U.S. patent number RE44,083 [Application Number 12/957,891] was granted by the patent office on 2013-03-19 for protective package for an automobile part.
This patent grant is currently assigned to Batavia Container, Inc.. The grantee listed for this patent is Edward Dahl, Scott R. Jensen, Jeff A. Waterman, Randy J. Wians. Invention is credited to Edward Dahl, Scott R. Jensen, Jeff A. Waterman, Randy J. Wians.
United States Patent |
RE44,083 |
Dahl , et al. |
March 19, 2013 |
Protective package for an automobile part
Abstract
A protective package for an automobile part; as assembled,
packaged and buttressed for shipping; minimizes or eliminates
damage to the automobile part being shipped, by providing a carton,
side rail supports in the carton to receive the part and padded
supports to secure the part in the carton.
Inventors: |
Dahl; Edward (Maple Park,
IL), Jensen; Scott R. (Chicago, IL), Waterman; Jeff
A. (South Elgin, IL), Wians; Randy J. (Hampshire,
IL) |
Applicant: |
Name |
City |
State |
Country |
Type |
Dahl; Edward
Jensen; Scott R.
Waterman; Jeff A.
Wians; Randy J. |
Maple Park
Chicago
South Elgin
Hampshire |
IL
IL
IL
IL |
US
US
US
US |
|
|
Assignee: |
Batavia Container, Inc.
(Batavia, IL)
|
Family
ID: |
40073705 |
Appl.
No.: |
12/957,891 |
Filed: |
December 1, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
11217902 |
Sep 1, 2005 |
7458465 |
Dec 2, 2008 |
|
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Current U.S.
Class: |
206/592; 206/521;
206/587; 206/586 |
Current CPC
Class: |
B65D
5/5052 (20130101); B65D 81/107 (20130101) |
Current International
Class: |
B65D
85/30 (20060101) |
Field of
Search: |
;206/335,448,453,454,583,586,590,591,592,449,521,756,587,485,594,319
;248/345.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Reynolds; Steven A.
Attorney, Agent or Firm: Chicago IP Law Evans; Steven M.
Claims
What is claimed and sought to be protected by Letters Patent of the
United States is:
1. A protective package for shipping a part comprising: (a) a
carton having a packing assembly therein; (b) the packing assembly
including a first side rail support and a second side rail support
adapted to position the part in the carton; (c) the packing
assembly including a first rear support in the first side rail in
the carton to support a rear portion of the part; (d) the packing
assembly including a second rear support in the second side rail in
the carton to support the rear portion of the part; (e) the packing
assembly including a first front support in the front side rail in
the carton to support a front portion of the part; (f) the packing
assembly including a second front support in the second side rail
in the carton to support the front portion of the part; (g) a first
slot being present in the first side rail support; (h) a second
slot being present in the second side rail support; (i) the first
slot receiving the first rear support and the first front support;
(j) the second slot receiving the second rear support and the
second front support; (k) a first spacer pad being inserted between
the carton and the first side rail; (l) a second spacer pad being
inserted between the carton and the second side rail; (m) the first
spacer pad, the second spacer pad, the first rear support, the
first front support, the second rear support and the second front
support cooperating to support the part within the carton and at
least minimize damage to the part; (n) the first spacer pad forcing
the first side rail inwardly to provide additional support for the
part; (o) the second spacer pad forcing the second side rail
inwardly to provide additional support for the part; (p) the first
spacer pad and the second spacer pad forming part of the packing
assembly; (q) the first front support and the second front support
being substantially similar in appearance; (r) the first front
support being formed from a corrugated front insert die-cut flat
with a front foam support mounted therein; (s) the front foam
support having a front jaw slot; and (t) the front jaw slot being
adapted to receive and partially support the part.
2. The protective package of claim 1 further comprising: (a) the
first rear support and the second rear support being substantially
similar in appearance; (b) the first rear support being formed from
a corrugated rear insert die-cut flat with a rear foam support
mounted therein; (c) the rear foam support having a rear jaw slot;
and (d) the rear jaw slot being adapted to receive and partially
support the part.
3. The protective package of claim 1 further comprising: (a) the
first side rail and the second side rail being substantially
similar in appearance; (b) the first side rail being formed from a
scored flat corrugated piece of material; (c) the first side rail
having an inner side and an outer side; (d) a large top panel
joining the inner side and the outer side; (e) the large top panel
extending into a larger inner panel; (f) the larger inner panel
forming a first part of the inner side; (g) the larger inner panel
being substantially parallel to the outer side; (h) the larger
inner panel extending into a first slot side and then into a second
base side; (i) a small bottom panel extending from the outer side
in a substantially perpendicular relationship; (j) the small bottom
panel then forming a smaller inner panel; (k) smaller inner panel
extending into a second slot side; (l) the second slot side
extending into a first slot base in order to form the rail channel
slot with second base side; and (m) the rail channel slot thus
formed receiving the part.
4. The protective package of claim 3 further comprising: (a) the
first rear support and the second rear support being substantially
similar in appearance; (b) the first rear support being formed from
a corrugated rear insert die-cut flat with a rear foam support
mounted therein; (c) the rear foam support having a rear jaw slot;
and (d) the rear jaw slot being adapted to partially receive and
partially inset the part.
5. The protective package of claim 4 further comprising: (a) the
outer side including a large top swing brace panel and a smaller
top swing brace panel scored in the outer side; (b) the large top
swing brace panel forming a large top brace support as
substantially perpendicular to the large top panel; and (c) the
smaller top swing brace forming a smaller top brace support as
substantially perpendicular to the large top panel.
6. The protective package of claim 5 further comprising: (a) the
shipping carton being a seamed shipping carton or a fold over
carton; (b) the large top brace support forming a larger top rest
lip; (c) the smaller top swing brace forming a smaller top rest
lip; and (d) the smaller top swing brace panel being spaced apart
from the large top swing brace panel in order to support the side
rail.
7. A method of forming a protective package for shipping a part
comprising: (a) providing a shipping carton with a generally
rectangular shape for the protective package; (b) shaping the
carton with rear dust flaps mounted thereon; (c) shaping a first
side rail to have a first part receiving slot and a second side
rail to have a second part receiving slot; (d) fitting the first
side rail and the second side rail into the carton on opposing
sides thereof; (e) spacing the first side rail and the second side
rail from the respective opposing sides of the carton with a side
spacer; .Iadd.(f) forming a first front insert from a corrugated
front insert die-cut flat; (g) folding a rear die-cut flat to form
a first rear insert; (h) placing a front foam support in the first
front insert; (i) inserting a larger jaw angle cut spacer into the
first rear insert; (j) inserting a foldable tongue from the rear
die-cut flat into the larger jaw angle cut spacer; (k) having a
second front insert being similar in shape to the first front
insert; (l) having a second rear insert being similar in shape to
the first rear insert; .Iaddend. (.[.f.]..Iadd.m.Iaddend.) placing
.[.a.]. .Iadd.the .Iaddend.first rear insert in the first side
rail; (.[.g.]..Iadd.n.Iaddend.) placing .[.a.]. .Iadd.the
.Iaddend.second rear insert in the second side rail;
(.[.h.]..Iadd.o.Iaddend.) inserting the part into the carton in
contact with the first side rail, the second side rail into the
first rear insert and the second rear insert;
(.[.i.]..Iadd.p.Iaddend.) placing .[.a.]. .Iadd.the .Iaddend.first
front insert in the first side rail and in contact with the part;
(.[.j.]..Iadd.q.Iaddend.) placing .[.a.]. .Iadd.the .Iaddend.second
front insert in the second side rail and in contact with the part;
.Iadd.and .Iaddend. (.[.k.]..Iadd.r.Iaddend.) closing the
carton.[.; (l) having the first rear insert being similar in shape
the second rear insert; (m) folding a rear die-cut flat to form the
first rear insert; (n) inserting a larger jaw angle cut spacer into
the first rear insert; (o) inserting a foldable tongue from the
rear die-cut flat into the larger jaw angle cut spacer; (p) having
the first front insert being similar in shape to the second front
insert; (q) forming the first front insert from a corrugated front
insert die-cut flat; and (r) placing a front foam support in the
first front insert.]..
8. The method of claim 7 further comprising: (a) folding .[.a pair
of.]. .Iadd.the .Iaddend.rear dust flaps for the carton inwardly in
order to hold the carton in a proper position for packing;
.Iadd.and .Iaddend. (b) folding a rear bottom flap over .[.pair
of.]. .Iadd.the .Iaddend.rear dust flaps.[.; (c) inserting the
first side rail and the second side rail into the carton; (d)
inserting the part into the shipping carton; and (e) closing the
carton.]..
9. The method of claim 8 further comprising: (a) inserting a first
spacer pad between the carton and the first side rail to push in
the first side rail; (b) inserting a second spacer pad between the
shipping carton and the second side rail to push in the second side
rail; (c) providing a rear closable end oppositely disposed from a
front closable end for the carton; (d) having a rail channel slot
in the first side rail and second side rail to receive the part;
and (e) supporting the part in the rail channel slot.
10. A protective package for shipping a part comprising: a carton
having a packing assembly therein; the packing assembly including a
first side rail support and a second side rail support adapted to
position the part in the carton; the packing assembly including a
first rear support in the first side rail in the carton to support
a rear portion of the part; the packing assembly including a second
rear support in the second side rail in the carton to support the
rear portion of the part; the carton being a seamed carton or a
fold over carton; the packing assembly including a first front
support in the .[.second.]. .Iadd.first .Iaddend.side rail in the
carton to support a front portion of the part; the packing assembly
including a second front support in the second side rail in the
carton to support the front portion of the part; a first slot being
present in the first side rail support; a second slot being present
in the second side rail support; the first slot receiving the first
rear support and the first front support; the second slot receiving
the second rear support and the second front support; a first
spacer pad being inserted between the carton and the first side
rail; a second spacer pad being inserted between the carton and the
second side rail; the first spacer pad, the second spacer pad, the
first rear support, the first front support, the second rear
support and the second front support cooperating to support the
part within the carton and at least minimize damage to the part;
the first spacer pad forcing the first side rail inwardly to
provide additional support for the part; the second spacer pad
forcing the second side rail inwardly to provide additional support
for the part; the first spacer pad and the second spacer pad
forming part of the packing assembly; the first front support and
the second front support being substantially similar in appearance;
the first front support being formed from a corrugated front insert
die-cut flat with a front foam support mounted therein; the front
foam support having a front jaw slot; and the front jaw slot being
adapted to receive and partially support the part.
.Iadd.11. A hood packing assembly, comprising: a carton having a
first wall and a second wall; a first sidewall within the carton
having a first upper panel and a first lower panel, wherein a first
rail channel slot is formed between the first upper panel and the
first lower panel, and the first rail channel slot is located a
greater distance from the first wall than the second wall of the
carton; a second sidewall within the carton, separate and apart
from the first sidewall, having a second upper panel and a second
lower panel, wherein a second rail channel slot is formed between
the second upper panel and the second lower panel, and the first
rail channel slot faces the second rail channel slot, and the
second rail channel slot is located a greater distance from the
first wall than the second wall of the carton; a first rail channel
slot spacer and a second rail channel slot spacer located within
the first rail channel slot; a third rail channel slot spacer and a
fourth rail channel slot spacer located within the second rail
channel slot; said first, second, third and fourth rail channel
slot spacers each include a slot for receiving a portion of an edge
of an automobile hood; and said slots in the first and second rail
channel slot spacers face each other, and said slots in the third
and fourth rail channel slot spacers face each other. .Iaddend.
.Iadd.12. The hood packing assembly of claim 11, further
comprising: an automobile hood located within the carton, wherein
at least a portion of a first edge of the automobile hood is
located within the first rail channel slot, and wherein at least a
portion of a second edge of the automobile hood is located within
the second rail channel slot. .Iaddend.
.Iadd.13. The hood packing assembly of claim 11, further
comprising: an automobile hood located within the carton, wherein
at least a portion of a first edge of the automobile hood is
located within the first rail channel slot and between the first
and second rail channel slot spacers and wherein at least a portion
of a second edge of the automobile hood is located within the
second rail channel slot and between the third and fourth rail
channel slot spacers. .Iaddend.
.Iadd.14. The hood packing assembly of claim 11, wherein the first
rail channel slot and the second rail channel slot are aligned to
be at a similar height within the carton. .Iaddend.
.Iadd.15. The hood packing assembly of claim 11, wherein the first
lower panel, the first upper panel, the second lower panel, and the
second upper panel are formed by folded corrugated cardboard.
.Iaddend.
.Iadd.16. The hood pack packing assembly of claim 11, wherein the
first, second, third, and fourth rail channel slot spacers are
constructed of compressible material. .Iaddend.
.Iadd.17. The hood pack packing assembly of claim 16, wherein the
compressible material includes foam. .Iaddend.
.Iadd.18. The hood packing assembly of claim 11, wherein the first
sidewall, the first upper panel, the first lower panel, and the
first rail channel slot are formed from a first single sheet of
corrugated cardboard, and wherein the second sidewall, the second
upper panel, the second lower panel, and the second rail channel
slot are formed from a second single sheet of corrugated cardboard.
.Iaddend.
.Iadd.19. The hood packing assembly of claim 11, wherein the first
and second rail channel slot spacers are positioned proximate
opposing ends of the first rail channel slot, and the third and
fourth rail channel slot spacers are positioned proximate opposing
ends of the second rail channel slot. .Iaddend.
.Iadd.20. The hood packing assembly of claim 11, wherein the first
and second sidewalls are constructed separately from walls of the
carton, and further comprising: a first sidewall spacer located
between the first sidewall and the carton; and a second sidewall
spacer located between the second sidewall and the carton.
.Iaddend.
.Iadd.21. The hood packing assembly of claim 20, wherein the first
and second sidewall spacers are constructed of compressible
material. .Iaddend.
.Iadd.22. The hood packing assembly of claim 21, wherein the
compressible material of the first and second sidewall spacers
includes foam. .Iaddend.
.Iadd.23. The hood packing assembly of claim 11, further
comprising: a separate foldable tongue located in each of the slots
in the first, second, third and fourth rail channel slot spacers.
.Iaddend.
.Iadd.24. A protective package, comprising: a carton having a first
wall and a second wall; a packing assembly within the carton,
comprising; a first side rail having a first rail channel slot; a
second side rail, separate and apart from the first side rail,
having a second side rail channel slot substantially parallel to
the first rail channel slot, and the first and second rail channel
slots are located a greater distance from the first wall than the
second wall of the carton; a first rail channel slot spacer and a
second rail channel slot spacer constructed of compressible
material and positioned within the first rail channel slot, wherein
the first and second rail channel slot spacers are located
proximate opposing ends of the first rail channel slot; and a third
rail channel slot spacer and a fourth rail channel slot spacer
constructed of compressible material and positioned within the
second rail channel slot, wherein the third and fourth rail channel
slot spacers are located proximate opposing ends of the second rail
channel slot; said first, second, third and fourth rail channel
slot spacers each include a slot for receiving a portion of an edge
of an automobile hood; and said slots in the first and second rail
channel slot spacers face each other, and said slots in the third
and fourth rail channel slot spacers face each other. .Iaddend.
.Iadd.25. The protective package of claim 24, wherein the
compressible material is foam. .Iaddend.
.Iadd.26. The hood packing assembly of claim 11, wherein the first
and second sidewalls and the first and second rails channel slots
formed therein extend the substantial length of the carton within
which the first and second sidewall are contained. .Iaddend.
.Iadd.27. The hood packing assembly of claim 11, wherein the widths
of the first, second, third and fourth rail channel slot spacers
are substantially similar to the depths of the first and second
rail channel slots. .Iaddend.
.Iadd.28. The hood packing assembly of claim 11, wherein the first
and second sidewalls are positioned at opposing sides of the
carton. .Iaddend.
Description
This invention relates to a protective package, especially for an
automobile part, and more particularly, to a protective package for
an automobile part, especially a hood, which complies with shipping
standards and permits efficient shipping of the part.
BACKGROUND OF THE INVENTION
When a vehicle accident occurs, it is usually necessary to replace
various parts of the vehicle. These parts of the vehicle are body
parts, frame parts, mechanical parts, or electrical parts. With the
body part, one major problem involves appropriate storage of body
parts, until the particular use is desired.
Because vehicle body parts are generally large and require a
substantial amount of storage space, it is usually desirable to
warehouse the body parts, and ship the body parts to the desired
location. The desired location is usually a body shop that actually
makes the vehicle repairs.
Since warehouse space can be expensive, it is desired to reduce the
number of warehouses and provide a shipping program to efficiently
transport the desired part to the desired location. With such
transportation, an effective package for the part permits shipping
of the part with no damage. Because not all body parts are heavily
supported or braced, it is difficult to ship parts.
Major keys to efficient use of warehouse space are proper storage
and utility of the packaging materials. Not only must the packaging
material be easily stored, it must also be easily assembled into
the desired package. Such a combination provides value and
efficiency to the packaging material.
One of the most difficult parts to ship is a vehicle hood or cover
for the engine compartment. Some aftermarket suppliers have stopped
shipping vehicle hoods because of the difficulty and expense of
getting the hoods, to a desired location in an undamaged
condition.
More particularly, it is known that is very difficult to ship a
hood for a Mercedes. In spite of substantial efforts to correct the
package and greatly reduce the damage to any part contained in the
package, the efforts have met with no success. In fact, more than
twenty-five (25%) percent of these shipped hoods are known to
arrive in a damaged condition.
This damage problem imposes many undesirable limits. One such limit
is the distance a hood may be shipped. To solve that problem, more
warehouses for parts or better shipping packages are required. Such
difficulties also lead a lack of flexibility in type or size of a
hood that can be packed and shipped. Furthermore, it is difficult
to develop a package acceptable to the commercial delivery
services. If the package containing the auto parts or the hood or
other body part can meet the standards of a commercial shipping
organization, such as Federal Express or United Parcel Service,
great advantages can be obtained. Such advantages include, but are
not limited to, damage insurance on the part being shipped.
SUMMARY OF THE INVENTION
Among the many objectives of this invention is the provision of a
protective package, which permits an automobile part to be shipped
in an efficient fashion.
A further objective of this invention is the provision of a
protective package, which prevents damage to an automobile part
shipped therein.
Yet a further objective of this invention is the provision of a
protective package, which meets industry standards for
shipping.
A still further objective of this invention is the provision of a
protective package, which is easily installed around an automobile
part.
Another objective of this invention is the provision of a
protective package, which is easily stored.
Still, another objective of this invention is the provision of a
protective package, which is easily assembled.
Also, an objective of this invention is the provision of a
protective package, which has repeated uses.
A further objective of this invention is the provision of a
protective package, which increases the distance an automobile part
may be safely shipped.
Yet a further objective of this invention is the provision of a
protective package, which has flexibility to safely many different
products.
These and other objectives of the invention (which other objectives
become clear by consideration of the specification, claims and
drawings as a whole) are met by providing a protective package for
an automobile part, which can be assembled, packaged and buttressed
for shipping, in order to minimize or eliminate damage to the
automobile part being shipped, by providing a carton, side rail
supports in the carton to receive the part and padded supports to
secure the part in the carton.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a see through perspective view of a package assembly
100 of this invention for a vehicle hood 110, in a sealed shipping
carton 300 shown in phantom.
FIG. 2 depicts a perspective view of an inward direction 112 of
hood 110.
FIG. 3 depicts a perspective, exploded, related view of all
components for package assembly 100.
FIG. 4 depicts a perspective view of a side rail 140 being
partially folded to form part of package assembly 100.
FIG. 5 depicts a perspective view of a side rail 140 being
completely folded to form part of package assembly 100.
FIG. 6 depicts a perspective view of a side rail 140 using swing
brace panels to add strength, form and rigidity to side rail
140.
FIG. 7 depicts a perspective view of the outer side 204 of side
rail 140 with a side foam spacer 150 being attached thereto.
FIG. 8 depicts a perspective view of thin spacer pad 146 used in
package assembly 100.
FIG. 9 depicts a perspective view of medium spacer pad 148 used in
package assembly 100.
FIG. 10 depicts a perspective view of thick spacer pad 160 used in
package assembly 100.
FIG. 11 depicts a perspective view of corrugated rear insert 164 in
a die-cut flat position 166.
FIG. 12 depicts a perspective view of rear foam 168 lying on
corrugated die cut flat 166 for rear insert 164.
FIG. 13 depicts a perspective view of rear foam 168 lying on
corrugated die cut flat 166 for rear insert 164.
FIG. 14 depicts a perspective view of rear foam 168 set in rear
insert 164 partially folded and wrapped.
FIG. 15 depicts a perspective view of rear foam 168 set in rear
insert 164 completely folded and wrapped.
FIG. 16 depicts a perspective view of rear foam 168 set in rear
insert 164 completely folded, wrapped and secured.
FIG. 17 depicts a perspective view of rear insert 164 as
assembled.
FIG. 18 depicts a perspective view of corrugated die cut flat 192
of front insert 190.
FIG. 19 depicts a perspective view of front foam 194 on corrugated
die cut flat 192 of front insert 190.
FIG. 20 depicts a perspective view of corrugated front insert 190,
in partially folded position 196 with front foam insert 194
positioned thereon.
FIG. 21 depicts a front perspective view of corrugated front insert
190, in completely folded position 200 with front foam insert 194
positioned therein.
FIG. 22 depicts a rear perspective view of corrugated front insert
190, in completely folded position 200 with front foam insert 194
secured therein.
FIG. 23 depicts a front perspective view of corrugated front insert
190, in completely folded position 200 with front foam insert 194
positioned therein, based on a 180 degrees of rotation for FIG. 22
about a vertical axis.
FIG. 24 depicts a perspective view of shipping carton 300.
FIG. 25 depicts a perspective view of rear insert 164 inserted in
side rail 140.
FIG. 26 depicts a perspective view of rear foam insert 168 secured
in side rail 140.
FIG. 27 depicts dust flaps 302 of shipping carton 300 used to hold
a proper shape for shipping carton 300.
FIG. 28 depicts shipping carton 300 with rear bottom flap 304 at
least partially secured.
FIG. 29 depicts a perspective view of shipping carton 300 having
two of side rail 140 inserted therein, one on the left side and one
on the right side.
FIG. 30 depicts package assembly 100 of this invention receiving
vehicle hood 110.
FIG. 31 depicts a person 102 reaching over rear bottom flap 304
into shipping carton 300 to grab hood 110.
FIG. 32 depicts car hood 110 securely held in the corrugated rear
insert 164.
FIG. 33 depicts the closing and securing of the rear top flap 310
on the fold over carton 350.
FIG. 34 depicts a perspective view of shipping carton 300 having
two of side rail 140 inserted therein.
FIG. 35 depicts a perspective view of shipping carton 300 having
two of side rail 140 inserted therein with medium spacer pads 148
exploded therefrom, based on FIG. 34.
FIG. 36 depicts a perspective view of shipping carton 300 having
two of side rail 140 inserted therein with corrugated front insert
190 being exploded therefrom.
FIG. 37 depicts shipping carton 300 having both of the two side
rails 140 inserted therein and with corrugated front insert 190
being secured therein.
FIG. 38 depicts closing and securing of the front flap assembly 330
of fold over carton 350.
FIG. 39 depicts securing side rails 140 to the fold over carton
350.
Throughout the figures of the drawings, where the same part appears
in more than one figure of the drawings, the same number is applied
thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, a protective package for
a part to be shipped has a slotted side rail placed on either side
of the part. The two side rails containing or supporting the part
are inserted into a carton. Some buttressing members are inserted
into the slots. Other buttressing members are positioned between
each slotted side rail and a side of the carton to further support
the part, considering that the part is not perfectly
rectangular.
This particular package meets the standards set by Federal Express
and solves that company's concern over high damage incidence rates.
Furthermore, the protective package meets and exceeds International
Safe Transit Association ISTA (hereafter ISTA) standards for
testing by being drop tested from 30 inches to a hard surface,
which is in excess of the normal 12 inch drop test, and still
provides adequate protection. Such a protective package solves the
problems of damage to the hood, shipping distance limitations,
flexibility in type or size of hood that can be packed. The
aftermarket automobile repair industry is interested in this pack
due to its flexibility and wide application.
Referring now to FIG. 1 and FIG. 2, a package assembly 100 contains
a vehicle hood 110, using a hood packing assembly 120 in a sealed
shipping carton 300. Sealed shipping carton 300 is known in the
packaging industry as a regular slotted carton (hereafter RSC). The
inward direction 112 places hood 110 in the hood packing assembly
120.
Adding FIG. 3 to the consideration, all components of hood packing
assembly 120 and sealed shipping carton 300 are shown in
relationship to each other. Shipping carton 300 receives or has a
side rail 140 on either side of hood 110. In each side rail 140 are
mounted a corrugated rear insert 164 and a corrugated front insert
190. Oppositely disposed from the inserts and between the shipping
carton 300 and both of side rails 140 are medium spacer pads 148,
in order to further support hood 110.
With FIG. 4 and FIG. 5, the formation of side rail 140 is depicted
as starting with a scored flat corrugated piece of material being
folded to form side rail 140. More particularly, side rail 140 has
an outer side 204 and inner side 206. Outer side 204 is spaced from
each end of the flat corrugated piece of material. At one side of
outer side 204 is large top panel 210. Large top panel 210 extends
into larger inner panel 212, which forms part of inner side 206 and
is preferably substantially parallel to outer side 204. Larger
inner panel 212 extends into first slot side 214 and then into
second base side 216.
Likewise, small bottom panel 220 extends from outer side 204 and is
substantially perpendicular thereto. Small bottom panel 220 then
forms smaller inner panel 222. Smaller inner panel 222 extends into
second slot side 224 and then, in turn, to the first slot base 226.
Rail channel slot 228 thus formed receives hood 110 in a proper
fashion because slot 228, in this case, is not centered on inner
side 206.
Thus, there are two side rails 140 which are folded in mirror
fashion, and placed in shipping carton 300 (FIG. 2). These two side
rails 140 have rail channel slots 228 on their inner sides 202
facing one another, and an outer side 204 facing the shipping
carton 300.
With FIG. 6 and FIG. 7, the reinforcement of side rail 140 is
clarified. Adjacent to larger inner panel 212 in outer side 204 is
a large top swing brace panel 240 and a smaller top swing brace
panel 242 that swing and away from each other. Both top panels 240
and 242 have an upper rest lip 250, which contacts and rests
against inner panel 212. At the lower portion of outer side 204 are
larger bottom swing brace 244 and smaller bottom swing brace panel
246, both of which swing in, but away from each other. Both of
swing brace panels 244 and 246 have a rest lip 252, which contacts
and rests against inner panel 222. Both sets of swing brace panels
offer increased rigidity and strength without increasing the
overall weight of the package
So from outer side 204 of side rail 140 as the swing brace panels
are set, the structure adds strength, form and rigidity to the side
rail 140 and hence to the hood packing assembly 120. For further
support, a side foam spacer 150 may be added at or adjacent to one
end of the outer side 204. The side foam spacer 150 is in fact
preferred to be so located.
FIG. 8, FIG. 9 and FIG. 10 combine to illustrate some of the
variety of spacer pads which are used between the shipping carton
300 and the hood packing assembly 120. More particularly, thin
spacer pad 146 uses one pad block 152 on spacer support 154, while
medium spacer pad 148 has aligned pad blocks 152 on either side of
spacer support 154. Spacer support 154 is preferably a corrugated
sheet with a size capable of fitting between shipping carton 300
and outer side 144 (FIG. 35). Thick spacer pad 160 uses three of
pad block 152 by wrapping the end of spacer support 154 around one
pad block 152 and stacking the two other pad blocks 152 over and
under the first with spacer support 154 therebetween.
Additionally, hood 110 or other part is supported by corrugated
rear insert 164 as shown in FIG. 11, FIG. 12, FIG. 13, FIG. 14,
FIG. 15, FIG. 16 and FIG. 17. The rear die-cut flat 166 is folded
to form corrugated rear insert 164 and receive larger jaw angle cut
spacer 262 therein. Larger jaw angle cut foam spacer 168 has larger
hood slot 264 in the end thereof.
With both the front insert 190 and corrugated front insert 190, the
folding is preferably done first. Then the desired foam insert is
fit therein. Finally, the corrugated rear insert 164 and corrugated
front insert 190.
The rear die-cut flat 260 has a foldable tongue 266 in one side
thereof, which fits into larger hood slot 264. The folding process
for rear die-cut flat 166 at least partially encases larger jaw
angle cut foam spacer 168 therein as shown in FIG. 15. Staples 268
can secure the larger jaw angle cut spacer 168 therein. A
corrugated rear insert 164 is present in both of rail channel slot
228.
Furthermore, hood 110 or other part is also supported by corrugated
front insert 190 as shown in FIG. 18, FIG. 19, FIG. 20, FIG. 21,
FIG. 22 and FIG. 23. In FIG. 18 the corrugated front insert die-cut
flat 192 receives front foam support 272 in the form of rectangular
solid with front jaw slot 274.
Front insert die-cut flat 192 is formed into a front box 276 to
receive front foam support 272 and have inner jaw cover 278 secured
thereover. Then outer jaw cover 280 is secured over inner jaw cover
278. The front foam support 272 is then inserted adjacent to hood
110 in each rail channel slot 228. Front foam support 272 is
preferred because of its shock absorption qualities, but other
supports may be used.
FIG. 19 shows front foam support 272 laying on corrugated front
insert die-cut flat 192. FIG. 20 shows front foam support 272
wrapped in front insert die-cut flat 270. For front jaw slot 274,
the sequence of front insert die-cut flat 192 folding is first the
folding of front insert tongue 282 under both inner jaw cover 278
and outer jaw cover 280. FIG. 23 secures front insert back flaps
284 with staples 268.
Corrugated front insert 190 (FIG. 18) with front foam insert 194
can be used in place of rear die-cut flat 260 (FIG. 11) with rear
insert foam 168. The opposite is also true. In this manner, all
four inserts may be the same. If there is extra space in channel
slot 228, it can be filled in any desirable manner. A foam piece
(not shown) may be cut to fit. A corrugated piece may be rolled and
cut to fit.
By considering FIG. 24, FIG. 25, FIG. 26, FIG. 27, FIG. 28, FIG. 29
and FIG. 30, one may see the relationship of the shipping carton
300 and the hood packing assembly 120 in support of hood 110.
Shipping carton 300 is formed into a hollow, three-dimensional
rectangle with a rear closable end 308 oppositely disposed from a
front closable end 312. Two of side rail 140 are inserted in the
shipping carton 300 oppositely disposed from each other and
substantially perpendicular to both rear closable end 308 and front
closable end 312. Rail channel slot 228 in each of side rail 140
face each other within shipping carton 300, and space hood 110 or
other auto part a desired safe distance away from shipping carton
300.
In FIG. 26, corrugated rear insert 164 is secured to side rail 140
with staples 268 through rear insert tongue 290 into second base
side 216. In this fashion, proper positioning is obtained for the
corrugated rear insert 164.
Now FIG. 27 shows the ease of assembly for shipping carton 300.
Rear dust flaps 302 of shipping carton 300 are folded inwardly in
order to hold shipping carton 300 in proper shape. Then using FIG.
28, rear bottom flap 304 may be secured with staples 268 to rear
dust flaps 302. While rear bottom flap 304 is secured to dust flaps
302, rear top flap 310 is left free to assist with packing until
shipment or storage is desired.
After the shipping carton 300 is partially assembled as discussed
above, FIG. 29 shows the insertion two of side rail 140 therein on
both the left and right side. Then, as shown in FIG. 30, hood 110
is properly directed into shipping carton 300.
With rear top flap 310 left open, FIG. 31 can illustrate a person
102 reaching into the rear of shipping carton 300 pulling hood 110
back to rest in rear insert jaw 162 of corrugated rear insert 164.
A corrugated rear insert 164 is secured in both of side rails 140,
as shown in FIG. 32. Both of corrugated rear insert 164 are
adjacent to rear bottom flap 304 and within rail channel slot 228
(FIG. 31). Then as shown in FIG. 33 rear top flap 310 on fold over
carton 350 is secured with staples 268, thereby causing the
securing of fold over carton 350 with rear full flap assembly
360.
Turning now to FIG. 34 and FIG. 35, side rails 140 are pushed in
toward each other evenly in order to securely snug and anchor the
vehicle hood 110 in place. Then thin spacer pad 146 (FIG. 8),
medium spacer pad 148 (FIG. 9), or thick spacer pad 160 (FIG. 10)
may be inserted as in FIG. 35 on both the right and left side of
the shipping carton 300. The appropriate spacer pad is placed
between the side rail 140 and the shipping carton 300 on both the
right and left side of hood 110. Each spacer pad is pushed back
along side rail 140 to take up the open space there. Any remaining
length that may stick out beyond the side rail 140 can be folded
over the front of the side rail 140.
Now in FIG. 36 and FIG. 37, a corrugated front insert 190 may be
inserted into rail channel slot 228 of FIG. 34 and around hood 110.
Then the corrugated front insert 190 is, as shown in FIG. 35, is
secured to side rail 140 by staples 268 from stapler 340 or other
fastening device.
The final package completion for package assembly 100 as depicted
in FIG. 38 and FIG. 39 shows fold over carton 350. Fold over carton
350 is known in the industry as a Full Overlap carton (hereafter
FOL).
Full rear bottom flap 352, at least, almost completely, if not
fully, covers the rear of fold over carton 350. Fold over carton
350 is used to ship smaller implements, such as a smaller hood 110.
Full rear top flap 354 folds over full rear bottom flap 352 and
closes rear full flap assembly 360, because the end rear dust flaps
362 over each side rail 140 before either flap 352 or 354 is used.
Then, full rear bottom flap 352 is raised and full top rear flap
354 is lowered thereover. Front full flap assembly 370 is closed in
same way as rear full flap assembly 360.
Staples 268 secure the full front flap assembly 330 in a closed
position. Also, staples 268 secure side rails 140 through the top
of seamed shipping carton 300 or fold over carton 350. Thus, is
hood 110, even in a smaller version, secured appropriately for
transport.
While it is not desired to be bound by any particular theory, the
following postulate is offered for the success of this package
assembly 100. Seamed shipping carton 300 or fold over carton 350
support the side rails 140 with the swing brace panels 142, and the
corrugated rear inserts 164 and the corrugated front inserts 190
work together. Either the seamed shipping carton 300 or the fold
over carton 350 renders the part such as hood 110 contained therein
at least substantially immovable relative to the packing assembly
120. Then the blows to package 100 are absorbed thereby without
damage to the part contained therein.
This application--taken as a whole with the abstract,
specification, claims, and drawings being combined--provides
sufficient information for a person having ordinary skill in the
art to practice the invention as disclosed and claimed herein. Any
measures necessary to practice this invention are well within the
skill of a person having ordinary skill in this art after that
person has made a careful study of this disclosure.
Because of this disclosure and solely because of this disclosure,
modification of this method and device can become clear to a person
having ordinary skill in this particular art. Such modifications
are clearly covered by this disclosure.
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