U.S. patent application number 13/366169 was filed with the patent office on 2013-08-08 for modular packaging system for fragile planiform materials.
The applicant listed for this patent is Arthur Rheal Huard, Jacqueline Lucy Laura Huard. Invention is credited to Arthur Rheal Huard, Jacqueline Lucy Laura Huard.
Application Number | 20130199954 13/366169 |
Document ID | / |
Family ID | 48901947 |
Filed Date | 2013-08-08 |
United States Patent
Application |
20130199954 |
Kind Code |
A1 |
Huard; Arthur Rheal ; et
al. |
August 8, 2013 |
MODULAR PACKAGING SYSTEM FOR FRAGILE PLANIFORM MATERIALS
Abstract
A modular packaging system of corrugated fibreboard construction
is provided for relatively large-scale, fragile planiform
materials, such as glass doors and architectural glass panels.
Panels in a predetermined range of dimensions are individually
enclosed within an adaptable, protective case. One or more loaded
panel cases, in a substantially vertical orientation, are stacked
horizontally and strapped together with a pair of buttressing
pillars at each end, on opposite faces thereof. Two shock-absorbing
base blocks are provided, upon which said panel case or bound stack
rests. Each base block is a laminate, constructed of bonded
corrugated fibreboard panels, and is disposed underneath the panel
case or stack of cases, proximal to a respective lateral edge
thereof, with its ends secured within recesses at the base of the
pillars bound at that end.
Inventors: |
Huard; Arthur Rheal;
(Toronto, CA) ; Laura Huard; Jacqueline Lucy;
(Toronto, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Huard; Arthur Rheal
Laura Huard; Jacqueline Lucy |
Toronto
Toronto |
|
CA
CA |
|
|
Family ID: |
48901947 |
Appl. No.: |
13/366169 |
Filed: |
February 3, 2012 |
Current U.S.
Class: |
206/454 |
Current CPC
Class: |
B65D 85/48 20130101;
B65D 81/056 20130101; B65D 81/127 20130101; B65D 5/5071
20130101 |
Class at
Publication: |
206/454 |
International
Class: |
B65D 85/48 20060101
B65D085/48 |
Claims
1. A packaging system for secure and protective containment of
fragile, relatively large-scale planiform materials, such as
architectural panels, which system comprising: (a) one or more
panel cases of predetermined surface dimensions, each case
enclosing fixedly therewithin a single fragile panel to be
packaged, which panel may be of indeterminate surface dimensions,
and have a thickness from a predetermined set of thickness values;
(b) two pairs of buttressing pillars, each pair bound level with or
proximal to a respective lateral edge of said panel case or a stack
thereof, its two pillars disposed opposite to and in alignment with
one another, abutting the respective faces of said case or stack,
thereby to support it in a substantially vertical orientation; (c)
two shock-absorbing base blocks, formed as elongated beams of
rectangular cross-section, each of which blocks disposed underneath
a respective end of said case or stack, a section of each of whose
ends inserted within a recess at the base of the corresponding
pillar of the respective said pair.
2. A packaging system as set forth in claim 1, wherein each of said
panel cases comprises: (a) a mounting panel, consisting of a
substantially rectangular board blank, onto which a fragile panel
to be packaged that is equal or smaller in surface dimensions with
respect thereto is affixed; (b) a plurality of corner pads, each
formed from a board blank, having two foldable flaps on adjacent
sides thereof, thereby to protectively sheath each corner of said
fragile panel and affix it to said mounting panel; (c) one or more
envelopes, each formed from a board blank, having at least two
foldable flaps on opposite sides thereof, thereby to encase said
mounting panel and said fragile panel mounted thereon, or a
previously applied such envelope and its contents.
3. A packaging system as set forth in claim 2, wherein each of said
board blanks is constructed of corrugated fibreboard adapted with
pre-pressed fold lines.
4. A packaging system as set forth in claim 1, wherein each of said
buttressing pillars is constructed of a board blank that is adapted
with foldable segments and flaps, and that is patterned
geometrically to allow its formation into a double-walled pillar
structure of substantially rectangular cross-section, having a
recess at its base to accommodate said base block.
5. A packaging system as set forth in claim 4, wherein one or more
segments of each of said buttressing pillar is disposed internally
to span diagonally the interior cavity thereof, thereby to provide
reinforcement to said structure.
6. A packaging system as set forth in claim 5, wherein said board
blank is constructed of corrugated fibreboard.
7. A packaging system as set forth in claim 2, wherein each of said
buttressing pillars is constructed of a board blank that is adapted
with foldable segments and flaps, and that is patterned
geometrically to allow its formation into a double-walled pillar
structure of substantially rectangular cross-section, having a
recess at its base to accommodate said base block.
8. A packaging system as set forth in claim 7, wherein one or more
segments of each of said buttressing pillar is disposed internally
to span diagonally the interior cavity thereof, thereby to provide
reinforcement to said structure.
9. A packaging system as set forth in claim 8, wherein said board
blank is constructed of corrugated fibreboard.
10. A packaging system as set forth in claim 4, wherein each of
said base blocks is a laminate, constructed of a plurality of
corrugated fibreboard panels that are bonded or strapped together,
thereby to form a solid, shock-absorbing block of rectangular
cross-section.
11. A packaging system as set forth in claim 5, wherein each of
said base blocks is a laminate, constructed of a plurality of
corrugated fibreboard panels that are bonded or strapped together,
thereby to form a solid, shock-absorbing block of rectangular
cross-section.
12. A packaging system as set forth in claim 7, wherein each of
said base blocks is a laminate, constructed of a plurality of
corrugated fibreboard panels that are bonded or strapped together,
thereby to form a solid, shock-absorbing block of rectangular
cross-section.
13. A packaging system as set forth in claim 8, wherein each of
said base blocks is a laminate, constructed of a plurality of
corrugated fibreboard panels that are bonded or strapped together,
thereby to form a solid, shock-absorbing block of rectangular
cross-section.
Description
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] The present invention relates generally to packaging systems
and particularly to a packaging system of corrugated fibreboard
construction for the transportation and storage of relatively
large-scale fragile planiform materials, such as glass doors and
architectural panels.
[0003] II. Brief Description of the Prior Art
[0004] Continual advances, over many centuries, in manufacturing
processes of glass resulted in the commercial availability of
increasingly large sheets of glass. With the introduction to market
of architectural glass, a need arose for packaging systems for the
safe transportation and storage of large and heavy glass
panels.
[0005] Various designs of crates and racks have emerged to satisfy
this need, typically featuring a wooden frame supporting a
horizontal stack of glass panels, each panel standing on edge
either vertically or somewhat inclined. One example of such a
system is U.S. Pat. No. 2,839,198A (F. J. Lefevre, 1958), proposing
an A-frame wood structure and a means of clamping inclined stacks
of glass panels onto it. Variations on this design are taught in
many subsequent patents.
[0006] Wood frame-based packaging systems, albeit traditional,
proven technology, inherently suffer from several disadvantages.
Wood frame crates are heavy, typically requiring two or more
persons or mechanized means to manipulate and move them; the
process of constructing wood frame crates is generally lengthy and
involved, requiring skilled workers, tools, and fasteners; once
assembled, wood frame crates are bulky, occupying precious floor
space in any commercial facility which uses them regularly; heavy
and bulky, and being moved about of a shipping floor, wood frame
crates present a workplace hazard; once delivered and unloaded,
they are either wastefully discarded, or shipped back to the
sender, as they are, at a non-trivial cost.
[0007] In the late nineteenth century, corrugated fibreboard and
prefabricated fibreboard box blanks became commercially available.
The rigidity, lightness, and shock absorption properties of this
inexpensive material, lent it well to the packaging of fragile
objects. In fact, one of its first uses was the packaging of glass
bottles and containers. Not surprisingly, corrugated fibreboard
packaging systems have continued to evolve in parallel with
developments in glass manufacturing. Numerous designs are now found
in the prior art teaching the use of fibreboard packaging systems
for glass and other fragile panels.
[0008] Corrugated fibreboard cases and envelopes intended to
package individual, relatively light panels, such as mirror panes,
have been known for decades and typically incorporate structural
elements by which the panel to be packaged is suspended internally,
at some distance from the container's outer walls, and is therefore
protected from impact damage. U.S. Pat. No. 2,177,241A (H. Burack,
1939), for instance, presents a paperboard box, in whose cavity a
receptacle is formed to suspend a fragile article away from the
outer walls. Another example is U.S. Pat. No. 2,105,086A (J. Liskin
and S. Stimmel, 1938) which teaches the suspension of a fragile
planiform article in an internal envelope formed of and integral
with the box blank. While suitable for individual, light panels,
these systems do not possess the structural rigidity necessary for
the packaging of stacks of relatively large and heavy panels.
[0009] Packaging systems have been devised for the containment of
individual automobile windshields, strapping the heavy, curved
glass panel to an interior position offset from the edges of the
encasing fibreboard envelope. U.S. Pat. No. 3,166,188A (M. C.
Koester, 1965), for instance, straps the windshield over inwardly
folded flaps to a safe interior position within the enclosing
envelope. In this application, corrugated fibreboard packaging in
the form of an envelope in which a fragile panel is suspended
appears to reach its structural limitation. A different system
altogether is required for the packaging of heavier, larger panels,
such as architectural glass, particularly when several panels are
to be packaged as a unit.
[0010] It has been known in the art that although individual sheets
of glass or other fragile material readily succumb to deformative
stresses, a tightly bound stack of abutting such sheets possesses
considerable resistance to damaging deformation. Indeed, binding
together multiple sheets or panels to be shipped has been part of
the solution to their packaging.
[0011] When a number of fragile panels of relatively large surface
area are to be packaged, it is advantageous to bind them together
in a substantially vertical orientation as a horizontal stack,
since this minimizes the footprint of the package and the
probability of damage. Few solutions have been proposed for the
containment of such a stack, which depart from the traditional
crate of metal and wood construction and avoid the aforementioned
shortcomings attendant thereto.
[0012] Broadly, proposed alternatives incorporate modular end units
which serve to support and sometimes bind the stack of vertical
panels, suspending it somewhat off the floor. Being somewhat
elevated protects the stack from floor impact damage, and allows it
to be manipulated by a mechanized means, such as a forklift.
[0013] One example of this solution can be seen in U.S. Pat. No.
5,909,808A (D. M. Bartholomew, 1999). This patent teaches an end
unit structure constructed of paperboard and nailed wood panels, a
wooden baseboard with nailed feet spanning the width of the package
and suspending it off the floor, and, optionally, a wooden top cap
board. Panels are strapped together with the end units. This design
suffers from many of the aforesaid disadvantages of traditional
wooden crates, and is limited to packaging a predetermined number
of identical panels.
[0014] Another example is U.S. Pat. No. 3,603,455A (David A. Barms,
1971). This patent teaches a two-part bracing member of corrugated
cardboard construction that is adaptable in dimensionality to
conform to a range of stack geometries. Two such bracing members
are employed--one near either end of the stack--binding it and
suspending it off the floor. Although flexible in that it can
accommodate any number of panels (within limits) in a range of
dimensions, this system, too, is limited to packaging panels of the
same width and height. Moreover, assembly of the two parts of the
bracing members requires drilling holes, fastening bolts, and
trimming protruding sections which adds considerably to the time
required to assemble the entire package.
[0015] There remains a need, evidently, for an inexpensive, light
packaging system for a stack of large panels of frangible
materials; a system which requires no particular skill to assemble
and very few tools, which is compact when stored unassembled, and
which may be readily disassembled for economical return to the
sender. The present invention addresses these, among other
objects.
SUMMARY OF THE INVENTION
[0016] It is the first and main object of this invention to provide
an economical packaging system for one or more relatively large
panels of fragile material, which may be transported and stored
disassembled and may be readily assembled when needed, requiring no
specific skill or specialized tools.
[0017] A second object of this invention is to provide a packaging
system as described above, which can accommodate panels in a range
of thicknesses and surface dimensions.
[0018] A third object of this invention is to provide a packaging
system as described above, which occupies minimal volume and which
has a minimal footprint.
[0019] A fourth object of this invention is to provide a packaging
system as described above, which protects its contents from floor
impact damage and which may be manipulated by a forklift.
[0020] These objects are met in embodiments of this invention
through a number of features, as outlined below.
[0021] The principle feature of the present invention is its
modular design, where each module is constructed primarily of
recyclable corrugated fibreboard blanks. The modularity of the
design allows it to be readily and economically transported and
stored. The corrugated fibreboard construction allows the system to
be light yet rigid, and inexpensive.
[0022] A second feature of the invention is an adaptable,
multi-part panel case, within which an individual panel in a range
of dimensions may be secured. Several such panel cases may be bound
in a substantially vertical orientation as a horizontal stack.
[0023] A third feature of the invention is an internally reinforced
support pillar, two pairs of which--one at each end of the
aforementioned horizontal stack--serve to buttress the stack and
stabilize the substantially vertical panel cases.
[0024] A fourth feature of the invention is a shock-absorbing base
block. Two such blocks--each disposed underneath the respective end
of the aforementioned bound and buttressed stack--suspend the stack
off the floor.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0025] A detailed description of preferred embodiments of the
present invention is provided hereafter, in which references are
made to the following figures:
[0026] FIG. 1--A perspective view of an assembled and bound
package, according to the present invention, containing three panel
cases.
[0027] FIG. 2--An orthographic front view of the package depicted
in FIG. 1.
[0028] FIG. 3--An orthographic side view of the package depicted in
FIG. 1.
[0029] FIG. 4--A plan view of the fibreboard blank for the support
pillar depicted in FIG. 5-7.
[0030] FIG. 5--A perspective isometric view of a support pillar
constructed from the fibreboard blank depicted in FIG. 4, with its
top and bottom flaps partly open.
[0031] FIG. 6--A perspective isometric view of the support pillar
depicted in FIG. 5 with its top and bottom flaps closed, tracing
its manner of engagement with the laminated base block depicted in
FIG. 9.
[0032] FIG. 7--A perspective view of the support pillar depicted in
FIG. 6 from the opposite direction.
[0033] FIG. 8--A perspective view of the reversed form of a support
pillar, according to the present invention.
[0034] FIG. 9--A perspective view of the laminated base block,
according to the present invention.
[0035] FIG. 10--An orthographic front view of the support pillar
depicted in FIG. 6.
[0036] FIG. 11--An orthographic section view of the support pillar
depicted in FIG. 10, corresponding to line 11, exposing its
internal structure.
[0037] FIG. 12--A perspective view of a second embodiment of the
support pillar, according to the present invention, with its top
flap opened.
[0038] FIG. 13--A plan view of the fibreboard blank from which the
second embodiment of the support pillar depicted in FIG. 12 is
constructed.
[0039] FIG. 14--An orthographic section view of a second embodiment
of the support pillar depicted in FIG. 12, corresponding to a
viewpoint similar to line 11 of FIG. 10.
[0040] FIG. 15--A perspective view of a third embodiment of the
support pillar, according to the present invention, with its front
wall removed to expose its inner structure.
[0041] FIG. 16--A plan view of the fibreboard blank from which the
third embodiment of the support pillar is constructed.
[0042] FIG. 17--An orthographic front view of the third embodiment
of the support pillar.
[0043] FIG. 18--An orthographic section view of the third
embodiment of the support pillar corresponding to line 18, exposing
its internal structure as seen from above.
[0044] FIG. 19--An orthographic section view of the third
embodiment of the support pillar corresponding to line 19, exposing
its internal structure as seen from below.
[0045] FIG. 20--A perspective isometric view of a corner pad
constructed according to the present invention.
[0046] FIG. 21--A plan view of a fibreboard blank from which the
corner pad depicted in FIG. 20 is constructed.
[0047] FIG. 22--An orthographic front view of four pieces of the
corner pad depicted in FIG. 20, affixed to a panel to be packaged,
which, in turn, is affixed to a mounting panel, according to the
present invention.
[0048] FIG. 23--A perspective view of a four-flap envelope,
according to the present invention, tracing its manner of
engagement with the mounting panel of FIG. 22.
[0049] FIG. 24--A perspective view of the four-flap envelope of
FIG. 23, engaged with and amid closure over the loaded mounting
panel.
[0050] FIG. 25--A plan view of a fibreboard blank for the four-flap
envelope of FIG. 23.
[0051] FIG. 26--A perspective view of a two-flap, outer envelope,
according to the present invention, tracing its manner of
engagement with the loaded four-flap envelope of FIG. 25.
[0052] FIG. 27--A perspective view of the outer envelope of FIG. 26
and the four-flap, loaded envelope it encases, forming a complete
panel case.
[0053] FIG. 28--A plan view of a fibreboard blank for the outer
envelope of FIG. 26.
[0054] FIG. 29--An orthographic front view of the assembly depicted
in FIG. 27.
[0055] FIG. 30--An orthographic section view of the assembly of
FIG. 29, corresponding to line 30 (for clarity, the corner pads are
hidden in this view).
DETAILED DESCRIPTION OF THE INVENTION
[0056] A packaging system constructed according to the present
invention, in its fully assembled, loaded, and bound state, is
depicted in FIG. 1-3 and is denoted generally by reference numeral
1.
[0057] Referring to FIG. 1, packaging system 1 is comprised of
three main elements: a stack 5 of one or more multi-part panel
cases 6, each containing a single fragile panel to be packaged
(three such panel cases are stacked in the exemplary embodiment
depicted in FIG. 1); two pairs of support and carriage pillars,
each pair consisting of pillar 2 and a geometrically mirrored
pillar 2m, the respective pillars of each pair embracing stack 5 on
opposite faces at either end thereof; two base blocks 3 upon which
stack 5 rests, an end section of each block securely engaged within
a corresponding recess at the bottom of each of support pillars 2
and 2m.
[0058] The use of two-part support structures (viz. pillars 2 and
2m) to buttress stack 5 permits the packaging of any number of
units of panel case 6, to a limit imposed by the ability of pillars
2 and 2m and blocks 3 to withstand the weight of the stack.
[0059] Although in the preferred embodiments, pillars 2 and 2m are
bound level with the lateral edges of stack 5 for maximum stability
and protection, pillars 2 and 2m may also be bound inwardly of
these edges by any offset which still provides acceptable
stability.
[0060] Stack 5 of panel cases 6, as discussed above and as seen in
FIG. 1 and FIG. 3, is interposed between pillars 2 and 2m, and the
entire assembly is bound together by steel or plastic strapping,
seen most clearly in FIG. 2. Vertical straps 4v bind stack 5 over
flanges which extend from each pillar 2 and 2m (denoted 2.2 in FIG.
4-7), binding pillars 2 and 2m to one another and affixing them to
stack 5. Horizontal straps 4h bind stack 5 over vertical straps 4v
(and thus over flanges 2.2) and through slots in pillars 2 (denoted
2.6 in FIG. 4-7) and the corresponding slots in support pillars 2m,
solidifying the attachment of pillars 2 and 2m to stack 5.
[0061] Referring now to FIG. 4-7, pillar 2 is formed, in the
preferred embodiments, from a corrugated fibreboard blank, denoted
generally by the numeral 2.0 in FIG. 4. Blank 2.0 is adapted with
pre-pressed fold lines to facilitate its transformation into the
solid double-walled structure of pillar 2. This transformation, in
the embodiment depicted in FIG. 4-7, is achieved in the following
manner: segment 2.8 is bent to an acute angle of approximately
20.degree. relative to base segment 2.1; base segment 2.1 is bent
at a right angle relative to the segment on its left; the latter
segment and, sequentially, each succeeding segment through segment
2.2 are bent at a right angle relative to their respective
preceding segment; segment 2.3 is bent down to cap the structure;
segment 2.4 is bent up to form an inner bottom cap; segment 2.5 is
bent up to form an outer bottom cap.
[0062] In the preferred embodiments, one or more sections of an
adhesive tape are applied circumferentially to pillar 2 to fix its
form; alternatively, the overlapping areas of segment 2.2 and the
segment it overlies, and--advantageously--overlapping areas of
other segments, are bonded or stapled.
[0063] Pillar 2m, depicted isolated in FIG. 8, is formed from a
blank of mirrored geometry with respect to that of blank 2.0,
following the same procedure.
[0064] Bracing segment 2.8 spans diagonally the interior cavity of
pillar 2, when so constructed, thereby increasing the unit's
structural rigidity and resistance to deformation. The diagonal
orientation of segment 2.8 is revealed in the exposed view of
pillar 2 depicted in FIG. 5 and in the section view of FIG. 11, an
aspect corresponding to a viewpoint represented by line 11 in FIG.
10.
[0065] An identical, though mirrored, arrangement of a diagonal
bracing segment is found in pillar 2m.
[0066] As seen in FIG. 4, bracing segment 2.8 is truncated at its
bottom to allow--in the formed pillar 2--the insertion of an end
section of base block 3, depicted in FIG. 9. In the preferred
embodiments, base block 3 is a laminate, constructed of a plurality
of bonded fibreboard panels. In an alternative embodiment, the
laminate fibreboard block is formed by strapping together the
constituent panels. The manner of engagement of support pillar 2
and base block 3 is shown in FIG. 6.
[0067] A plurality of slots 2.6t and 2.6b are pre-cut in blank 2.0.
Slots 2.6t and 2.6b are so positioned that when blank 2.0 is
manipulated according to the aforesaid procedure to form unit 2,
Slots 2.6t and 2.6b are disposed in superposed registration with
one another near the top and bottom of pillar 2, respectively,
allowing the transverse passage of the aforementioned straps 4h
therethrough.
[0068] The vertical edge of slots 2.6t and 2.6b which is nearer
stack 5 in the assembled package is level with the rear face of the
innermost wall of unit 2 on its side facing stack 5. This allows
straps 4h to lie in abutment with said wall face unhindered.
[0069] An identical arrangement of strapping slots is found in
pillar 2m.
[0070] Two pairs of hand carrying slots 2.7, a representative one
is labeled in FIG. 4, are pre-cut in blank 2.0. Slots 2.7 are
positioned on blank 2.0, so that when it is formed into pillar 2
they are disposed in superposed registration with one another on
the side of pillar 2 facing away from stack 5 in the assembled
package, providing two handhold openings. The vertical positioning
of the two handhold openings is set to allow comfortable handgrip
by person of normal stature.
[0071] An identical arrangement of handhold openings is found in
support pillar 2m.
[0072] Referring now to FIG. 12-14, a second preferred embodiment
of pillar 2, denoted generally by the numeral 2B in FIG. 12,
provides an internal bracing of an alternative geometry. Base
segment 2B.1 is extended, in this embodiment, at a right angle with
segment 2B.9 which carries the diagonal bracing segment 2B.10.
Segment 2B.11 extends from segment 2B.10 in the opposite direction,
as seen in FIG. 12 and in FIG. 14 which corresponds to a viewpoint
similar to that of line 11 in FIG. 10. Segment 2B.11 serves to
better anchor segment 2B.10 in its diagonal position, thus to
further reinforce the pillar structure.
[0073] Referring to FIG. 15-19, a third preferred embodiment of
pillar 2, denoted generally by the numeral 2C in FIG. 15, provides
an internal bracing of a second alternative geometry. In this
embodiment, the upper half of base segment 2C.1 is extended at a
right angle with segment 2C.12, which carries diagonal bracing
segment 2C.13. At its lower half, base segment 2C.1 is extended
directly with diagonal bracing segment 2C.14. Diagonal segment
2C.13 is clearly seen in FIG. 18--a sectional top view,
corresponding to line 18 of FIG. 17. Diagonal segment 2C.14 is
clearly seen in FIG. 19--a sectional bottom view, corresponding to
line 19 of FIG. 17. The two cross diagonal bracing segments further
fortify the pillar structure in this embodiment.
[0074] It will be apparent to those skilled in the art that various
other geometries of inner bracing are possible which may provide
similar benefits.
[0075] Referring to FIG. 20-22, a corner pad--depicted isolated in
FIG. 20 and denoted generally by the numeral 8--is provided to
protectively sheath each of the corners of a fragile panel to be
packaged (denoted 7 in FIG. 22) and secure it to a mounting panel
(denoted 9 in FIG. 22). Corner pad 8 consists of a main section
8.0, adjacent two of whose sides are extended with inwardly folded,
partially overlapping flaps 8.1 and 8.2. Corner pad 8 is
constructed, in the preferred embodiment, of a corrugated
fibreboard blank, depicted in FIG. 21, which is adapted with a
plurality of pre-pressed fold lines 8.3. The multiplicity of fold
lines 8.3 permit flaps 8.1 and 8.2 to be folded squarely over
fragile panel 7 according to its thickness, so that it is
accommodated snugly therewithin. Flaps 8.1 and 8.2, in the
preferred embodiments, are taped; alternatively, their overlapping
sections may be stapled or bonded together.
[0076] It will be clear to those skilled in the art that various
other two-flap envelope geometries will provide corner pads of
equally effective functionality.
[0077] Once applied to the respective corners of panel 7, corner
pads 8 are then taped or bonded to mounting panel 9, as seen in
FIG. 22, so that panel 7 is secured in a substantially central
lateral position with respect to mounting panel 9, and level with
the bottom edge thereof.
[0078] Mounting panel 9 effectively normalizes panel 7
dimensionally, so that an envelope of corresponding predetermined
dimensions may be used, as described hereinafter, to securely
encase the so mounted panel 7 irrespective of its dimensions.
[0079] Referring to FIG. 23-24, a four-flap envelope, denoted 10 in
FIG. 23, is provided to encase panel 7, when mounted by corner pads
8 onto mounting panel 9, as described above. The manner of
engagement of mounted panel 7 and envelope 10 is traced in FIG. 23,
and their relation when coupled is shown in FIG. 24.
[0080] In the preferred embodiments, vertical flaps 10.1 are folded
first, followed by the folding of horizontal flaps 10.2. Once flaps
10.1 and 10.2 are folded to abut corner pads 8 and one another,
they are fixed in this position by an adhesive tape. Alternatively,
the overlapping areas of flaps 10.1 and 10.2 are bonded together or
stapled.
[0081] Envelope 10 is constructed, in the preferred embodiments, of
a corrugated fibreboard blank, depicted in FIG. 25, which is
adapted with a plurality of pre-pressed fold lines 10.3. Each of
fold lines 10.3 corresponds to a particular thickness panel 7 may
have, and permits flaps 10.1 and 10.2 to be folded squarely over
panel 7 when of this thickness.
[0082] Referring now to FIG. 26-30, a two-flap, outer envelope,
denoted 11 in FIG. 26, is provided to encase envelope 10 and its
contents. As seen in FIG. 26, envelope 10, with panel 7 secured
therewithin, is engaged with envelope 11 so that the remaining
exposed area of panel 7 is covered by envelope 11. FIG. 27 depicts
envelopes 10 and 11 engaged, to form the aforementioned panel case
6.
[0083] In the preferred embodiments, envelope 11 is constructed of
a corrugated fibreboard blank, depicted in FIG. 28, which is
adapted with a plurality of pre-pressed fold lines 11.2. Each of
fold lines 11.2 corresponds to a particular thickness envelope 10
may assume when loaded, and permits flaps 11.2 to be folded
squarely over envelope 10 when of this thickness.
[0084] Flaps 11.1, in the preferred embodiments, are taped to
envelope 10; alternatively, they may be bonded or strapped.
[0085] When the use of outer envelope 11 is deemed superfluous, it
may be eliminated, and mounting panel 9 engaged with four-flap
envelop 10, so that panel 7 is emplaced therebetween. Conversely,
if greater surface impact protection is desired than that provided
by mounting panel 9, envelope 10, and envelope 11, one or more
progressively larger envelopes--each formed of a corrugated
fibreboard blank adapted with at least two opposite foldable
flaps--may be applied to encase the previously applied envelope and
its contents.
[0086] Although, advantageously, corrugated fibreboard is the board
blank material contemplated for use in the various parts of the
preferred embodiments, other materials which allow a board blank to
be adapted with foldable segments and flaps may be employed
alternatively.
[0087] It is to be understood that the forgoing description of the
preferred embodiments of the present invention and the accompanying
drawings are intended to better elucidate the invention by way of
examples, and not in any way to narrow its purview or the scope of
the appended claims to the embodiments exemplified.
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