Appliance package and method therefor

Information

  • Patent Grant
  • 6578346
  • Patent Number
    6,578,346
  • Date Filed
    Wednesday, January 19, 2000
    24 years ago
  • Date Issued
    Tuesday, June 17, 2003
    21 years ago
Abstract
An appliance packaging assembly and method therefor, including a reinforced tray disposed under the appliance, a plurality of rigid posts disposed between the tray and alongside the appliance, a transparent film disposed about the posts and the appliance, a reinforced cover having a lifting flange member on a side portion thereof, the cover disposed over the plurality of wrapped posts and appliance, and tensioned strap disposed along side the posts and about the tray and cover and over the lifting flange member thereof.
Description




BACKGROUND OF THE INVENTION




The invention relates generally to packaging assemblies, and more particularly to transparent appliance packaging assemblies and methods therefor.




Presently, many appliances are packaged in full corrugated boxes after manufacture for shipping and handling. These appliances include among others refrigerators, freezers, laundry machines, ranges, dishwashers, water heaters, and vending machines. A commonly used full corrugated refrigerator package known as an Interlocking Flange Container (IFC), for example, comprises corrugated top and bottom caps interlockingly coupled to a corrugated tube by folding flaps, which are then secured by horizonal wire or strap disposed about the top and bottom caps.




Most manufacturers use interior packaging components including spacers and padding to varying degrees in connection with full corrugated packages to protect the appliance disposed therein, for example around the corners and handles thereof. Some industry shipping and packaging standards actually specify minimum dimensions for spacers between the container and appliance.




The IFC and other full corrugated packaging have many advantages including relatively quick assembly and high reliability. Many of these packages including the IFC packages may also be lifted and handled by a “Basiloid” spade or blade mounted on a lift truck. The Basiloid blade is a generally u-shaped member that may be hooked under the interlocking folded flaps of the top cap on a side portion of the container, and permits handling of the container without clamping or fork lifting. The Basiloid blade is used widely in the United States. In Europe however the Basiloid blade is not as well known, and most appliances are handled by clamp trucks, which grasp the container from opposing sides thereof.




Despite the advantages of IFC and other full corrugated packages discussed above, these packages prevent visual inspection of package contents without opening thereof. Visual inspection is highly desirable for product identification and assessment of damage that may occur during shipping. Full corrugated packages are also laborious to assemble, produce large amounts of waste, and are relatively costly.




More recently, transparent film type, or see-through, packaging has been proposed for appliances in an effort to reduce materials, labor and costs. U.S. Pat. No. 4,881,840 entitled “Appliance Shipping Container with Integral Corner Post”, for example, discloses a partially corrugated container wrapped with a transparent film. The container comprises corrugated side panels with die-cut windows disposed on corresponding opposing sides of the appliance. The corrugated side panels also have overlapping folded cover portions that are retained over an upper portion of the appliance by a band of horizontal strap disposed thereabout.




Transparent appliance packaging has the advantage that its contents can be visually inspected more readily in comparison to full corrugated packages, although visibility in known transparent packages suitable for heavier appliances is obstructed to some degree, for example by the opposing side panels disclosed in U.S. Pat. No. 4,881,840 discussed above. The packaging process for transparent appliance packaging may also be automated thereby reducing labor costs, although the initial capital investment is generally high. Known transparent appliance packaging has not been accepted widely by industry for its inability to accommodate heavier packaging applications, and for its relatively unproven performance.




Another known transparent appliance package comprises a reinforced frame having angled fiberboard corner posts which are screwed to wooden battens fastened to a bottom portion of the appliance. The appliance and posts are then wrapped in a transparent stretch film. After wrapping, a corrugated tray and cover are disposed under and over the wrapped appliance and posts. A wooden batten is subsequently disposed across an outer side portion of the cover and screwed to two of the posts for handling by a Basiloid blade. Finally, a horizonal strap is disposed about the cover and the wooden batten thereof for additional strength.




The present invention is drawn toward advancements in the art of package assemblies, and more particularly to transparent packaging assemblies and methods therefor.




An object of the invention is to provide novel packaging assemblies and methods therefor that overcome problems in the art.




Another object of the invention is to provide novel packaging assemblies and methods therefor that are improved over the prior art by providing any one or more of the following advantages, including among others, greater economy, improved strength suitable for heavier appliances, improved packaging protection, quick and easy assembly, improved product visibility, easy opening, and reduced waste.




Still another object of the invention is to provide novel packaging assemblies that may be lifted and handled by a Basiloid blade.




A more particular object of the invention is to provide novel packaging assemblies and methods therefor useable for appliances comprising generally a reinforced tray disposable under an appliance to be packaged, a plurality of posts disposable between the tray and alongside the appliance, a transparent film disposable about at least the posts and the appliance, a reinforced cover having a lifting flange member disposed over the plurality of wrapped posts and appliance, and strap disposed about the tray and cover and over the lifting flange member thereof.




Another more particular object of the invention is to provide novel packaging assemblies and methods therefor useable for appliances comprising generally a corrugated paperboard cover having folded side portions, and a lifting flange member disposed across an outer portion of one of the cover side portions. The lifting flange member having a reinforcing member extending from an inner portion of the cover. The lifting flange member is disposed across the outer portion of the corresponding side portion, and a portion of the cover is folded over the reinforcing member.











These and other objects, aspects, features and advantages of the present invention will become more fully apparent upon careful consideration of the following Detailed Description of the Invention and the accompanying Drawings, which may be disproportionate for ease of understanding, wherein like structure and steps are referenced generally by corresponding numerals and indicators.




BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a partial diagrammatic view of a packaging assembly according to an exemplary embodiment of the invention.





FIG. 2

is more complete partial diagrammatic view of the package assembly according o the exemplary embodiment of the invention.





FIG. 3

is perspective view of a complete package assembly according to the exemplary embodiment of the invention.





FIG. 4



a


is a partially assembled package.





FIG. 4



b


is a partial sectional view along lines b—b of

FIG. 4



a


of a fully assembled package.











DETAILED DESCRIPTION OF THE INVENTION





FIG. 1

is a partial exploded view of a packaging assembly


10


useable for packaging an appliance


20


, which in the exemplary embodiment is a refrigerator. More generally, however, the packaging assembly


10


and the packaging methods of the present invention are suitable for packaging most any appliance, especially heavier appliances, including among others freezers, laundry machines, ranges, dishwashers, water heaters, and vending machines. The packaging assembly of the present invention may also be used for packaging other articles besides appliances.




The packaging assembly


10


comprises generally a tray


30


having side portions


33


disposable under the appliance


20


to be packaged. The side portions


33


of the tray are sufficiently high to support posts


50


during assembly of the package


10


as discussed further below and preferably have a relatively low profile to avoid unnecessary visual obstruction of the packaged appliance. In the exemplary embodiment, the tray


30


is generally rectangular shaped and has a plurality of corners


32


defined by the side portions


33


thereof.




The tray


30


is formed preferably of a relatively low cost material, for example a corrugated paperboard material, although other non-corrugated and non-paperboard materials may be used alternatively. In the exemplary embodiment, the tray


30


and particularly the side portions


33


thereof are formed by folding a sheet of corrugated paperboard stock and fastening flap portions thereof with an adhesive or staples or interlocking flanges or other known means, including combinations thereof.




The tray


30


is preferably reinforced with one or more reinforcing members. In

FIG. 1

, two battens


40


, for example 1×4 wood runners, are disposed on an inner portion


34


of the tray


30


in spaced apart relation so that the battens


40


are located between the appliance


20


and the tray


30


. In one embodiment, each batten


40


is fastened to an underside portion of the appliance


20


, for example by two bolts


36


screwed into corresponding threaded openings of the appliance. The tray


30


is preferably fastened to the battens


40


with the same bolts


36


that fasten the battens


40


to the appliance


20


. The tray


30


may, however, be fastened to the battens


40


with staples or adhesive or other means. Alternatively, the battens


40


are not fastened to the appliance


20


, as preferred, and instead the appliance is merely positioned on the wood runners previously fastened to the tray


30


, which is later secured by a transparent film and tensioned strap as discussed below. In another alternative embodiment, the reinforced tray is formed entirely of a relatively rigid material without the battens.




The packaging assembly


10


also comprises a plurality of rigid posts


50


each having a first end portion


52


and an opposing second end portion


54


. The rigid posts are preferably fabricated from a relatively low cost, high strength material other than a corrugated paperboard material to support heavier loads characteristic of appliances. In the exemplary embodiment, the rigid posts


50


are angled corner posts having right angle sectional shapes for strength and in some applications to enclose the appliance when assembled with the package


10


, as discussed further below.




The posts


50


are preferably a laminated fiberboard material, for example a product known commercially as ANGLEBOARD or another product known commercially as CORNERBOARD, both of which are available from ITW Angleboard, Glenview, Ill. The high strength provided by these preferred products permits sizing or configuring the posts


50


with a relatively low profile to provide maximum product visibility, and at the same time provide a strong package suitable for relatively heavy appliances. The preferred ANGLEBOARD and CORNERBOARD products also have the advantage of being reusable, thereby producing less packaging waste after use.




After the tray


30


is placed below the appliance


20


, and in some applications fastened thereto, first end portions


52


of the posts


50


are disposed generally between the side portions


33


of the tray and the appliance


20


. In the exemplary embodiment, the angled corner posts


50


are disposed in corresponding corners


32


of the tray


30


between side portions


33


thereof and the appliance


20


. The tray


30


is sized relative to the appliance


20


so that the posts


50


are supported at least temporarily in a generally upright position adjacent the appliance without other means until a transparent film is applied thereabout, as discussed further below.





FIG. 1

illustrates padding members


60


preferably disposed between the appliance


20


and posts


50


and on an upper portion


21


of the appliance


20


. In some applications, a specified amount of padding between the appliance and packaging assembly is required, for example to comply with industry shipping and packing standards. In other applications, however, the padding members are not necessary, and thus not necessarily a part of the package assembly.





FIG. 1

illustrates some of the padding members formed as right angle-shaped members


62


that are mounted on inner portions of the angled corner posts


50


so that the padding members are disposable toward the appliance


20


about corner portions thereof. The padding members are preferably fastened to the posts, for example with an adhesive prior to assembly of the posts in the tray.

FIG. 1

also illustrates some of the padding members configured as recessed padding members


64


similarly mounted to other posts to accommodate a handle


21


or other protruding portions of the appliance


20


.

FIG. 1

also illustrates strip padding members


63


removably disposable on the upper portion


21


of the appliance


20


, for example with tape. The padding members may be, for example, an expanded polystyrene or poly-foam or other shock absorbing material.





FIG. 2

illustrates a transparent wrapping or film


70


disposed tightly about at least the posts


50


and the appliance


20


after assembly of the posts


50


in the tray


30


as discussed above and illustrated in FIG.


1


. The transparent film


70


is also disposed preferably over the strip padding members


63


on the upper portion


21


of the appliance


20


, and about the side portions


33


of the tray


30


. The transparent film


70


retains the posts


50


and any padding members


60


fastened thereto firmly about the appliance


20


, and retains the tray


30


coupled to the posts


50


if the tray is not fastened directly to the bottom portion of the appliance. The transparent film


70


may also retain strip the padding members


63


on the upper portion of the appliance. The low profile, high strength posts


50


in combination with the tightly wrapped transparent film


70


provide excellent packaging strength and vastly improve product visibility.




The transparent film


70


is preferably a heat shrinkable bag disposed over and covering the upper and side portions of the appliance


20


and posts


50


, and preferably over the side portions


33


of the tray


30


. The heat shrinkable bag is then shrunk tightly thereabout upon application of heat. Heat srinkable bags suitable for this purpose are known generally and widely available commercially. The application of the heat shrinkable bag may be performed relatively quickly with minimum labor.




The transparent material


70


may be alternatively a stretch film applied about the posts


50


, appliance


20


and preferably the tray


30


. Stretch films may be applied manually or by automated machinery, for example with a spiral or other wrapping machine.





FIG. 2

also illustrates the packaging assembly


10


comprising a cover


80


disposable over the appliance


20


and over second end portions


54


of the posts


50


. The cover


80


generally has the same shape as the tray


30


, and in the exemplary embodiment the cover


80


is rectangular shaped with a plurality of corners


82


defined by corresponding side portions


83


thereof. The cover


80


is formed preferably of the same materials discussed above in connection with the tray


30


.




The cover


80


is also preferably reinforced. In

FIG. 4



a


, two battens


40


, for example 1×4 wood runners, are disposed on an inner portion of the cover


80


in spaced apart relation so that the battens are located between the appliance


20


and the cover


80


, as discussed generally above in connection with the tray


30


. The battens


40


are preferably fastened to the cover


80


with staples or adhesive or other means before the cover is placed over the wrapped appliance


20


and posts


50


. In another alternative embodiment, the reinforced cover is formed entirely of a relatively rigid material without the battens, also discussed above regarding the tray.




The cover


80


is placed generally over the appliance


20


on the tray


30


after the transparent film


70


has been applied thereabout and about the posts


50


and any padding members


60


, as discussed above, so that the second end portion


54


of each wrapped post


50


is disposed between the side portion


83


of the cover


80


and the wrapped appliance


20


. In the exemplary embodiment, the corners


82


of the cover


80


are aligned with the corners


32


of the tray


30


when the cover


80


is disposed over the wrapped appliance


20


and posts


50


so that the second end portions


54


of the angled corner posts


50


are disposed in corresponding corners


82


of the cover


80


.





FIGS. 2

,


3


and


4




b


illustrate the cover


80


having a lifting flange member


86


disposed across at least one side thereof. The lifting flange member


86


is engagable by a Basiloid blade to permit lifting and handling of the packaged appliance when the cover


80


is fastened to the package assembly as discussed further below. In other embodiments, the cover


80


may have lifting flange members


86


disposed across more than one side thereof. In the exemplary refrigerator packaging application, the lifting flange member


86


is located preferably on a back side portion of the refrigerator to prevent damage thereto during Basiloid blade lifting and handling. In embodiments where the cover


80


is a corrugated paperboard material, the corrugation direction is preferably arranged transversely to the lifting flange member


86


for strength.





FIGS. 1 and 2

also illustrate a lift padding member


66


located opposite the lifting flange member


86


when the cover


80


is place over the wrapped appliance


20


and posts


50


to further protect the appliance


20


during Basiloid blade lifting and handling. The lift padding member


66


may be taped or otherwise removably fastened to the appliance prior to wrapping the transparent film


70


thereabout. The lift padding member


66


is also preferably made from the same materials as the other padding members


60


, as discussed above.




The lifting flange member


86


of the cover is defined preferably by a portion of the cover folded over a portion of a reinforcing member extending from an inner portion of the cover, as illustrated in

FIGS. 4



a


and


4




b


. The reinforcing member is preferably fabricated from a relatively low cost, high strength material other than corrugated paperboard to permit Basiloid blade lifting thereof. In the exemplary embodiment, the reinforcing member is an angled corner member


90


, formed for example from a laminated fiberboard material, preferably one of the products known commercially as ANGLEBOARD and CORNERBOARD available from ITW Angleboard, Glenview, Ill., as discussed above.




In the exemplary embodiment of

FIGS. 4



a


and


4




b


, the cover


80


is formed of a corrugated paperboard or other similarly workable sheet stock. The cover


80


comprises generally a cover portion having an inner and outer portions


84


and


85


, and side portions


83


formed by folding portions of the sheet stock and fastening flap portions


79


thereof, as discussed generally above.

FIGS. 4



a


and


4




b


also illustrates battens


40


disposed on the inner portion


84


of the cover


80


.




The lifting flange member


86


is disposed across an outer portion of a side portion


87


of the cover


80


. The lifting flange member


86


includes preferably a first portion


92


of the angled corner member


90


disposed along, and preferably fastened by an adhesive or otherwise to, the inner portion


84


of the cover. A second portion


94


of the angled corner member


90


extends from the inner portion


84


of the cover


80


and is disposed across an outer portion


88


of the cover side portion


87


.

FIG. 4



b


illustrates a portion of the cover


80


folded over the second portion


94


of the angled corner member


90


. A Basiloid blade is disposable between the covered second portion


94


of the angled corner member


90


and the outer portion


88


of the cover side portion


87


to lift the packaged appliance when the cover


80


is secured to the package as discussed further below. In

FIG. 4



b


, one of the battens


40


is shown having a recess


41


for accommodating a portion of the angled corner member


90


.




In

FIG. 4



b


, the portion of the cover


80


folded over the reinforcing member


90


is preferably a continuous member having a first portion


81


extending continuously from the cover


80


along a first side


95


of the second portion


94


of the angled corner member


90


, and a second portion


85


extending therefrom continuously back toward the cover


80


along an opposing second side


96


of the second portion


94


of the angled corner member


90


. The side portion


87


of the cover


80


also extends preferably continuously from the second portion


85


thereof.





FIG. 3

illustrates strap applied about the tray


30


and cover


80


and over the lifting flange member


86


, upon assembly of the package portions illustrated in

FIGS. 1 and 2

. The strap preferably comprises two separate bands of tensioned strap


100


and


101


each disposed about the tray


30


, the cover


50


, along opposing posts


50


and over a corresponding portion of the lifting flange member


86


. The bands of tensioned strap


100


and


101


are also disposed preferably about reinforced portions of the tray


30


and the cover


80


, and in the exemplary embodiment the straps are disposed about outer portions of the tray and cover opposite the corresponding battens


40


disposed therein. Thus configured, the packaging assembly may be lifted and handled upon engagement of the lifting flange member


86


by a Basiloid blade. The packaging assembly may also be lifted and handled by a clamp truck.




While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific exemplary embodiments herein. The invention is therefore to be limited not by the exemplary embodiments herein, but by all embodiments within the scope and spirit of the appended claims.



Claims
  • 1. A packaging assembly useable for packaging an appliance, comprising:a tray disposable under an appliance to be packaged, a plurality of rigid posts each having a first end portion disposed in the tray, each post disposable alongside the appliance to be packaged and having an opposing second end portion; a transparent film disposed about the plurality of posts; a cover disposed over the second end portion of the plurality of wrapped posts, the cover having a lifting flange member having a discrete reinforcing member arranged across at least one side of the cover; strap applied about the posts, the cover and the tray, the strap disposed over the lifting flange member of the cover and the discrete reinforcing member.
  • 2. The packaging assembly of claim 1, the strap is two separate bands of tensioned strap disposed about the tray and the cover, each band of tensioned strap disposed along corresponding opposing posts and over a corresponding portion of the lifting flange member.
  • 3. The packaging assembly of claim 2, the posts are angled corner posts, the tray and cover each having a plurality of corners, the first and second end portions of the angled corner posts are disposed in corresponding corners of the tray and cover.
  • 4. The packaging assembly of claim 3, the tray and cover are each formed of a corrugated paperboard material and are each reinforced with battens disposed on inner portions thereof in spaced apart relation, each band of tensioned strap disposed about outer portions of the tray and cover opposite a corresponding one of the battens.
  • 5. The packaging assembly of claim 1 further comprising a lift padding member located opposite the lifting flange member of the cover.
  • 6. The packaging assembly of claim 1 further comprising padding members fastened to inner portions of the posts and cover, and padding members disposable on an upper portion of the appliance to be packaged.
  • 7. The packaging assembly of claim 1, the transparent film is a thermally shrinkable transparent bag disposed over and around the posts.
  • 8. The packaging assembly of claim 1, the posts are angled corner posts made from fiberboard material.
  • 9. The packaging assembly of claim 1, the cover is a corrugated paperboard material, the lifting flange member of the cover is defined by a side portion of the cover folded over a portion of a reinforcing member extending from an inner portion of the cover.
  • 10. A method of packaging an appliance, comprising:placing the appliance on a reinforced tray; positioning a plurality of rigid angled comer posts along side the appliance and disposing a first end portion of each post between the appliance and the tray; covering at least side portions of the appliance and the plurality of posts with a transparent film; placing a reinforced cover over the appliance and disposing a second end portion of each wrapped post between the appliance and the cover, the cover having a lifting flange member with a discrete reinforcing member, the lifting flange member and the discrete reinforcing member thereof disposed across a side of the cover; applying strap about the cover and the tray and alongside the posts, the strap disposed over the lifting flange member and the discrete reinforcing member of the cover.
  • 11. The method of claim 10 further comprising applying two separate tensioned straps about reinforced portions of the tray and the cover, each tensioned strap disposed along opposing posts and over a corresponding portion of the tray and cover and over the lifting flange member of the cover.
  • 12. The method of claim 10 further comprising disposing a lift padding member between the appliance and the lifting flange member of the cover.
  • 13. The method of claim 10 further comprising disposing padding members between the appliance and portions of the plurality of posts and cover before covering with the transparent film.
  • 14. The method of claim 10 further comprising disposing a transparent bag over the appliance, posts, and at least a portion of the tray, and heat shrinking the transparent bag to form the transparent film.
  • 15. The method of claim 10 further comprising fastening two battens to an underside portion of the appliance to reinforce the tray, the tray is a corrugated paperboard material and is disposed under the battens.
  • 16. The method of claim 15 further comprising fastening the corrugated paperboard tray and the battens to the underside of the appliance.
  • 17. The method of claim 10, the cover is a corrugated paperboard material, further comprising forming the lifting flange member of the cover by folding a portion of the cover over a portion of the discrete reinforcing member extending from an inner portion of the cover and along an outer side portion thereof before placing the cover over the appliance.
  • 18. A packaging assembly, comprising:a cover having a lifting flange member with a reinforcing member arranged across at least one side thereof; a tray disposed in substantially parallel spaced apart relation relative to the cover; a plurality of posts extending between the tray and the cover, each of the plurality of posts having a first end portion disposed toward the tray and an opposite end portion disposed toward the cover; a first strap applied about the cover and the tray, the first strap extending substantially parallel to the plurality of posts, the first strap disposed over the lifting flange member and over the reinforcing member of the cover.
  • 19. The packaging assembly of claim 18, a second strap applied about the cover and the tray, the second strap extending substantially parallel to the plurality of posts, the second strap disposed over the lifting flange member of the cover, the reinforcing member is captured by a flap portion of the cover.
CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a divisional continuation of co-pending U.S. application Ser. No. 09/239,657, filed on Jan 29, 1999, entitled “Appliance Package and Method Therefor.”

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5909808 Bartholomew Jun 1999 A
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Entry
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