U.S. patent application number 12/552871 was filed with the patent office on 2010-03-04 for specialized packaging.
Invention is credited to Damon T. Hamilton, Kenneth T. Jenkins.
Application Number | 20100050573 12/552871 |
Document ID | / |
Family ID | 41723302 |
Filed Date | 2010-03-04 |
United States Patent
Application |
20100050573 |
Kind Code |
A1 |
Hamilton; Damon T. ; et
al. |
March 4, 2010 |
SPECIALIZED PACKAGING
Abstract
The present invention comprises an outer box comprising four
sidewalls, a first end and a second end; a rat box comprising a
crush zone, the rate box positioned at at least one end of the
outer box; a half moon support fitting against the walls of the
outer box comprising a surface in contact with a product surface
and angled slots diverging interiorly from an outer edge of the
half moon support; torpedo shield panels positioned inside of the
outer box having a center panel and two side panels diverging at an
angle with respect to the center panel, the side panels at least
partially fitting into the slots of the half moon support; and an
inner support having a plurality of contact points for contacting
an inner product surface, the inner support extending beyond each
end of the product and received by the rat box, thereby suspending
the product within the outer box.
Inventors: |
Hamilton; Damon T.;
(Wilkes-Barre, PA) ; Jenkins; Kenneth T.; (Old
Forge, PA) |
Correspondence
Address: |
MITCHELL A. SMOLOW
720 HAMPTON ROAD
SHAVERTOWN
PA
18708
US
|
Family ID: |
41723302 |
Appl. No.: |
12/552871 |
Filed: |
September 2, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61093714 |
Sep 2, 2008 |
|
|
|
Current U.S.
Class: |
53/461 ;
229/120.02 |
Current CPC
Class: |
B65D 5/5057 20130101;
B65D 85/20 20130101; B65D 5/505 20130101 |
Class at
Publication: |
53/461 ;
229/120.02 |
International
Class: |
B65B 11/00 20060101
B65B011/00; B65D 25/04 20060101 B65D025/04 |
Claims
1. A protective packaging for a product comprising: a) an outer box
comprising four sidewalls, a first end and a second end; b) a rat
box comprising a crush zone, the rat box positioned at at least one
end of the outer box; c) a half moon support fitting against a
sidewall of the outer box comprising a surface in contact with a
product surface and angled slots diverging interiorly from an outer
edge of the half moon support; d) a torpedo shield positioned
inside of the outer box having a center panel and two side panels
diverging at an angle with respect to the center panel, the side
panels at least partially fitting into the slots of the half moon
support so as to redirect an impact force away from the product;
and e) an inner support having a plurality of contact points for
contacting an inner product surface, the inner support extending
beyond each end of the product and received by the rat box, thereby
suspending the product within the outer box.
2. The protective packaging of claim 1 further comprising two half
moon supports and two torpedo shields, each being a mirror image of
one another.
3. The protective packaging of claim 1 wherein the inner support
has a triangular cross sectional geometric shape.
4. The protective packaging of claim 1 wherein the inner support
has an octagonal cross sectional geometric shape.
5. The protective packaging of claim 1 wherein the inner support
comprises a single structure spanning the length of and extending
beyond the end of the product.
6. The protective packaging of claim 1 wherein the inner support
comprises two structures positioned at and extending beyond each of
the first end and the second end.
7. The protective packaging of claim 1 wherein the first end and
the second end each comprise a rat box.
8. The protective packaging of claim 1 wherein the rat box
comprises an orifice having a cross sectional geometric shape
mirroring that of the inner support and sized to receive the inner
support.
9. A protective packaging for a product comprising: a) an outer box
comprising four sidewalls, a first end and a second end; b) a rat
box comprising a crush zone, the rat box positioned at at least one
end of the outer box; and c) an inner support having a plurality of
contact points for contacting an inner product surface, the inner
support extending beyond each end of the product and received by
the rat box, thereby suspending the product within the outer
box.
10. The protective packaging of claim 9 wherein the inner support
has a triangular cross sectional geometric shape.
11. The protective packaging of claim 9 wherein the inner support
has an octagonal cross sectional geometric shape.
12. The protective packaging of claim 9 wherein the inner support
comprises a single structure spanning the length of and extending
beyond the end of the product.
13. The protective packaging of claim 9 wherein the inner support
comprises two structures positioned at and extending beyond each of
the first end and the second end.
14. The protective packaging of claim 9 wherein the first end and
the second end each comprise a rat box.
15. The protective packaging of claim 9 wherein the rat box
comprises an orifice having a cross sectional geometric shape
mirroring that of the inner support and sized to receive the inner
support.
16. A method for packaging a product for shipment comprising the
steps of: a. placing an inner support within the product; and b.
placing the inner support and product within an outer box; wherein
the outer box comprises four sidewalls, a first end and a second
end; a rat box comprising a crush zone is positioned at at least
one end of the outer box; and the inner support comprises a
plurality of contact points for contacting an inner product
surface, the inner support extending beyond each end of the product
and received by the rat box, thereby suspending the product within
the outer box.
17. The method of claim 16 further comprising: a half moon support
fit against a sidewall of the outer box, the half moon support
comprising a surface in contact with an outer product surface and
angled slots diverging interiorly from an outer edge of the half
moon support; and a torpedo shield positioned inside of the outer
box having a center panel and two side panels diverging at an angle
with respect to the center panel, the side panels at least
partially fitting into the slots of the half moon support so as to
redirect an impact force away from the product.
18. The method of claim 17 further comprising two half moon
supports and two torpedo shields, each being a mirror image of one
another.
19. The method of claim 16 wherein the inner support has a
triangular cross sectional geometric shape.
20. The method of claim 17 wherein the inner support has an
octagonal cross sectional geometric shape.
21. The method of claim 17 wherein the inner support comprises a
single structure spanning the length of and extending beyond the
end of the product.
22. The method of claim 17 wherein the inner support comprises two
structures positioned at and extending beyond each of the first end
and the second end.
23. The method of claim 17 wherein the rat box comprises an orifice
having a cross sectional geometric shape mirroring that of the
inner support and sized to receive the inner support.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Application No.
61/093,714 filed Sep. 2, 2008.
FIELD OF THE INVENTION
[0002] This invention relates generally to novel packaging for
shipped objects and more particularly to packaging for chimney
pipe.
BACKGROUND OF THE INVENTION
[0003] Manufactured products are generally shipped or mailed to
their final destination. One such product is chimney pipe. In many
applications, chimney pipe is installed outside and visible to the
public. As such, modern chimney pipes are plated or coated to make
them aesthetically pleasing.
[0004] It is not uncommon for chimney pipe to be scratched, dented
or otherwise damaged during shipping, requiring the installer to
ship the item back for replacement. This can cause project delays
with resultant cost overruns, wasted time, effort and
resources.
[0005] Known packaging uses rectangular boxes in which the chimney
pipe is placed. There may or may not be padding surrounding the
chimney pipe. Most often the packaging is in direct contact with
the pipe with no crush zones so that, for example, if a pointed
object pierces the box, the chimney pipe is easily scratched or
dented.
[0006] Formed plastic has been used to encase and protect shipped
items. However, this packaging method greatly the increases the
packaging costs, is not environmentally sound, and is too expensive
to be cost effective for lower priced items such as chimney
pipe.
[0007] Accordingly, there is still a continuing need for an
economical, light weight, environmentally-friendly packaging which
more effectively protects shipped products than does known
packaging. The present invention fulfills this need and further
provides related advantages.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides an improved package design
for protecting a product during shipment.
[0009] In a first embodiment, the present invention comprises:
[0010] a) an outer box comprising four sidewalls, a first end and a
second end; [0011] b) a rat box comprising a crush zone, the rate
box positioned at at least one end of the outer box; [0012] c) a
half moon support fitting against the inner wall of the outer box
comprising a surface in contact with a product surface and angled
slots diverging interiorly from an outer edge of the half moon
support; [0013] d) torpedo shield panels positioned inside of the
outer box having a center panel and two side panels diverging at an
angle with respect to the center panel, the side panels at least
partially fitting into the slots of the half moon support; and
[0014] e) an inner support having a plurality of contact points for
contacting an inner product surface, the inner support extending
beyond each end of the product and received by the rat box, thereby
suspending the product within the outer box.
[0015] In a second embodiment, the at least one half moon support
and the torpedo shields are omitted.
[0016] It is an object of the present invention to provide
packaging which protects shipped products from scratches.
[0017] It is an object of the present invention to provide
packaging which protects shipped products from dents.
[0018] It is an object of the present invention to provide
protective packaging which is economical.
[0019] It is an object of the present invention to provide
protective packaging which is environmentally-friendly.
[0020] It is an object of the present invention to provide
protective packaging which has reduced waste.
[0021] It is an object of the present invention to provide
protective packaging which is light weight.
[0022] Other features and advantages of the present invention will
be apparent from the following more detailed description of the
preferred embodiments, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings are included to provide a further
understanding of the present invention. These drawings are
incorporated in and constitute a part of this specification,
illustrate one or more embodiments of the present invention, and
together with the description, serve to explain the principles of
the present invention.
[0024] FIG. 1 is a perspective view of the novel packaging
according to the present invention.
[0025] FIG. 2 is a side elevational view of the novel packaging
according to the present invention.
[0026] FIG. 3 is a cross-sectional plan view of the novel packaging
according to the present invention shown in FIG. 2.
[0027] FIG. 4 is a plan view of the cardboard cut outs which are
folded into a rat box of the packaging according to a first
embodiment of the present invention.
[0028] FIG. 5 is a plan view of the cardboard cut outs which are
folded into the inner support of the packaging according to the
present invention.
[0029] FIG. 6 is a plan view of the cardboard cut outs which are
folded into the torpedo shield of the novel packaging according to
the present invention.
[0030] FIG. 7 is a cut out of several half moon supports.
[0031] FIG. 8 shows a cross sectional view of a support according
to the prior art.
[0032] FIG. 9 shows a cross sectional view of a half moon support
interlocked with the torpedo shield.
[0033] FIG. 10 is a plan view of the cardboard cut outs which are
folded into a rat box of the packaging according to a second
embodiment of the present invention.
[0034] FIG. 11 is a cross-sectional plan view of the novel
packaging according to a second embodiment of the present
invention.
[0035] Other features and advantages of the present invention will
be apparent from the following more detailed description of the
preferred embodiments, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] As required, detailed embodiments of the present invention
are disclosed; however, it should be understood that the disclosed
embodiments are merely exemplary of the invention that may be
embodied in various forms. The figures are not necessary to scale,
and some features may be exaggerated to show details of particular
components. Therefore, specific structural and functional details
disclosed are not to be interpreted as limiting, but merely as a
basis for the claims and as a representative basis for teaching one
skilled in the art to variously employ the present invention.
[0037] In the following exemplars, the present invention is
fabricated of cardboard. Cardboard is economical, rigid,
lightweight, offers protection against scratching and denting and
is environmentally-friendly. However, the invention is not limited
to cardboard.
[0038] Turning now to the Figures, FIG. 1 is a perspective view of
the novel packaging according to a first embodiment of the present
invention. An outer box 1100 shown with its front face removed,
encloses a product 1 being shipped. In this embodiment, product 1
has an elongated cylinder shape, for example, a chimney pipe.
However, the packaging is not limited to an elongated cylinder
shape and may be used with slight modifications to package objects
having various shapes and cross sections.
[0039] An elongated package, such as packaging used to ship chimney
pipe, is most prone to damage when it falls on an end, due to the
substantial force concentrated on a relatively small surface area.
To protect the ends of the product 1, a `rat box` 1200 is
constructed and used at either end of the package 1000, each rat
box 1200 having end crush zones 1210.
[0040] Two half moon supports 1500 hold product 1 in the center of
the box 1100. Each half moon support 1500 includes a product
interface surface shaped to mate with the product 1. Each half moon
support 1500 has a corresponding half moon support 1500 on the
opposite side of the product 1 thereby creating support around the
perimeter of the product 1.
[0041] Each half moon support 1500 has an angled slot 1510 which
receives an edge of a torpedo shield 1400. Torpedo shields 1400 are
shown in phantom for clarity. There are torpedo shields 1400 on
opposite sides of product 1. These torpedo shields 1400 are
designed to provide additional protection to the product 1 should
an object break the integrity of outer box 1100. The elongated
torpedo shield 1400 fits within the angled slots 1510 of the half
moon supports 1500.
[0042] Preferably, each torpedo shield 1400 is comprised of a
single piece having a center panel and two side panels diverging at
an angle with respect to the center panel, the side panels at least
partially fitting into the slots 1510 of the half moon support
1500. The geometry of the torpedo shield 1400 serves to
transfer/redirect an impact force away from the product 1 into the
half moon support 1500. This transfer/redirection of impact force
is novel from the prior art which uses geometry that serves only to
act as a physical block to an impact. Without the novel force
redirection capability of the present invention, the prior art can
suffer deformation of the product when receiving an impact, even if
the prior art geometry prevents direct impact contact to the
product.
[0043] FIG. 2 is a side elevational view of the novel packaging
according to the present invention. In this view, outer box 1100 is
shown enclosing product 1. Rat boxes 1200 containing crush zones
1210 are shown at either end of package 1000. The two half moon
supports 1500 are shown in cross section. Rigidity is achieved by,
for example, several folded cardboard layers. Torpedo shield 1400
is shown in phantom for clarity. The torpedo shield on the opposite
side of product 1 is not visible from this view.
[0044] FIG. 3 is a cross-sectional plan view of the novel packaging
according to the present invention shown in FIG. 2.
[0045] Viewing FIGS. 2 and 3, the outer box 1100 is visible
enclosing shipped product 1. The rat box 1200 is shown at either
end of the package 1000 each having end crush zones 1210. The two
half moon supports 1500 have a product interface surface shaped to
hold product 1 in the center of the box 1100. A torpedo shield 1400
is shown in phantom (FIG. 2) over product 1. The elongated torpedo
shield 1400 fits within the half moon support 1500.
[0046] It is possible that an impact striking at an angle to the
end of package 1000 could collapse the ends of a hollow product 1,
for example, a chimney pipe. In order to protect such hollow
products 1, an inner support 1600 is provided. Inner support 1600
has, for example a triangular cross sectional shape which fits
snugly inside of the open ends of product 1. Optionally, other
cross sectional shapes that provide interior support to a hollow
product may be used, for example, an octagonal cross sectional
shape or any other geometric cross sectional shape that provides
supporting contact points within the product 1.
[0047] Although inner support 1600 may span the entire length of
product 1, in a preferred embodiment, inner support 1600 comprises
two separate end pieces. Regardless of whether inner support
comprises two separate pieces or a single piece, inner support 1600
extends beyond the product 1 to engage a mating cutout in the rat
boxes 1200. In this manner, product 1 is suspended within package
1000.
[0048] FIG. 4 is a plan view of a cardboard cut-out pattern which
is folded into a rat box 1200 of the novel packaging according to
the present invention. The mating cutout, for example, triangular
cut out 1211 in panel 1201, 1213 in panel 1203, 1251 in panel 1231
and 1253 in panel 1233 is provided. A panel 1202 connects panels
1201 and 1203. Similarly, a panel 1232 connects panels 1231 and
1233.
[0049] Fold lines 1271, 1273 and 1275, 1279 indicate where panels
1201 and 1203 fold over each other making a box shape with the
triangular cut outs 1211 and 1213 overlapping each other to make a
single triangular hole.
[0050] A portion 1285 between fold lines 1271 and 1273 becomes a
side of the folded rat box 1200. Similarly, a portion 1287 between
fold lines 1275, 1279 becomes the other side of rat box 1200.
Notches 1281 overlap notches 1283 of panels 1202 and 1232 to create
a recess to receive the top and bottom edges of torpedo shields
1400. Tabs 1260 fold to make the other sides of the rat box 1200.
Rat box 1200 is now ready to receive and hold the inner support
1600.
[0051] FIG. 5 is a plan view of the cardboard cut-out which folds
into the exemplar triangular shaped inner support 1600 of the novel
packaging according to the present invention.
[0052] Surface 1610 is one of the faces of the inner support 1600.
By folding on the fold lines 1651, 1610 becomes one of the
triangular faces, panels 1620 become two of the other faces.
Sections 1640 allow space for folding and provide a flattened apex
of the triangular shape. Panels 1630 overlap each other.
[0053] FIG. 6 is a plan view of the cardboard cut outs which are
folded into the torpedo shield 1400 of the novel packaging
according to the present invention. By folding torpedo shield 1400
cut out on center line 1423, a double layer thickness with panels
1410 overlapping each other is formed. Panels 1420 each overlap as
do panels 1430. Notches 1433 overlap notches 1431 on one side and
notches 1421 on the other side. These notches fit into slots 1510
of half moon support 1500 shown in FIG. 7. By partially folding
panels 1420 and 1430, the torpedo shield 1400 takes on its
characteristic shape as shown in FIG. 1.
[0054] Panels 1430 are partially folded on line 1411. Panels 1420
are also partially folded at line 1413 to create the characteristic
shape of torpedo shield 1400. The upper and lower corners of the
partially folded torpedo shield 1400 fit into the recesses created
from notches 1281 and 1283 of FIG. 4.
[0055] FIG. 7 is a cut out of several half moon supports 1500. The
cutout is cut on line 1515 to result in two identical mirror
images. Each is folded into a half-moon support 1500.
[0056] For ease of reading, only one panel side 1520 of the cut out
is described. Other sides are similarly formed. Panels 1517, 1519,
1521 and 1523 are connected to each other at fold lines 1511.
Depending upon the thickness of the materials used and the desired
strength, the left set of panels 1520 may be folded into 1, 2 or 4
half moon supports 1500. Panels 1517 may be folded onto panel 1519.
They may additionally be folded onto panels 1521 and 1523.
[0057] The panels are scored, or partially cut on line 1513 to
allow easier folding. The panels are then folded on line 1513 to
create the half moon shape. The inner surface 1517 is designed to
fit against and support the product 1 (FIG. 1). Optionally this
inner surface may be covered with a material to further prevent
scratching of the product.
[0058] In this manner, the structure of the half moon supports 1500
and the torpedo shield 1400 fit together to make a structure which
surrounds the product 1 perimeter, holds itself together without
connectors, is rigid, and resists torsional forces. Due to the
geometry of the half moon supports 1500, the angled slots 1510 and
the torpedo shield 1400, a rigid structure is formed.
[0059] FIG. 8 shows a cross sectional view of a support according
to the prior art. A flat elongated piece 11 is shown with it folded
at 90 degree angles to create side panels 13. The slots 15 are
perpendicular to the front edge 17 allowing the side panels 13 to
slide into them. This allows for easy construction.
Problematically, the side panels 13 slide out just as easily as
they slide into slots 15.
[0060] Twisting elongated piece 11 causes the left edge 13 to move
in the direction of arrow A into slot 15. If left side panel 13 is
fully inserted into slot 15, then it does not move. However, the
right edge panel 13 is forced to move in the direction marked by
arrow B out of slot 15 causing it to partially disassemble. With
the prior art design, if a force contacts elongated piece 11 in a
direction marked by arrow "C", the entire elongated piece 11 may be
pulled out of slots 15. These may progressively `creep`; moving
further and further out until it is disassembled. Furthermore, as
discussed above, the prior art does not allow for
transfer/redirection of the impact force away from the product.
[0061] FIG. 9 shows a cross sectional view of a half moon support
1500 interlocked with the torpedo shield 1400. Due to the geometry
of the present device, it is harder to disassemble. Center panel
1410 must be bowed to allow side panels 1420, 1430 to be inserted
into slots 1510. However, when a force is applied in the direction
marked by arrow "D", side panels 1420, 1430 resist being pulled out
of slots 1510 and return to their original positions after the
force is removed. This geometry only disassembles when force D is
great enough to pull side panel 1430 entirely out of slots 1510. In
this manner, the present invention employs a more rigid internal
structure, which is more resilient and better protects the product
than does the prior art.
[0062] The above embodiment of the present invention is envisioned
for use with spans of product 1, where without such rigidity,
package 1000 could fold upon receiving a side impact thereby
causing damage to product 1.
[0063] When shorter spans of product 1 are packaged, for example,
spans of about twenty four inches or less, the added rigidity
provided by half moon supports 1500 and torpedo shields 1400 become
optional. Packages 1000 of such lengths have been found to be
sufficiently rigid so a to not fold during a side impact. However,
to better protect such shorter spans of product 1, when half moon
supports 1500 and torpedo shield 1400 are omitted, inner support
2600 (FIG. 11) ideally comprises more contact points than a
triangular cross-sectional geometric shape provides. Preferably, an
octagonal cross-sectional geometric shape is utilized, although
inner support 2600 is not limited to an octagonal cross-sectional
geometric shape.
[0064] FIG. 10 is a plan view of a cardboard cut-out pattern which
is folded into a rat box 1200 of the novel packaging according to a
second embodiment. The mating cutout, for example, octagonal cut
out 2211 in panel 2201 and 2213 in panel 2203 is provided. A panel
2202 connects panels 2201 and 2203.
[0065] Fold lines 2271, 2273 and 2275, 2279 indicate where panels
2201 and 2203 fold over each other making a box shape with the
octagonal cut outs 2211 and 2213 overlapping each other to make a
single octagonal hole.
[0066] A portion 2285 between fold lines 2271 and 2273 becomes a
side of the folded rat box 1200. Similarly, a portion 2287 between
fold lines 2275, 2279 becomes the other side of rat box 1200.
Notches 2281 overlap notches 2283 of panel 2202 to create a recess
to receive the top and bottom edges of optional torpedo shields
1400, should they be utilized. Tabs 2260 fold to make the other
sides of the rat box 1200. Rat box 1200 is now ready to receive and
hold the inner support 2600.
[0067] FIG. 11 is a cross-sectional plan view according to the
second embodiment. The optional two half moon supports 2500 have a
product interface surface shaped to hold product 1 in the center of
the box. An optional torpedo shield 2400 is shown over product 1.
The optional elongated torpedo shield 2400 fits within the optional
half moon support 2500, received by slots 2510 of optional half
moon support 2500. Inner support 2600 fits snugly inside of the
open ends of product 1.
[0068] Although the present invention has been described in
connection with specific examples and embodiments, those skilled in
the art will recognize that the present invention is capable of
other variations and modifications within its scope. These examples
and embodiments are intended as typical of, rather than in any way
limiting on, the scope of the present invention as presented in the
appended claims.
* * * * *