Claims
- 1. A container for a door installation kit that includes a standard size door and a plurality of jambs, some of which are at least as tall as said door, the container comprising:
- A bottom piece, made of a foldable sheet material, said bottom piece sized so that it may be folded to envelope the bottom end of the door, said bottom piece having a front edte, back edge, and two side edges, wherein said side edges each have a pre-cut tab, and tab insert, said bottom piece having a bottom spacer flap extending from said front edge, said bottom spacer flap being foldable to form an L-shaped spacer, said spacer having a plurality of cut-out portions that are sized to allow said door jambs to be inserted therein in an upright position;
- A top piece, made of foldable sheet material, said top piece sized so that it may be folded to envelope a top end of said door, said top piece having a front edge, back edge and two side edges, wherein said side edges each have a pre-cut tab and insert.
- 2. The container of claim 1, wherein said bottom piece and said top piece each have two parallel longitudinal creases to facilitate folding, said creases extending across said top and said bottom piece, the space between such parallel creases being approximately the thickness of the door.
- 3. The container of claim 1, wherein said top piece has cut-out portions to allow the door jambs to extend through said top piece, thereby locating and securing the door jambs.
- 4. The container of claim 3, wherein said top piece has a top spacer flap extending from the front side thereof, said top spacer flap being foldable to form and L-shaped spacer that may be inserted between said door and said top piece.
- 5. A container for a package door unit that includes a door and jambs, which are at least as tall as said door, and one or more shorter door unit parts, which are approximat half as high as said door, comprising:
- A bottom piece made of foldable sheet material, such as cardboard, said bottom piece being of sufficiently dimensions so that it may be folded to envelope a bottom end of said door, said bottom piece having a front edge, a a back edge and two side edges, wherein said side edges each have a tab and tab insert, said bottom piece having a bottom spacer flap extending from said front edte, said bottom spacer flap being foldable to form a L-shaped spacer that may be inserted betgween said door and said bottom piece, said spacer having cut-out portions that are of sufficient size to allow said door jambs to be inserted therein in an upright position;
- A top piece, made of foldable sheet material such as cardboard, siad top piece being of sufficient dimensions so that it may be folded to envelope a top end of said door, said top piece having a front edge, back edge and two side edges, wherein said side edges each have a tab and tab insert, said top piece having a top spacer flap extending from the front side thereof, said top spacer flap being foldable to form an L-shaped spacer that may be inserted between said door and said top piece;
- A middle piece made of foldable sheet material such as cardboard, said middle piece being of sufficient width to allow with middle piece to extend across the door unit to be packaged, said middle piece having a front and back side, said back side having extending position tabs at convenient locations to secure said door unit parts, and said middle piece having side tabs which are folded into L-shaped positions for cushioning between the door and door jambs;
- whereby said tabs of said top piece and said bottom piece are capable of being inserted and locked into the respective tab inserts to form said top piece and said bottom piece into boxes for containing the door and the door unit parts.
- 6. The container of claim 5, wherein said middle piece has a middle spacer flap extending from said front side, said middle spacer flap being foldable to form an L-shaped spacer that may be inserted between said door and the top of said door unit part.
REFERENCE OF PRIOR PATENTS:
This application is a continuation-in-part of application Ser. No. 07/047,623, filed May 7, 1987, now U.S. Pat. No. 4,884,687 which is incorporated herein in its entirety.
1. Field of the Invention:
The present invention generally relates to the field of Packaging, Shipping, and Product Display of Door Units. In particular, it relates to a door installation kit such as may be used for homes and offices. These door kits contain a number of parts necessary for on-site installation, such as the door, a hinge jamb, a strike jamb, a head jamb, a sill, a sweep, molding, and installation strips. The invention consists of a special container that allows the component parts of the kit to be conveniently packaged, displayed and transported.
2. Description of the Prior Art:
A standard method of packaging and shipping doors and other flat ridged articles is to package and ship them in bundles containing a number of such articles. Several types of packaging units are disclosed in the parent application (Ser. No. 07/047,623) of this Continuation-In-Part Application.
The primary objective of the present invention is to provide a packaging unit to securely transpot and store a complete door installation kit as a unit without damaging the numerous different parts of the door installation kit. The invention provides a means for each door kit to be packaged in a manner such that the various parts will not rattle or rub against each other during storage and transportation.
Furthermore, effective marketing of the door installation kits requires that the aesthetic features of the door itself be visible to prospective purchasers. Thus, another important objective of the invention is to provide a means for packaging complete door installation kits while attractively displaying the door. Other important features of the door unit packaging are that it be light-weight, inexpensive and easy to disassemble.
Past methods of storing and packaging door kits used staples or glue to assemble the door container. However, the use of staples may result in visible damage, as the staples go through the container and into the door and door parts. Although the staples and holes are not visible when the door is installed, potential customers may not realize this and may hesitate in buying the door kit. Using glue to assemble the containers is messy, as glue will ooze out to the sides resulting in an unattractive appearance. Thus, the use of staples or glue to form the containers may deter potential customers from buying the packaged door units. Therefore, it is necessary to improve the present method of assembly so that a neat, attractive appearance is achieved.
The foregoing objectives are achieved in an improved method for assembling a door unit installation kit, together with a container that allows the kit to be conveniently packaged, stored, transported and displayed. The kit includes a door, jambs, and other parts designed for door installation, regardless if it is a left or right-handed door, or inward or outward opening door. The container is characterized by at least a cardboard top piece and a cardboard bottom piece that holds these kit parts together. The cardboar pieces are foldable and are placed under and around the kit parts, and have cut-out portions at appropriate locations to hold the component parts of the kit securely in place. The container is assembled by folding and inserting tabs into locking inserts in the container pieces, and placing the kit parts therein.
US Referenced Citations (13)
Continuation in Parts (1)
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47623 |
May 1987 |
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Patent Grant
4967905
