U.S. patent application number 13/757055 was filed with the patent office on 2013-06-06 for methods for packaging floor panels, as well as packed set of floor panels.
This patent application is currently assigned to FLOORING INDUSTRIES LIMITED, SARL. The applicant listed for this patent is FLOORING INDUSTRIES LIMITED, SARL. Invention is credited to Mark CAPPELLE, Lode DE BOE.
Application Number | 20130139478 13/757055 |
Document ID | / |
Family ID | 48523003 |
Filed Date | 2013-06-06 |
United States Patent
Application |
20130139478 |
Kind Code |
A1 |
CAPPELLE; Mark ; et
al. |
June 6, 2013 |
Methods for packaging floor panels, as well as packed set of floor
panels
Abstract
Method for packaging floor panels, more particularly floor
panels of the type that consists of rectangular oblong floor panels
that are intended to form a floor covering, wherein these floor
panels are industrially manufactured in at least two widths and are
provided with coupling parts at least at two opposite sides,
wherein floor panels of different width are provided in the same
package, more particularly the same box, wherein these floor panels
are provided in a box in layers, wherein in at least one of these
layers at least two floor panels are placed next to each other,
with their longitudinal directions substantially parallel to each
other.
Inventors: |
CAPPELLE; Mark; (Staden,
BE) ; DE BOE; Lode; (Moorslede, BE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FLOORING INDUSTRIES LIMITED, SARL; |
BERTRANGE |
|
LU |
|
|
Assignee: |
FLOORING INDUSTRIES LIMITED,
SARL
BERTRANGE
LU
|
Family ID: |
48523003 |
Appl. No.: |
13/757055 |
Filed: |
February 1, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12494480 |
Jun 30, 2009 |
8375679 |
|
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13757055 |
|
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11887363 |
Sep 28, 2007 |
8161701 |
|
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PCT/IB2006/000993 |
Mar 28, 2006 |
|
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12494480 |
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Current U.S.
Class: |
53/474 |
Current CPC
Class: |
B65D 85/62 20130101;
F16B 5/0016 20130101; E04F 15/02 20130101; B65G 47/08 20130101;
E04F 15/02038 20130101; B65B 11/004 20130101; B65B 35/44
20130101 |
Class at
Publication: |
53/474 |
International
Class: |
B65B 5/10 20060101
B65B005/10 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 31, 2005 |
BE |
2005/0169 |
Jan 12, 2006 |
BE |
2006/0024 |
Claims
1. Method for packaging floor panels of the type that consists of
rectangular oblong floor panels that are intended to form a floor
covering, wherein these floor panels are industrially manufactured
in at least two widths and are provided with coupling parts at
least at two opposite sides, wherein floor panels of different
width are provided in the same package including a box, wherein
these floor panels are provided in the box in layers, wherein in at
least one of these layers at least two floor panels are placed next
to each other, with their longitudinal directions substantially
parallel to each other.
2. The method of claim 1, wherein the filling degree of the
package, seen in width direction, for each of the aforesaid layers
is at least 90%, whereby the filling degree is defined as
(A/B).times.100, wherein: A=the sum of the entire widths of the
floor panel situated next to each other in one layer; B=the
internal width of the box.
3. The method of claim 1, wherein herein floor panels of three
different widths are provided in the same package, wherein the sum
of the first width and a second width is a whole, or almost a
whole, multiple of the third width.
4. The method of claim 1, wherein herein floor panels of three
different widths are provided in the same package, wherein the sum
of the width of the narrowest and the width of the broadest floor
panels substantially corresponds to two times the width of the
floor panels of intermediate width.
5. The method of claim 1, wherein herein floor panels of three
different widths are provided in the same package when packaging
the floor panels, and wherein, on the one hand, at least layers are
formed, which, seen in a cross-section, comprise exactly two floor
panels that are of the intermediate width, and, on the other hand,
layers are formed, which, seen in cross-section, also comprise only
two floor panels, of which a first, however, is of the smallest
width and a second is of the largest width.
6. The method of claim 1, wherein at least two floor panels of a
first width are commonly wrapped or packaged to provide a first
subpackage; and wherein at least two floor panels of a second width
are commonly wrapped or packaged to provide for a second
subpackage; and in that said first and second subpackage are
provided in the same box or another common package, such that at
least two floor panels of different width are placed next to each
other, with their longitudinal directions substantially parallel to
each other.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of
U.S. patent application Ser. No. 12/494,480, filed on Jun. 30,
2009, the entirety of which is incorporated herein by reference.
U.S. patent application Ser. No. 12/494,480 is a divisional
application of U.S. patent application Ser. No. 11/887,363 filed on
Sep. 28, 2007 which is a national stage application of PCT
Application No. PCT/IB/000993 filed on Mar. 28, 2006 which claims
the benefit of priority from U.S. Provisional Application No.
60/672,538, filed on Apr. 19, 2005, Belgian application BE
2005/0169 filed on Mar. 31, 2005, and Belgian application BE
2006/0024 filed on Jan. 12, 2006. The entirety of these application
is incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to methods for packaging of floor
panels, as well as to packed sets of floor panels.
BACKGROUND
[0003] In general, the invention relates to packaged hard floor
panels, which, at two or more sides, are provided with coupling
parts and which can be provided on an existing subfloor, either
floatingly or glued, or in any other manner, in order to form a
floor covering. Hereby, the invention is intended in particular for
laminate panels, for example, with a printed decor and a top
structure on the basis of synthetic material, prefabricated
parquet, with panels mostly consisting of several layers of
material with, at the upper side, a top layer of solid wood with a
thickness of several millimeters, veneer parquet consisting of
panels having a layer of veneer at their upper side, or solid
parquet. This does not exclude that the invention is also applied
for other hard floor panels, whether or not composed of several
parts, for example, with top layers of other materials, such as,
amongst others, cork, stone or stone-like materials, linoleum,
vinyl, carpet, and so on. According to an important example, the
invention is used for packaging so-called LVT flooring (Luxury
vinyl tiles) or CVT flooring (composite vinyl tile). Such flooring
is essentially manufactured from PVC (polyvinylchloride) and, in
the case of LVT flooring, comprises several fused layers of soft
PVC, i.e. PVC comprising a plasticizer content larger than 12 phr.
It is clear that also LVT or CVT flooring panels may be provided
with coupling parts.
[0004] It is known that such coupling parts can be formed by means
of a classical tongue and groove connection, wherein these, when
installing the floor panels, possibly are glued into each other, or
by means of mechanical coupling parts providing for a mutual
locking of the floor panels in horizontal as well as in vertical
directions, for example, as described in the international patent
application WO 97/47834. This document describes how the respective
coupling parts at two opposite sides can be formed in a continuous
machine, in other words, while moving the floor panel over rotating
mechanical cutting tools. This method is also called "continuous
milling".
[0005] It is clear that it is not excluded that such locking system
can also be performed in other forms than in a tongue and groove
connection.
SUMMARY
[0006] According to a first object, the invention aims at an
improved method for packaging floor panels, which allows a
particularly smooth and efficient packaging. To this aim, the
invention relates to a method for packaging floor panels, of the
type, wherein several floor panels, which are provided with
coupling parts at least at two opposite sides, are packaged in a
box, which is composed of at least one sheet-shaped packaging
element by means of a folding process. Preferably, at least part of
the aforementioned folding process is performed while the packaging
element and the floor panels to be packaged have already been
brought together.
[0007] Preferably, said sheet-shaped packaging element consists of
cardboard, in particular corrugated cardboard.
[0008] The method according to the first object of the invention
allows to package the floor panels in a smooth manner at a high
frequency, as a result of which one packaging machine applying this
method has such a high packaging capacity that this latter
corresponds to the production capacity of several production lines
of floor panels. Hereby, it is noted that such packaging machine
may or may not be installed in line with one or more production
lines. Also, such packaging machine can be fed with floor panels
coming from a magazine in which major amounts of panels are stocked
after having been produced on one or more production lines.
[0009] A method for packaging floor panels according to the first
object of the present invention also offers the advantage that a
buffer magazine for already folded boxes possibly is made
redundant.
[0010] In a preferred form of embodiment of the present invention,
the packaging element is folded around the quantity of floor panels
to be packaged therein. This is, for example, possible by
depositing the quantity of floor panels to be packed on said
packaging element, while this, either when it is still unfolded or
already partially folded, before, as already mentioned, folding the
packaging element around the quantity of floor panels to be
packaged. An important advantage of such packaging method is that
the box can be assembled very close around the floor panels, such
that floor panels in the box can not shift in mutual respect, which
might lead to scratches on the decorative layer of the floor
panels, to a heightened risk of damage to the coupling parts and/or
other parts. In particular, this is of importance with floor panels
comprising a core of MDF or HDF and/or wherein the coupling parts
substantially consist of MDF of HDF.
[0011] In order to obtain a good packaging, preferably, during the
folding process, the quantity of floor panels to be packaged and
the bottom of the box to be formed first will be positioned against
each other, directly or indirectly, and only afterwards the
sidewalls will be folded against the quantity of floor panels. This
offers the advantage that stacked upon each other floor panels,
which are somewhat shifted in mutual respect, automatically will be
positioned in mutual respect during folding of the sidewalls.
[0012] Preferably, also at least a number of portions of the box
are interconnected during the formation thereof by means of glue,
more particularly so-called "hot melt" glue. This offers the
advantage that a number of complicated steps from traditional
folding processes can be excluded.
[0013] It is noted that said box further also can be packaged in a
plastic film, for example, a shrink film, such that the risk of
moisture penetration, for example, during transport or stocking, is
restricted. Because a package obtained according to the eighth
aspect of the invention can rest very closely against the floor
panels, the risk of a floor panel piercing this plastic film is
minimized, too, such that an optimum protection against moisture
penetration is obtained.
[0014] It is also noted that the floor panels in most cases are
packaged in a quantity of 5 to 30 panels, and when relatively large
panels are concerned, for example, panels that are longer than 1 m,
preferably less than 10, such that in all cases the weight of the
packaging unit is limited to a weight that is ergonomic for the
user of the floor panels and that does not pose too high
requirements in respect to the solidity of the packaging material.
Within the scope of the invention, it is also possible that panels
differing from each other, for example, panels of different length,
are packaged together.
[0015] A method for packaging floor panels according to the the
present invention can be applied with any form of boxes. So, for
example, boxes with inwardly inclined sidewalls can be applied,
whereby the sidewalls then are folded against the floor panels.
This kind of boxes may, for example, find its application there,
where floor panels of differing shape are packed together, such as,
for example, when packaging floor panels of different widths
together, whereby the floor panels are stacked in layers in such a
manner, that preferably the width of the layers decreases from the
bottom towards the top in the box. Applying such box also allows
for that, when several of such boxes, preferably with their
sidewalls towards each other and alternately with the bottom
directed upward or downward, are stacked on a pallet, there is
almost no lost space or, in other words, that the space taken on
the pallet consists almost exclusively of floor panels and of
packaging material.
[0016] It is noted that according to the invention, by a "box"
always a packaging element has to be understood that is
manufactured from one or more sheet-shaped elements and that, after
folding, has at least a bottom, or a portion present at the bottom
of the packed set of floor panels, and at least two sidewalls. The
sheet-shaped element may be manufactured of different materials,
however, here it is clear that herein, materials are intended that
as such have a certain rigidity, such as, for example, cardboard,
corrugated cardboard or the like.
[0017] It is clear that the invention also relates to a set of
floor panels that is thus packaged.
[0018] The invention also relates to a packed set of floor panels,
with as a characteristic that the set of floor panels is packed in
a package that consists at least of a folded sheet-shaped element
comprising a bottom and a number of upright sidewalls, whereby at
least a number of the sidewalls are interconnected by means of
glue. Moreover, preferably a shrink film or the like is provided
around the whole. According to a variant, it is, however, not
excluded to omit the shrink film and to provide the box with a
cover lid. Preferably, the box herein is oblong and glue
connections are exclusively present at the short sides. This latter
allows a smooth production of such boxes, in view of the fact that
exclusively glue connections have to be performed at the location
of the short sides.
[0019] According to a second object, the invention aims at a method
for advantageously packaging floor panels of different widths in
one and the same package. To this aim, the invention relates to a
method for packaging floor panels, more particularly floor panels
of the type consisting of rectangular oblong floor panels that are
intended for forming a floor covering, whereby these floor panels
are industrially manufactured in at least two widths and are
provided with coupling parts at least at two opposite sides,
wherein floor panels of different widths are provided in the same
package, more particularly the same box, with the characteristic
that these floor panels are provided in a box in layers, wherein in
at least one of these layers at least two floor panels are placed
next to each other, with their longitudinal directions
substantially parallel to each other.
[0020] This method has the advantage that a variety of beneficial
packaging possibilities is created for providing and/or presenting
such floor panels of different widths in a package, more
particularly a box. So, for example, may the floor panels be
provided next to each other in successive layers in such a manner
that the filling degree of the package is optimized,
notwithstanding the fact that different widths are present in one
box. This method also allows to provide the floor panels next to
each other in such a manner that the presence of different width is
immediately, or almost immediately, visible, either immediately
through a transparent portion of the package, or rather immediately
after such box has been opened and possibly only a number of floor
panels has been removed from it.
[0021] It is clear that, in order to obtain an efficient packaging,
the majority of the layers and preferably all layers take up at
least 70% of the internal width of the box, such that the freedom
of movement of the floor panels in the package is restricted.
[0022] In a preferred form of embodiment, the filling degree of the
package, seen in width direction, for each of the aforesaid layers
is at least 90%, whereby the filling degree is defined as
(A/B).times.100, wherein:
[0023] A=the sum of the entire widths of the floor panels situated
next to each other in one layer; [0024] a. B=the internal width of
the box.
[0025] By "width of the floor panels", herein the total width of
the floor panels is meant, including the coupling means. In this
form of embodiment, the risk of a mutual shifting of the floor
panels is minimized, such that, for example, the risk that the
decorative layer of the floor panels, as, for example, laminate
panels, becomes damaged, is also restricted. With floor panels that
are provided with coupling parts of MDF of HDF, the thus limited
freedom of movement also results in a restriction of the risk of
damage at these coupling parts.
[0026] The internal width of the box may, for example, be chosen
such that it substantially corresponds to the largest of the
aforesaid different widths of the floor panels. In this manner, the
shifting of the widest floor panels is optimally restricted or even
excluded. Additionally, this choice leads to a sturdy packaging, as
the widest panels can contribute to the strength of the
package.
[0027] It is clear that a method for packaging according to the
tenth aspect requires less efforts in the distribution. In order to
obtain that the installing person has too little or too much of a
certain width, one box moreover preferably has as many floor panels
of each width, and still better as many or almost as many meters
run of floor panels of each width.
[0028] In a preferred form of embodiment, the method is applied for
packaging floor panels of three different widths in the same
package, wherein the sum of a first width and a second width is a
whole, or almost a whole, multiple of the third width. So, for
example, does the sum of the widths of the narrowest and of the
widest floor panels substantially correspond to two times the width
of the floor panels of intermediate width. According to an
important form of embodiment of the invention, the present example
allows a very compact packaging, whereby according to this form of
embodiment, on the one hand, at least layers are formed, which,
seen in a cross-section of the package, comprise exactly two floor
panels that are of the intermediate width, and, on the other hand,
layers are formed, which, also seen in a cross-section of the
package, at the same time comprise only two floor panels, of which
a first, however, is of the smallest width and a second is of the
largest width.
[0029] It is noted that in one and the same package, also floor
panels of different widths can be combined with floor panels of
different lengths, preferably in a manner that does not allow any,
or almost any, mutual shifting among the different floor panels, in
width direction of the floor panels as well as in the longitudinal
direction of the floor panels. Preferably, herein in one box of
each width the same amount of meters run shall be provided, and/or
of each length the same amount of square meters. For packaging
these panels, a combination can be made of the present invention
according to the tenth aspect and the packaging method for panels
of different lengths that is known from BE 1015299.
[0030] The packaging method that is applied according to the
invention preferably can be a method such as described by means of
the first object of the invention, as such packaging still further
restricts the shifting of the panels, however, other packaging
methods can be applied as well, for example, packaging in an
already assembled cardboard box and/or a shrink film.
[0031] It is noted that avoiding scratches by means of applying a
method according to the invention is of particular importance with
laminate panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] With the intention of better showing the characteristics of
the invention, hereafter, as an example without any limitative
character, several preferred forms of embodiment are described,
with reference to the accompanying drawings, wherein:
[0033] FIG. 1 shows a method according to the invention;
[0034] FIGS. 2 to 7, in perspective, represent views of the
packaging steps taking place in the areas indicated by F16, F17,
F18, F19, F20 and F21 in FIG. 1;
[0035] FIG. 8 represents a view in perspective onto a set of floor
panels that is obtained, amongst others, by means of a method
according to the invention;
[0036] FIG. 9 represents a cross-section according to the line
XXIII-XXIII in FIG. 8;
[0037] FIGS. 10 and 11 represent variants according to a same view
as in FIG. 23.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
[0038] FIGS. 1 to 7 show a method for packaging floor panels 1
according to the present invention. Hereby, several floor panels 1,
which, at least at two opposite sides 3A-3B and/or 4A-4B, are
provided with coupling parts, for example, 17A-17B, as described
above, are packaged in a box 35. This box 35 consists of at least
one sheet-shaped packaging element 36 that is composed by means of
a folding process.
[0039] According to the packaging process represented in FIG. 1,
floor panels 1 are supplied in stacks by pushing a fixed number of
such floor panels 1, in this case seven, from a stack 37 onto a
transport device 38 by means of a to- and fro-moving drive element
39. Said stack 37 is each time filled up from below and ordered by
means of a pressing element 40, such that the floor panels 1 are
lying precisely one above the other. The supply of the packaging
elements 36 here takes place by providing them one after the other
on a second transport device 41.
[0040] Said transport devices 38 and 41 bring the floor panels 1
and the packaging elements 36 together during the folding process,
after which the packaging elements 36 are folded around the
quantity of floor panels 1 to be packed therein and subsequently
the packed floor panels 1 are transported off, such as
schematically represented at the uppermost portion of the transport
device 41. When bringing them together, the floor panels 1 are put
on the aforementioned packaging element 36, while the packaging
element 36 either is still unfolded or is already partially folded,
before, as aforementioned, folding the packaging element 36 around
the quantity of floor panels 1 to be packaged. Preferably, the
panels 1 are automatically deposited at the right place on the
packaging element 36. This is possible, for example, by adjusting
the supply from both aforementioned transport devices 38 and 41 to
each other, for example, by means of sensors that detect the
location of the floor panels 1 as well as of the packaging elements
36 and regulate the speed of the respective supplies.
[0041] FIGS. 2 through 7 show how such packaging element 36 can be
folded in various successive stages. FIGS. 2 and 3 show that, in
this example, the folding process is performed in part, before the
packaging element 36 is brought together with the floor panels 1.
During the further course of the folding process, represented in
FIGS. 4 to 7, a box 35 with a bottom 42 and sidewalls 43 is formed,
wherein the quantity of floor panels 1 and the bottom 42 first,
directly or indirectly, are positioned against each other and only
afterwards the sidewalls 43 are folded against the quantity of
floor panels 1. Preferably, at least a number of portions of the
box 35 during the formation thereof are connected by means of glue
44, more particularly so-called "hot melt" glue. In the represented
example, the portions that are connected by means of glue 44 can be
restricted to the transverse walls of the box 35, which in this
manner are connected to the flaps 45.
[0042] It is clear that the box 36 represented in FIGS. 16 to 21
also meets the characteristics of the ninth aspect of the
invention.
[0043] FIGS. 8 and 9 represent a set of floor panels 1, which is
obtained by means of a method according to, amongst others, the
tenth aspect of this invention. In this method for packaging floor
panels 1, it is started from rectangular oblong floor panels 1,
which industrially have been manufactured in at least two widths,
in this case three widths B1-B2-B3, and are provided with coupling
parts at least at two opposite sides 3A-3B. Herein, floor panels 1
of different width are provided in the same package, more
particularly in the same box 35, and preferably afterwards have
been wrapped with a film 46, for example, a shrink film.
[0044] The floor panels 1 are provided in the box 35 in layers 47,
wherein in at least one of these layers 47 at least two floor
panels 1 are placed next to each other, with their longitudinal
directions substantially parallel to each other. The filling degree
of the package, seen in width direction, for each of the layers 47,
as represented, preferably is at least 90%. In the example of FIG.
23, the filling degree is defined as (B1+B2)/W in respect to the
layers 47 in which two floor panels 1 are provided next to each
other, and B3/W in respect to the layers 47 in which only one floor
panel 1 is provided. Wherein B1, B2 and B3 relate to the various
total widths of the floor panels 1 and W relates to the internal
width of the box 35. In this example, it applies that the sum of a
first width B1 and a second width B2 is a whole, or almost a whole,
multiple of the third width B3 and in this case is equal, or almost
equal, to the width B3 of the widest floor panels 1.
[0045] FIG. 10 shows an important variant of such set of floor
panels 1. This set is obtained by applying a method according to
the tenth aspect of the invention, wherein, on the one hand, layers
47 are formed, which, seen in a cross-section, comprise exactly two
floor panels 1 that have the intermediate width B2, and, on the
other hand, layers 47 are formed, which, seen in cross-section,
also comprise only two floor panels 1, of which a first, however,
has the narrowest width B1 and a second has the largest width B3.
In this example, the widths are chosen such that the sum of the
width B1 of the narrowest floor panels 1 and the width B3 of the
widest floor panels 1 substantially corresponds to two times the
width B2 of the floor panels 1 of intermediate width.
[0046] FIG. 11 shows a variant wherein at least two floor panels 1
of a first width B1 are commonly wrapped or packaged to provide a
first subpackage 48A; and wherein at least two floor panels 1 of a
second width B2 are commonly wrapped or packaged to provide for a
second subpackage 48B; wherein said second subpackage 48B is
separate from said first subpackage 48A and preferably free from
floor panels having said first width; and in that said first and
second subpackage 48A-48B are provided in the same box 35 or
another common package, such that at least two floor panels 1 of
different width B1-B2 are placed next to each other, with their
longitudinal directions substantially parallel to each other. In
the example a third subpackage 48C is provided for comprising at
least two floor panels 1 of a third width B3. Clearly also here,
the floor panels 1 are provided in the box 35 in layers 47.
[0047] In the illustrated example the subpackage 48A-48B-48C has
been created by wrapping said at least two panels of a common width
B1-B2-B3 with a transparent film 46. According to another example,
cardboard could be used for the subpackages as well, be it in
combination with a film 46 or not.
[0048] Preferably, the packed set of panels according to the
invention is such that the decorative side 11 of at least one floor
panel 1 can be seen through the packaging material. As is the case
in FIGS. 10 and 11, preferably the decorative sides 11 of at least
two floor panels 1 of different width B1, B3 are visible through
the packaging material. Such embodiment is helpful to the consumer
making his choice in a DIY store. In the embodiment of FIG. 11, all
three different widths B1, B2, B3 are visible.
[0049] It is to be noted that the box 35 not necessarily needs to
have a bottom 42 that runs continuously from one side edge of the
package to the other side edge, like in FIGS. 9 to 11. It is
possible, but not illustrated here, that the box 35 in fact
consists of two or more L-shaped or U-shaped elements, preferably
made from card board, wherein each element preferably encapsulates
the edges of the layers 47 of the packed set of floor panels and
cover at least the coupling parts 3A, or 3B as the case may be, at
the respective edge. Preferably the element also coves at least a
portion of the bottom of the packed set of floor panels 1 close to
the coupling parts 3A.
[0050] It is also clear that the invention also relates to sets of
floor panels that are packaged by the application of methods of the
invention.
* * * * *