Packing For Fragile Articles

Abstract

A unitary molded packing element used in packing cases for fragile articles such as fluorescent light tubes in which the packing element comprises a plurality of mutually parallel, elongated arcuate sockets defined by apertured coplanar ribs; in which outer side margins and end margins are defined by hollow, triangular elements which are relatively strong in compression and permit both longitudinal and transverse flexure of the packing elements; and in which the separator elements include notched tabs which are interlockable when in inverted pairs.

Description

The packing element of the present invention is an improvement over that disclosed in the U.S. Letters Pat. to Chaplin No. 3,163,312 issued Dec. 29, 1964.

Primary objects of the present invention are to provide a novel molded packing element in which tubular, fragile bulbs or the like can be readily packed and protected during shipping and storage; to provide hollow triangular marginal ribs which strengthen a packing element in compression but permit flexure; to provide interlocking tabs between inverted article separators; and to provide a tube packing element with cushion shock absorbing members in the tube cradling socket portions and separator ribs.

Other objects and the nature and advantages of the invention will become apparent from a consideration of the following description taken in conjunction with the accompanying drawings forming a part thereof, wherein:

FIG. 1 is a side elevational view of a package utilizing the improved separator or packing elements, with portions broken away;

FIG. 2 is a vertical section taken substantially on the plane of line 2--2 of Fig. 1;

FIG. 3 is a fragmentary end elevation or section taken on the plane of line 3--3 of FIG. 1;

FIG. 4 is a vertical section through separator elements substantially on the plane of line 4--4 of FIG. 1;

FIG. 5 is an enlarged top plan view of a separator element of the invention;

FIG. 6 is a section taken on the plane of line 6--6 of FIG. 5;

FIG. 7 is a top fragmentary perspective view of a portion of the separator element of FIG. 5;

FIG. 8 is a bottom perspective view of the separator element;

FIG. 9 is a view similar to FIG. 4 showing a plurality of separator elements in a stacked or nested condition;

FIG. 10 is a perspective view of another embodiment of the separator element;

FIG. 11 is a fragmentary, enlarged section, showing the manner in which the interlocking tabs of a pair of separator elements cooperate;

FIG. 12 is an enlarged top plan view of a separator element according to another embodiment of the invention;

FIG. 13 is a section taken on the plane of line 13--13 of FIG. 12;

FIG. 14 is a top fragmentary perspective view of a portion of the separator element of FIG. 12;

FIG. 15 is a bottom perspective view of the separator element of FIG. 12; and

FIG. 16 is a section taken on the plane of line 16--16 of FIG. 12.

Referring in greater detail to the figures of the drawing (similar reference numerals refer to similar parts), FIG. 1 illustrates a packing case indicated generally at 10 and comprising a bottom wall 12, end walls 14 and 15, side walls 16 and 18 and a lid 20. The case 10 may be produced from any suitable material such as wood, paperboard, etc., and details are not of particular significance except that the packing elements of the invention will permit the use of a minimum-dimension packing case accordingly requiring the smallest amount of packing and/or shipping space.

Within the case 10 there is arranged or packed superimposed layers of a plurality of fluorescent tubes ;or similar articles 22, and in the preferred embodiment there is provided six tubes per layer or each case will comprise eighteen tubes. Each three tubes of a layer are separated by a strip element 23.

Additionally, a series of center pads or separator elements flanked by two strip elements 23 may be used, particularly in packaging especially long tubes. These center pads or separator elements, of course, are open at both ends. The respective layers of tubes 22 are separated from each other by cooperating pairs of separator elements 24, 24'; 26, 26'; and 28, 28' disposed beneath the respective layers. The separator packing elements 24 -- 28' are identical and thus only packing element 24, for example, will be described in detail. The uppermost layer includes an upper, inverted separator element 29, 29' as clearly seen in FIGS. 1, 3 and 4.

The packing elements 24 -- 28', as illustrated in FIGS. 3 -- 8, are molded as a one-piece element from any suitable material including a plurality of mutually parallel arcuate or semi-cylindrical sockets 30 opening upwardly and inwardly as seen in FIG. 7, for example.

For purposes of orientation, the packing elements have a base plane or lowermost wall B and the sockets 30 extend or open vertically therefrom, the elements 24 -- 28', each including opposed side walls indicated generally at 32, 34 and an end wall indicated generally at 36.

The sockets 30 comprise arcuate or semi-cylindrical base walls 37 defined at opposite sides by intermediate, hollow, vertically projecting, coplanar, triangular rib elements 38 each of which having arcuate sides 40 and 42 merging into the base wall 37, and being closed by transverse end walls 43 and 44. Although the ribs are relatively solid, the end walls 43 and 44 descend to the base B and thus flexure of the base transversely of the sockets 30 is permitted. The ribs 38 at sides 40 have rectangular openings 46 therethrough, which form a relatively thin and flexible upper edge 48 on a majority of the rib elements which separate adjacent portions of the fluorescent tubes or the like 22 as seen, for example, in FIGS. 2 -- 4. The opening 46 can be formed in either side of rib side 40 or 42.

The side walls 32 and 34 each comprise a plurality of hollow, triangular elements 50 which open outwardly and have arcuate inner walls 52 which merge into the base 37 of the endmost sockets 30. The valley 53 at every second triangular element 50 is in coplanar relation with the corresponding valley between adjacent end walls 43, 44 of the rib elements 38, and since the valley 53 descend to the base B, transverse flexure is permitted along these coplanar valleys. This flexure affords shock absorbing qualities through the separator element. On the other hand, the triangular elements 50 are substantially rigid and provide a cushion against lateral blows to the package 10 at the side walls 16 and 18.

The end wall 36 of the separator element also comprises a series of hollow, triangular elements 54 which open outwardly and protect the ends of the tubes 22 from blows on the end walls 14 and 15 of the packing case. The triangular elements 54 disposed in pairs at the end of each socket 30 and the valley 56 between an adjacent pair of elements 54 descends to the base B and permits flexure of the packing element along the longitudinal axis of the respective sockets 30. The angled opening formed will receive the tube contact pins regardless of position and will protect them against deformation by outside forces.

The packing elements terminate in a lip or ledge 58 at the end opposite the wall 36, and the lip 58 is disposed in the plane of the base B of the element.

The packing elements, when inverted as seen in FIGS. 1, 3 and 4, for example, see 28, 29, provide substantial rigidity since the apex of the marginal ribs will abut each other; being oriented by the packing case.

Referring to FIGS. 10 and 11, a separator element is indicated generally at 124 and in most major respects is similar in structure and function to element 24. For example, the separator or packing element 124 includes a molded one-piece element including semi-cylindrical sockets 130 opening upwardly and outwardly from a base plane B'. The element 124 includes opposed side walls 132 and 134 and an end wall 136.

The sockets 130 include semi-cylindrical base walls 137 defining opposite sides of hollow, vertically projecting, coplanar, triangular ribs 138 closed by transverse end walls 143 and 144. Walls 143 and 144 descend to base B' and permit flexure of the sockets.

The rib sides have an opening 146 formed therethrough and form relatively flexible separator tabs 148. The side walls 132 and 134 are formed from hollow triangular elements 150 which have inner arcuate walls 152. The valley 153 between each second element 150 coincides with walls 143 and 144 to permit transverse flexure. The end wall 136 includes hollow triangular elements 154 and every second pair of these elements defines a valley 156 in substantially coplanar alignment with ribs 138 and descends to base plane B'.

The embodiment of FIG. 10 shows that the tabs 148 are formed with notched edges 149 at one side of the element, and reversed notches 149' at the other side. The notches 149 and 149' are in substantially mirror-image relationship, i.e. the series of notches 149 at the left-hand side of center separators or ribs 151 are offset with respect to the notches 149'. Further, the upper edges project above the upper edge of the hollow triangular wall elements; see plane A in FIG. 11. The notched out portions are below plane A.

In the uppermost layer of tubes, the separator elements are inverted at the uppermost layer 124 and the tabs 149' will interlock with tabs 149 as seen in FIG. 11. The last layer of each case is "capped" with inverted and interlocked separators. The interlocked pattern permits lateral separation of the tabs which are disposed above and below the fragile tube center lines generally at plane A.

Referring to FIGS. 12--16, a separator element is indicated generally at 224 and in most major respects is similar in structure and function to elements 24 and 124. For example, the separator or packing element 224 includes a molded one-piece element including semi-cylindrical sockets 230 opening upwardly and outwardly from a base plane B". The element 224 includes opposed side walls 232 and 234 and an end wall 236.

The sockets 230 comprise arcuate or semi-cylindrical base walls 237 defined at opposite sides by intermediate, hollow, vertically projecting, coplanar, triangular rib elements 238 each of which has arcuate sides 240 and 242 merging into the base wall 237, and being closed by transverse end walls 243 and 244.

The rib sides have an opening 246 formed therethrough and form relatively flexible separator tabs 248. The side walls 232 and 234 are formed from hollow, triangular elements 250 which have inner arcuate walls 252. The valley 253 between each second element 250 coincides with walls 243 and 244 to permit transverse flexure. The end wall 236 includes hollow, triangular elements 254 and every second pair of these elements defines a valley 256 and substantially coplanar alignment with ribs 238 and descends to the base plane B".

The ribs 238 at sides 242 have a plurality of raised tab cushion shock absorbing members 249 formed thereon. The sockets 230 are provided with a plurality of sunken pocket cushions or shock absorbing members 231 with two such pocket cushions 231 in each socket 230 adjacent the side walls 232 and 234 and three such pocket cushions 231 in each of the other sockets 230. The tab cushion members 249 and pocket cushion members 231 provide the separator element 224 with the added ability to prevent the transmittal of shock from externally of the package to the fluorescent light tubes to be contained therein. The added cushioning effect in addition to guarding against possible "connector pin" damage and against glass envelope breakage guards against "flake off" of the fluorescent powder lining the inside of the tubes which otherwise due to excessive shock may tend to decrease lighting efficiency.

It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification.

Claims

What is claimed is:

1. A unitary packing element of molded material for separating and protecting the ends of a plurality of elongated cylindrical tubes in a package, the packing element comprising:

a sheet having a plurality of mutually parallel article-receiving sockets having an arcuate cross section;

said sheet including an end and opposed side walls extending vertically from a base,

said end wall comprising a plurality of hollow, triangular segments closed towards its socket and opening outwardly therefrom,

each socket having a pair of triangular segments facing one end of each socket and a valley portion therebetween terminating at the base of the sockets,

said side walls each comprising a plurality of hollow triangular segments opening outwardly from the endmost sockets including an arcuate inner wall forming a fragmentary portion of an adjacent socket,

said socket comprising an arcuate base terminating in a plurality of hollow, intermediate rib segments, parallel to said side walls,

said intermediate ribs being in alignment with a valley between each second pair of triangular segments in said end wall,

said sockets having a free end opening away from the said end wall.

2. The structure as claimed in claim 1 in which said intermediate rib segments generally comprise a hollow triangular element having arcuate sides opening into respective adjacent sockets, at least one of said sides having an opening forming a relatively thin flexible upper terminal lip.

3. The structure as claimed in claim 2 in which said thin flexible upper terminal lips are notched whereby an inverted packing element will interlock with an underlying element to enclose a flexible element being protected.

4. The structure as claimed in claim 5 in which said terminal lips project above the uppermost portion of said triangular segments and are aligned with a lower notch portion.

5. The structure as claimed in claim 1 which pairs of vertically extending segments of said side walls are coplanar with the plane passing through corresponding walls of said intermediate rib segments.

6. The structure as claimed in claim 1 in which said side end walls are relatively rigid but permit both longitudinal and transverse flexure of said packing element.

7. The structure as claimed in claim 1 in which said intermediate rib segments generally comprise a hollow triangular element having arcuate sides opening into respective adjacent sockets, at least one of said sides having a plurality of tab cushion shock absorbing members formed thereon.

8. The structure as claimed in claim 1 in which said sockets have a plurality of pocket cushioning shock absorbing members formed therein.