U.S. patent application number 13/464268 was filed with the patent office on 2012-12-06 for layered product stacking structure.
This patent application is currently assigned to Hexacomb Corporation. Invention is credited to Robert E. Jaegers.
Application Number | 20120305440 13/464268 |
Document ID | / |
Family ID | 47260841 |
Filed Date | 2012-12-06 |
United States Patent
Application |
20120305440 |
Kind Code |
A1 |
Jaegers; Robert E. |
December 6, 2012 |
LAYERED PRODUCT STACKING STRUCTURE
Abstract
A product-stacking structure that holds a plurality of products
on a horizontal base and includes a plurality of side sections
extending generally upright from the horizontal base section (e.g.,
walls). The walls are configured and dimensioned for retaining
bottom features of the products within. The horizontal base
includes a horizontal base surface and a void region creating a
boundary that restricts movement of upper features of the products
in at least one horizontal direction. The product-stacking
structure also includes a supportive pad affixed to the first
portion over the horizontal bottom section and within the plurality
of side sections to cover the void region and configured for
supporting products stacked thereon.
Inventors: |
Jaegers; Robert E.; (Lake
Zurich, IL) |
Assignee: |
Hexacomb Corporation
Deerfield
IL
|
Family ID: |
47260841 |
Appl. No.: |
13/464268 |
Filed: |
May 4, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61482481 |
May 4, 2011 |
|
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Current U.S.
Class: |
206/564 |
Current CPC
Class: |
B65D 71/0096 20130101;
B65D 2301/10 20130101; B65D 21/0224 20130101 |
Class at
Publication: |
206/564 |
International
Class: |
B65D 21/032 20060101
B65D021/032; B65D 71/00 20060101 B65D071/00 |
Claims
1. A product-stacking structure configured to hold a plurality of
products having a top and bottom feature comprising: a horizontal
base including a horizontal base surface and an internal lateral
edge that defines a central void; and a supportive pad configured
and having sufficient strength for supporting products stacked
thereon with the pad supported on similar products therebelow, the
pad having a first pad surface and being affixed to the horizontal
base covering the void region with the internal edge positioned
proud of the first pad surface, the internal edge creating a
boundary that restricts horizontal movement of features of the
products that are positioned within the void.
2. The stacking structure of claim 1, further comprising a
plurality of sidewalls extending generally upright from the
horizontal base and configured and dimensioned for retaining
features of the products therebetween.
3. The stacking structure of claim 2, wherein the supportive pad is
disposed within the plurality of side sections.
4. The stacking structure of claim 2, wherein the boundary and side
sections are configured to hold outer edges of the plurality of
products, such that the plurality of products are held together
against each other.
6. The stacking structure of claim 2, wherein a height of the
plurality of sidewalls and a thickness of the surface region are
configured to expose at least a major portion of the products
adjacent the sidewalls for viewing.
7. The stacking structure of claim 2, wherein the horizontal base
and side sections are constructed from a unitary blank.
8. The stacking structure of claim 1, wherein the horizontal base
is constructed from a corrugated paper structure, and the
supportive pad is constructed from a honeycomb sandwich
material.
9. The stacking structure of claim 1, wherein the internal lateral
edge defines a plurality of separate void regions.
10. A product-stacking structure configured to hold a plurality of
products having a top and bottom feature comprising: first portion
that includes: a horizontal base including a horizontal base
surface and an internal lateral edge that defines a central void
region, and a plurality of sidewalls extending generally upright
from the horizontal base; and a supportive pad configured and
having sufficient strength for supporting products stacked thereon
with the pad supported on similar products therebelow, the pad
having first and second pad surfaces on opposite sides thereof, the
first pad surface being affixed to the horizontal base covering the
void region with the internal edge positioned proud of the first
pad surface; wherein the internal edge creating a boundary that
restricts horizontal movement of features of the products that are
positioned within the void, and the sidewalls extending beyond the
second pad surface sufficiently for retaining features of products
therebetween.
11. The stacking structure of claim 10, wherein the first portion
is made of corrugated cardboard and the pad is made of a honeycomb
sandwich material.
12. A stacked product arrangement, comprising: first and second
stacking structures as described in claim 10; and a first plurality
of products supported on the first stacking structures and
prevented from sliding laterally by the first stacking structure
sidewalls; a second plurality of products supported on the second
stacking structure and prevented from sliding laterally by the
second stacking structure sidewalls; wherein the second stacking
structure is disposed and supported on the first products, which
are received within the void region of the second stacking
structure, thereby retaining the second stacking structure
laterally on the first products.
13. The stacked product arrangement of claim 12, wherein the first
and second products have a same shape.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 61/482,481 filed May 4, 2011. The entire disclosure
of the above-referenced application is incorporated herein by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a stacking structure for
supporting products.
BACKGROUND
[0003] The packaging industry uses a variety of materials, in a
variety of configurations to reduce or eliminate damage to
transportable items in transit and to display items in a retail
location. Typical materials include corrugated cardboard. A typical
configuration may be as simple as a six-sided box, of various
dimensions.
[0004] Additionally, configurations strive to reduce the
time/effort required to get the contained items from loading dock
to presentation shelves (e.g., in the context of retail merchandise
and similar). One example may include a cut-away window in the box.
This may be an ordinary box holding multiple retail items (e.g.,
bottles of laundry detergent), and a perforation line, such that
when the perforated portion is removed, the product is at least
partially visible and accessible. This way, stock workers do not
need to fully unload each box onto the shelf, but may quickly
remove the perforated window, and shelve the whole box. This may be
directly onto the retail shelf, to allow retail customers to
identify the product for sale, or may be for placement on
stock-room shelves, to allow stock workers to identify the product
faster than if left in enclosed boxes.
[0005] Additionally it is known in the art to use extra pads along
edges and especially at corners, or to provide additional support
at the base of an object or a pallet to support the base of several
objects. These base pads, sometimes referred to as carriers, skids,
runners, pallets, or simply bases, are used to cushion, protect,
and keep together objects during storage and transport. On the base
layer, multiple layers of products may be stacked, and each layer
of product may include a supporting layer between. For example,
FIG. 1A illustrates a bulk packaging of multiple spool-type items
110, each with a main body 112 and two protrusions 114 (e.g., the
two ends of the inner spool). The spools 110 are stacked on a
bottom pallet 116, and, as depicted in FIG. 1B, a dividing layer of
honeycomb board has holes 118 punched out to receive the top end of
each spool from the lower layer, and the bottom end of each spool
from the upper layer. As depicted in FIG. 1C, the top piece 120,
having no upper layer of spools, is flat, with punch-cut then
crushed dimples to receive the top end of each spool on the top
layer of spools.
[0006] The present disclosure provides a packaging arrangement that
can provide increased structural integrity and versatility with
respect to products with which it can be used.
SUMMARY
[0007] The present disclosure relates to a stacking structures for
supporting a plurality of products. Example embodiments may include
a product stacking structure configured to hold a plurality of
products having a top and bottom feature. The stacking structure is
comprised of a horizontal base and a supportive pad. The horizontal
base includes a horizontal base surface and an internal lateral
edge that defines a central void. The supportive pad is configured
to have sufficient strength for supporting products stacked thereon
with the pad supported on similar products therebelow. The
supportive pad also has a first pad surface which is affixed to the
horizontal base covering the void region with the internal edge
positioned proud of the first pad surface. The internal edge
creates a boundary that restricts horizontal movement of features
of the products that are positioned within the void. In the
preferred embodiment, the internal lateral edge defines a central
void; however, in alternative embodiments, the internal lateral
edge may define a plurality of separate void regions.
[0008] The stacking structure may further comprise of a plurality
of sidewalls extending generally upright from the horizontal base
and configured and dimensioned for retaining features of the
products therebetween. In the preferred embodiment, the height of
the plurality of sidewalls and a thickness of the surface region
are configured to expose at least a major portion of the products
adjacent the sidewalls for viewing.
[0009] Additionally, the supportive pad is disposed on the
horizontal base and within the plurality of side sections. The
boundary created by the internal edge and the side sections are
configured to hold outer edges of the plurality of products, such
that the plurality of products are held together against each
other.
[0010] In the preferred embodiment, the horizontal base is
constructed from a corrugated paper structure, and the supportive
pad is constructed from a honeycomb sandwich material. Further,
both the horizontal base and side sections in the preferred
embodiment are constructed from a unitary blank of sheet
material.
[0011] A product-stacking structure in another embodiment may also
be configured to hold a plurality of products having a top and
bottom feature comprising a first portion and a supportive pad. The
first portion further comprises a horizontal base including a
horizontal base surface and an internal lateral edge that defines a
central void region, and a plurality of sidewalls extending
generally upright from the horizontal base. The supportive pad is
configured to have sufficient strength for supporting products
stacked thereon with the pad supported on similar products
therebelow. The supportive pad has a first and second pad surface
on opposite sides thereof, where the first pad surface being
affixed to the horizontal base covering the void region with the
internal edge positioned proud of the first pad surface. In
addition, the internal edge creates a boundary that restricts
horizontal movement of features of the products that are positioned
within the void, and the sidewalls extending beyond the second pad
surface sufficiently for retaining features of products
therebetween. The first portion may also be made of corrugated
cardboard and the pad is made of a honeycomb sandwich material.
[0012] In addition, the stacked structures may form a stacked
product arrangement comprising (1) a first and second stacking
structures having a first portion and a supportive pad; (2) a first
plurality of products supported on the first stacking structures
and prevented from sliding laterally by the first stacking
structure sidewalls; and (3) a second plurality of products
supported on the second stacking structure and prevented from
sliding laterally by the second stacking structure sidewalls. The
second stacking structure is disposed and supported on the first
products, which are received within the void region of the second
stacking structure, thereby retaining the second stacking structure
laterally on the first products. In one embodiment, the stacked
product arrangement may be configured to retain a first and second
products having the same shape.
BRIEF DESCRIPTION OF FIGURES
[0013] FIG. 1 A shows a prior art packaging arrangement;
[0014] FIG. 1B is a cross-sectional view of a dividing board
thereof;
[0015] FIG. 1C is a cross-sectional view of the top board
thereof;
[0016] FIGS. 2A and 2B are top perspective and bottom views of a
stacking structure according to the preferred embodiment;
[0017] FIG. 2C is a top perspective view thereof in an unassembled
configuration;.
[0018] FIGS. 3A and 3B are top and bottom perspective views of a
stacking structure of another embodiment;
[0019] FIGS. 4 and 5 are perspective bottom views of other
embodiments of a stacking structure;
[0020] FIG. 6 illustrates a pallet load of stacking structures and
packaged products according to an embodiment; and
[0021] FIG. 7 illustrates two unassembled blanks for forming
component pieces of the stacking structure of FIG. 2A-2C.
DETAILED DESCRIPTION
[0022] With reference to FIGS. 2A-2C, an embodiment of a
product-stacking structure can be constructed as a shallow-walled
tray. The example embodiment includes a supportive pad 218 and a
tray portion. The tray portion further comprises (1) a horizontal
base 210 having a horizontal base surface 214 and a void 212 formed
by an internal lateral edge 232, and (2) side sections or walls 216
formed along the perimeter of the horizontal base 210 and generally
extending upright from the base 210. The walls 216 may be part of
the same unitary blank of sheet material used to form the base 210,
such as a single piece of sheet material, for example, corrugated
material, or it may alternatively be adhered or otherwise attached
to the horizontal base 210 or pad 218 separately with an adhesive
such as, but not limited to PVA glue, EVA glue, water based
adhesives, starch based adhesives, HotMelt .RTM., and solventless
adhesives. The stacking structure may generally be made of a
fiber-based material, such as paper or paper-board, and will be
discussed in greater details below in FIGS. 3A-3B, although other
suitable materials can be used.
[0023] The assembled stacking structure may be of any suitable
shape. The example stacking structure has a rectangular shape when
viewed from the top, with four side walls 216 to create a shallow
tray. The structure, however, may be of any N-sided shape, with
substantially similar side lengths, substantially similar opposing
side lengths (e.g., as in a non-square rectangle), or irregular
side lengths, and in some embodiments has one or more curved walls.
In the case of irregular side lengths, the stacking structure may
simply be irregular, may be irregular but still able to be tightly
packed (e.g., as in a tessellation), or may form part of a more
regular shape (e.g., as in an isosceles trapezoid, two of which
form a regular hexagon).
[0024] In the preferred embodiment, four walls 216 surround the
perimeter of the horizontal base 210 and are generally upright. The
walls 216 may be of any height less than the height of the packed
products. In the example embodiment and as seen in FIG. 6, the
height 618 of the walls 216 is substantially less than the height
620 of the packed products, such that when the packed products are
stacked in a first stacking structure and under a second stacking
structure, the products remain substantially uncovered. While some
embodiments, the height 618 of the side walls 216 can be different,
in preferred embodiments, the height 618 is at least about 2%, and
in some embodiments at least about 5%, and in others at least about
10% of the height 620 of the packet product 610. While an
alternative embodiment can have a sidewall height 618 that reaches
the next stacking structure above it, the preferred height 618 is
less than about 95% of the height 620 of the packed product 610,
and more preferably less than about 50%, and most preferably less
than about 20% or even than about 10% depending on the strength of
the walls, the configuration of the product so that the walls can
keep the product from sliding, and the amount of product that is
desired to remain visible when supported on the stacking structure.
The height 618 of the walls 216 and the thickness 236 of the
supportive pad 218 may also be configured such that when the
supportive pad 218 is inserted within the walls 216 of the
horizontal base 210, the packed products remain substantially
uncovered when stacked. The boundary created by the internal
lateral edge 232, discussed further in FIG. 2B, and the side walls
216 can be configured to hold the outer edges of the packed
products such that the products are held close together against
each other.
[0025] FIG. 213 illustrates the bottom view of the horizontal base
section 210 of a single assembled stacking structure. As
illustrated, the horizontal base 210 may include an internal
lateral edge 232 that defines a void 212, where the tray material
is absent, and positioned proud of the supportive pad 218. The void
region is defined as the void 212 formed where the horizontal base
surface 214 meets the internal lateral edge 232, and the void
region is configured and dimensioned to restrict movement of the
features of packed products in at least one horizontal direction.
The void 212 created by the internal lateral edge 232 may be of any
shape, including regular and irregular shapes. In the preferred
embodiment, the internal lateral edge 232 creates one central void
212 configured to receive the top features of bottles. However, in
other embodiments, the internal lateral edge 232 may form multiple
voids 212 placed in various places along the horizontal base
surface 214. The multiple voids 212 do not have to be substantially
similar to the top features of particular packed products. For
example, the internal lateral edge 232 may form multiple voids 212
along the perimeter of the horizontal base surface 214 and the top
features of the packed products may be positioned between the voids
212 and not necessarily within the void 212. Example alternative
embodiments of the void region may be seen in FIGS. 4 and 5.
[0026] Additionally, the internal lateral edge 232 is configured
and dimensioned such that it has sufficient strength and thickness
240 to restrict movement of the features of packed products in at
least one horizontal direction. The thickness 240 of the internal
lateral edge 232 may be, for example, about 1/16 inch to one 1 inch
thick. In the preferred embodiment, the internal lateral edge 232
has a thickness between a 1/4 inch to 1/2 inch. The thickness 240
can vary, and is preferably selected for sufficient strength to
retain the products placed in the void region.
[0027] In the assembled form, the recess or void 212 created by the
internal lateral edge 232 may have a depth equal to the width of
material used to make horizontal base 210. The region 212 formed by
the internal lateral edge 232 may be formed by original
construction, or may have been formed with material that was
subsequently removed (e.g., a cut-out).
[0028] As illustrated in FIG. 2C, a single assembled stacking
structure may include two component parts: a tray portion and a
supportive pad 218. The supportive pad 218 is configured and has
sufficient strength for supporting products stacked thereon with
the pad 218 supported on similar products therebelow. The
supportive pad 218 has a first and second pad surf tee. The
supportive pad 218 may be inserted onto the horizontal base 210,
such that the second pad surface is against the horizontal base
210, and within the walls 216 creating a double layer bottom in the
horizontal base surface 214 and a single layer bottom in the void
212. In the preferred embodiment, only one supportive pad 218 is
exposed through the voids 212, and the supportive pad 218 is
disposed between the walls 216 opposite the voids 212. The
supportive pad 218 may be affixed to the horizontal base 210, or
the supportive pad 218 may not be affixed such that it is
removable. In the preferred embodiment, an adhesive 234, such as
those described below, is placed on the top surface of the
horizontal base surface 214 and the supportive pad 218 is affixed
thereto. In addition, the supportive pad 218 may have substantially
the same width and length of the horizontal base 210 or may have a
smaller width and/or length of the horizontal base 210. In the
preferred embodiment, the supportive pad 218 has substantially the
same width and length as the horizontal base 210.
[0029] In addition, the supportive pad 218 in the preferred
embodiment is made from a single piece of continuous material
without any indentations. Alternatively, the supportive pad 218 may
be made of more than one piece of material. In addition, the first
pad surface (e.g. the side facing opposite the bottom-side of the
stacking structure) may also have indentations, grooves, or
cut-outs for receiving the bottom features of the packed products
and to help prevent the packed products from moving in at least one
horizontal direction in some embodiments. Further, in addition to
or as an alternative to the shallow-wall feature of the stacking
structure, a bottom piece may be used that envelopes more of each
product's bottom feature edge, than the wall does. For example, a
second pad or horizontal base having one or more void regions may
be positioned over and optionally affixed to the first pad 218.
These void regions or indentions may create a second boundary that
substantially matches the products' bottom features, securing the
bottom end of the products, similarly to the top end of the items.
Other bottom inserts are also possible, such as thicker inserts,
multiple inserts, or inserts including a void spaces.
[0030] With reference to FIGS. 3A-3B, the product-stacking
structure in one embodiment includes a supportive pad 218 and a
horizontal base 210 having a horizontal base surface 214 and an
internal lateral edge 232 that defines a void 212. The supportive
pad 218 may be inserted on top of the horizontal base 210, creating
a double layer bottom of the horizontal base surface 214 and a
single layer bottom where the internal lateral edge 232 creates the
void 212. In assembled form, the void created by the internal
lateral edge 232 may have a depth equal to the width of material
used to make the horizontal base 210.
[0031] FIG. 3A illustrates the top view of one embodiment of the
product-stacking structure. In FIG. 3A, the supportive pad 218 may
include a core layer 220, an upper surface, 224, and a lower
surface 226. Similarly, the horizontal base 210 may include a core
layer 222, an upper surface 228, and a lower surface 230. The
supportive pad 218 and horizontal base 210 may generally be made of
a fiber-based material, such as paper or paper-board, as will be
discussed in greater detail below.
[0032] The upper surface 224 and lower surface 226 of the
supportive pad 218 in one embodiment are paper facings that
sandwich the core layer 220, which can be a honeycomb material,
such as paper, although other materials can alternatively be used
for the facings and core. The honeycomb structure can have cells of
six walls having a hexagonal shape, or can alternatively have an
octagonal shape, or a shape with more or less sides, such as 3-4
sides. Because of the ease of working with paper materials and the
availability of various honeycomb structures, products can be
manufactured in a variety of shapes and sizes to meet any
particular requirements. The honeycomb structure 220 can provide
for plenty of air spaces within or in between the cell walls to
provide for a low-density honeycomb material. Alternative pads can
be made of solid paper board or one or more layers of corrugated
cardboard, for example, and in other embodiments, other materials
can be used, such as plastic sheet.
[0033] In the preferred embodiment, the supportive pad 218 has a
thicker and stronger core 220 than the tray portion which is made
of a corrugated structure. However, in other embodiments, a
honeycomb or other low-density construction may be used in place of
the corrugated structure in the tray portion. A typical thickness
236 of the supportive pad 218 may range from 1/4 inch to two
inches, although this height can be varied depending on the
strength, such as the compressive or beam strength, for example,
desired. The thickness 236 of the supportive pad 218 is sufficient
for supporting products stacked thereon with the pad supported on
similar products therebelow.
[0034] The use of paper materials can be cost competitive to
materials such as wood, metal, and plastic, while at the same time
offering benefits that are not available through the use of
traditional wood materials. Paper products can be made lighter than
wood, plastic, or metal products, and when formed into a honeycomb
structure may have remarkable strength, including increased bending
stiffness over other configurations.
[0035] Various adhesives may be used between the layers to adhere
the sheets between the layers to each other, as well as to adhere
the supportive pad structure 218 to the horizontal base 210 and/or
the creases formed between the horizontal base 210 and the wall
sections 216, such as, but not limited to PVA glue, EVA glue, water
based adhesives, starch based adhesives, HotMelt .RTM., and
solventless adhesives. Preferred embodiments may utilize PVA glue,
especially as between honeycomb walls.
[0036] As illustrated in FIG. 3A, the supportive pad 218 is affixed
onto the horizontal base 210 to form one embodiment of the stacking
structure. In the preferred embodiment, the adhesive 234, such as
those described above, is positioned between the supportive pad 218
and horizontal base 210. The stacking structure may be of any
N-sided shape, with substantially similar side lengths,
substantially similar opposing side lengths (e.g., as in a
non-square rectangle), or irregular side lengths. As illustrated in
the example embodiment, the stacking structure has a rectangular
shape. Some or all of the sides can be curved in some embodiments,
such an those with a round shape.
[0037] FIG. 3B illustrates the bottom view of the horizontal base
210 of a single assembled stacking structure. As illustrated, the
horizontal base section 210 may include a void 212 formed by an
internal lateral edge 232, and a horizontal base surface 214. The
void 212 may be formed by original construction, or may have been
formed with material that was subsequently removed (e.g., a
cut-out).
[0038] In another embodiment of the stacking structure, the
stacking structure comprises of a horizontal base 210 having a
surface region 214 and a void region 212, but without the
supportive pad 218. The tray may also comprise of walls 216 formed
along the perimeter of the horizontal base 210 and generally
extending upright from the base 210.
[0039] FIG. 4 illustrates an angled bottom view of an alternative
example embodiment. In this alternative embodiment, the recessed
region 212, e.g., the void region of the stacking structure has
straight internal lateral edges 232 creating straight boundary
lines. The dashed circles 238 in the figure illustrate where
product top features may sit, with their tops in contact with the
pad structure, and the elevated regions (e.g., the horizontal base
surface) holding the product top features at two points (e.g.,
where the circular top feature contacts the boundary lines of each
corner of the elevated portion of the recessed region. In this
configuration, the bottles are still held from falling in any
direction away from the center of the group, and the other bottles
being likewise held from moving, prevent the bottles from moving in
any direction. This may include even bottles with no contact with
the boundary of the elevated portion, such as the center bottle of
a three-by-three configuration.
[0040] FIG. 5 illustrates an angled bottom view of an alternative
example embodiment. In this alternative embodiment, the internal
lateral edges 232 create boundaries for multiple voids or recesses
212. Each individual void 212, for example, may be configured to
receive top features of individual packed products.
[0041] Once the stacking structures are constructed, one or more
items may be placed within the stacking structure. Next, a second
stacking structure may be placed on top of the items, with at least
a portion of the void region receiving the top features of the
packed products, repeating for as many layers as desired. Packed
products may include items having a uniform shape or non-uniform
shape and may weigh up to 100 pounds and have a width of 8 feet. In
the preferred embodiment, the packing trays are configured to
receive bottles, such as detergent bottles, weighing up to 200
ounces and having a width up to 15 inches. However, the tray may
also be configured to receive other items such as cans, cups,
vases, and other items including containers and other products.
[0042] FIG. 6 illustrates a pallet of stacking structures and
packaged products. In the preferred embodiment, the stacking
structure is configured and dimensioned such that one or more
packed products may be placed within (e.g. above the supportive pad
218) the stacking structure, or below the stacking structure. The
boundary created by the internal lateral edge 232 receives at least
part of the bottles' tops, and envelopes some portion of the top
feature of each. In the case of a round top, it may be preferable
to envelope more than half the top feature, such that the top
feature can not easily move in any horizontal direction. By way of
example, packed products 610 are placed within a first packing tray
612. A second stacking structure 614 is placed on top of the items
610, with at least a portion of internal lateral edge 232 and void
212 receiving the top features 616 of the packed products 610. In
this illustrated example, the stacking structure holds four items
that are arranged in levels, each grouping nine packing trays
three-by-two, with a total of three levels. This pallet
configuration includes eighteen trays and seventy-two bottles, but
any other dimensions could be used, and any other sized stacking
structures could be used.
[0043] The pallet in this example is illustrated without a top
layer of stacking structures. Alternatively, a top layer of
identical stacking structures may be used (e.g., with empty tray
portions on top), the top layer may have a flat top, or the top may
include similar stacking structures, but upside down with the pad
affixed on the other side of the bottom portion (e.g., with the
side walls 216 extending downward, with the bottle tops in the
recessed void, and the pad affixed above
[0044] FIG. 7 illustrates an unassembled layout of a component
piece of a tray portion, according to another example embodiment of
the present invention. As illustrated, there are two blanks 501 and
502 with identical but reciprocal layouts. When manufacturing
includes constructing a solid piece of material and then cutting
out specific areas (e.g., to form the lateral edges defining the
voids when assembled), this reciprocal layout, with the widest part
of one piece adjacent a narrower part of the second piece and vice
versa, may require less material than constructing only one piece
at a time.
[0045] The unassembled tray portion 510 and 512 may include several
partitions 514. These may be formed by scoring, crushing, folding,
or any other suitable technique for creating an angle in the
material or preparing the material to have an angle formed at that
spot in the material. FIG. 7 also illustrates a hinge line 516,
perpendicular to the partition lines, which may also be formed by
scoring, crushing, folding, or any other suitable technique.
Preferably, a technique may be used that maintains structural
integrity of the material, since at least some of these
partition/hinge lines should remain attached.
[0046] An example method of construction, according to one example
embodiment, is to assemble the tray portion from a blank 501 and
502. FIG. 7 shows two blanks 501 and 502 cut from a sheet of
corrugated cardboard.. Each blank 501 and 502 is folded at the
partitions 514 and hinges 516 to form the tray portion, which is
then glued to a pad 218. The pattern created by the lateral edge
232 may be configured to create void 212, when assembled, and the
void region (e.g. the internal lateral edge 232 and the void 212
taken together) may be configured to partially secure the packed
products.
[0047] Specific implementations (e.g., including specific boundary
line configurations defining the shape of the void region(s)) could
be made for any number of scenarios, products, product sizes,
product groupings, etc. A particularly advantageous candidate
product may be a bottle or other product with an odd or irregular
shape. The stacking structure can be used with products that do not
have a substantially flat, extensive horizontal area below a top
protrusion (e.g., a bottle cap), such as the sloping bottles
illustrated in FIG. 6. Products may include a relatively tall top
protrusion since the pad limits penetration into the void region.
Products with a relatively wide bottom can also be used and can be
contained within the sidewalls. It will be understood that other
shapes of products can alternatively be used.
[0048] The above illustrations included a shallow-wall stacking
structure to secure the bottom feature of the package items (e.g.,
on two sides of each product), with the other products otherwise
securing the bottom feature (e.g., on the other two sides of each
product). However, more than four items could be packaged, such as
2 by 3, where two middle items are secured by the wall on only one
side, or 3 by 3, where a center item is secured only by other
items, which are partially secured by the wall. The same can be the
case, for example, for the top features secured by the boundary of
the void region. A 3 by 3 arrangement may be similar to the 2 by 2
arrangements illustrated, but include additional voids or cut-outs
for the four bottles along the edges and between the corners, while
the center bottle may make no contact with the boundary, and be
secured by only the other secured bottles. Any other configuration
or arrangement may also be implemented for the void region and
boundary pattern.
[0049] One having ordinary skill in the art should appreciate that
there are numerous shapes and sizes of the unassembled materials,
assembled wall heights, void regions, surface regions, boundary
shapes, etc. which may be desired as specific implementations for
particular product designs, consistent with and according to
exemplary embodiments of the present invention. Additionally, one
having ordinary skill in the art will appreciate that although the
preferred embodiments illustrated herein reflect a generally
shallow and rectangular tray, any number of shapes, depths, or
configurations are possible. The supportive pad material and/or the
tray portion material may be any number of materials, such as a
corrugated or honeycomb sheet structure, as well as multiple layers
of sheet material, or other material.
[0050] As used herein, the terms "front," "back," and/or other
terms indicative of direction are used herein for convenience and
to depict relational positions and/or directions between the parts
of the embodiments. It will be appreciated that certain
embodiments, or portions thereof, can also be oriented in other
positions.
[0051] In the example embodiments described herein, certain terms
are used to describe specific implementations, but do not preclude
other implementations. For example, area may be described as a
cut-out area or void, but need not be literally cut out of
material. The void may be achieved by other means, such as
manufacturing the components to include certain recessed portions
in the first instance. Additionally, several embodiments may refer
to products, but any item of suitable characteristics may be used
with example embodiments of the present invention, not just
products, bottles, retail items, or any other limitation unrelated
to an item's configured structure.
[0052] In addition, the term "about" should generally be understood
to refer to both the corresponding number and a range of numbers.
In addition, all numerical ranges herein should be understood to
include each whole integer within the range. While an illustrative
embodiment of the invention has been disclosed herein, it will be
appreciated that numerous modifications and other embodiments may
be devised by those skilled in the art. Therefore, it will be
understood that the appended claims are intended to cover all such
modifications and embodiments that conic within the spirit and
scope of the present invention.
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