment 25 the
spacer 16 would be made shorter, so as to be flush with the bottom
surface of the sheet portion 28 when sheet 28 has been pushed down
to engage beneath the caps 24.
[0052] The load strength of corrugated boards in a range of board
weights has been tested, using specimens reinforced against
buckling failure by having two adjoining areas being bent mutually
at an angle of about 90 degrees to form a so-called Z-spacer, it
being understood that the corrugations are edge-on to the direction
of applied load, to provide optimum columnar strength.
[0053] Turning to FIGS. 8 and 9, a top locator/load transfer cover
40, shown inverted, and illustrated as being of moulded paper
board, has eight score-cut holes 30 to receive and engage beneath
the lower edges of container caps, such as the caps 24 of FIG.
5.
[0054] A central upstanding rib 42 of inverted U-section (when
viewed in its inverted orientation of use) extends the length of
the cover 40. The rib 42 is dimensioned to be substantially
coplanar with the tops of the container cans (such as 24).
Laterally extending ribs 44 of similar cross-section intersect with
rib 42 at upstanding caps 46, the tops of ribs 44 being co-planar
with the top of rib 42 and the caps 46, and also with the container
caps 24, when assembled.
[0055] The illustrated undersurface of the cover 40 forms passages
45 into which dividers 48 are slotted. The dividers 48 extend to
the floor of the tray or base upon which the package contents would
stand, to provide a contiguous, reinforced support structure. The
dividers 48 and the interior width of the ribs 42, 44 may be
dimensioned to provide a tight slide-in fit, or the dividers may be
spot-glued in place, or located by `toe tabs` fitted into tray
recesses.
[0056] It will be understood that different arrangements and
smaller numbers of dividers may be used, in accordance with the
need for separation of containers, and the desired load bearing
capacity of the combined contents and package to meet pallet load
requirements. Referring to FIGS. 10 and 11, the embodiment 101 has
a bottom tray 102 with eight containers 104, only one of which is
fully represented. A top sheet 106 has eight container caps 108
projecting above, and engaged by respective die-cut cap apertures
of the sheet 106.
Aperture tabs 110 are engaged beneath the lower edges of the caps
108, to secure the top sheet 106.
[0057] Ten upstanding tab portions 112 project from die-cut tab
apertures of the top sheet 106. The upper edges of the tab portions
112 are coplanar with the tops of the container caps 108, to
provide support to the tray 102 of an overlying like package.
[0058] The dividers 114 from which the tab portions 112 extend are
supported by the tray 102 of the package, such that when packages
110 are stacked five-high as part of a pallet load, the dividers
114 and their associated projecting tab portions 112 provide
substantially continuous columnar support from the bottom tray to
the top of the stack of packages, as reinforcement to the load
bearing capacity of the containers 104 and their respective caps
108, which also form contiguous columnar supports from the bottom
tray to the top of the package stack
[0059] Turning to FIGS. 12, 13 and 14: a stackable tray 120, has
symmetrical sloped sides and ends that provide a shallow `draw`
angle, to enable it to be nested with like trays 120, having the
associated top sheets sized to the size of the bottom tray, so as
to fit within the nested trays, and to fill the top tray to its
upper edge, to provide a strong return package. The tray 120 is
illustrated as having a slot-indented bottom, to engage the bottom
of the Z-spacers, which may be provided with shallow, bottom-edge
tabs to fit the slot indents. The trays 120 and top sheets 122 each
have an oriented peg-slot 121, 123 that enables their ready
separation by store shelf stockers, using a cart 124 having
correspondingly oriented pegs 125, 127. These pegs 125, 127 may be
bayonet-mounted to the cart, such that a quarter twist will free
the respective peg from the cart, enabling the ready downward and
unobstructed removal of the trays 120 and top sheets 122 from off
the pegs 125, 127. The dividers 114 may be flattened and packaged
separately for return, or packaged to the nested trays when the
sizes are compatible.
* * * * *