Patent Application
20090057380
The present invention is directed to an extra strength packaging container. More particularly, the present invention pertains to a packaging container formed from a rigid U-shaped material having a reinforced base and corners to withstand stresses associated with lifting, dropping, or general handling of packaging containers.
U-shaped packaging containers, or U-board, are known packaging material for many objects. The board is formed from a layered, or laminated, construction of paper and/or paper board that is subsequently formed into a U-shape (U-shaped cross-section). The board generally is rigid; that is, the walls are rigidly formed into the U-shape (transverse relative to the base) and are rigid longitudinally along the length of the channel. The walls do not fold down onto the base, nor can the board, without more, be folded length-wise onto itself.
U-board is used for a wide variety of commonly packaged items. U-board can be used to package long, fragile items to prevent creasing or other damage that may be caused by dropping, bumping or general handling of the package. To prevent such damage requires that the corner strength of the packaging container be durable and of good integrity. In a common use, U-board is used for packaging doors and windows to protect the edges and corners of these items from damage due to bumping, dropping or general handling. The sides of the U-board that extend beyond the corners may be used for advertising.
While U-board has been used with a great deal of success for packaging such items, it would be desirable to further strengthen U-boards, particularly with regard to the base and the corners, which are subject to the greatest stresses during handling.
Accordingly, there is a need for extra strength, reinforced U-board. Desirably, such reinforcement minimizes the amount of additional materials and cost needed to reinforce the unit. More desirably, reinforcement of the U-board is readily made and usable, and has a high degree of integrity.
A U-board packaging container having a reinforced base and corners is fashioned from alternating layers of paper and/or paper board material of varying widths or strips, and laminating the strips into a board. Narrow strips of material are disposed between wider strips of material such that the narrow strips of material serve as a reinforcing material. The narrow strips of reinforcing material may or may not be the same material as the wider strips of material.
The laminated board is shaped into a rigid unit of generally U-shaped cross-section, creating an extra-strength U-board, having a main body portion with a generally flat bottom wall and upstanding, opposing side walls.
In a preferred embodiment, the reinforcing material layer extends across the bottom wall and at least partially up the side walls of the U-board to cover fully the bottom wall of the internal channel as well as the radius of curvature of the corners of the internal channel.
The U-board may be foldable to form an internal base channel and opposing internal side channels to create a protective package for an associated item, such as a window or a door.
These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.
The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated.
It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.
Referring now to the figures and in particular to
As shown in
As shown in
In manufacturing of an extra-strength U-board 10, one or more narrow strips of reinforcing material 12, is centered on the top of one or more strips of wider container material 14, of differing or of the same width, with an adhesive means placed between the two layers 12, 14. A strip or strips of container material 14 is centered on top of the previously laid narrower reinforcing strips 12. This alternating layered sequence is repeated until a sufficiently rigid board 10 is fashioned. Specifically, build-up of reinforcing material 12 in the center of the flattened board strengthens the bottom 16, bottom corners 20, and bottom edges 21 of the folded board 10. Reinforcing only the bottom wall 16 and the bottom corners 20 provides reinforcement only in the areas of the U-board likely to endure the greatest stresses in addition to reducing costs.
Fold lines F illustrate where the flattened extra-strength U-board can be folded to produce the U-shaped channel 22. Prior to the adhesive of the board 10 setting, the board 10 is bent or folded along fold lines F as shown in
The extra-strength U-board 10 is rigid, and accordingly, the walls 16, 18 are rigidly formed into the U-shape (transverse relative to the bottom wall 16) and are rigid longitudinally along the length l14 of the reinforced channel 22. In other words, the walls 18 do not fold down onto the bottom 16, nor can the reinforced channel 22 be readily folded, length-wise onto itself.
The extra-strength U-board 10 can be folded and positioned around the particular item D (as seen in
It will be appreciated that while the board container material 14 is typically a paper or paperboard-based material, the reinforcing material 12 can be a paper or paperboard-based material, a polymeric material (such as high-density polyethylene (HDPE), low density polyethylene (LDPE) or the like), or any other suitable material that can be inserted between the container material 14 layers in the desired formation (e.g., wet adhesive) process to provide the enhanced strength. It will also be appreciated that the reinforcing material layers 12 can be formed from whole or non-perforated material, perforated material, mesh-like material and the like, the later two having open areas. The mesh-like material, having open areas, can facilitate bonding by allowing communication of adhesive between layers of material 12, 14 and around the reinforcing material layers 12.
All patents referred to herein are hereby incorporated by reference, whether or not specifically referred to within the text of this disclosure.
In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.
From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.
