This disclosure relates to a system and process for packing a large item for shipping and storage, and more particularly to a packing structure and a method for packing a large item for shipping or storage.
Everyday thousands of large items, such as, e.g., articles of furniture, home appliances, musical instruments, etc., are being packed and shipped from factories, warehouses and retailers to nearby or remote locations by truck, ship, airplane and the like. These large items are typically packed using several foam pieces and one or more corrugated boxes. This typical packing approach does not sufficiently protect the packaged items from the hazards of shipping/storage, such as, e.g., shock, vibration, compression, moisture, and the like. Further, the current packing approaches allow the items to move inside the packing. The shortcomings of these packing approaches have resulted in a large and growing amount of damage to the packaged items during transport or storage. Accordingly, there is a need for an improved packing structure and packing method.
According to an aspect of the disclosure, a packing structure include a lower tray that covers a bottom portion of an item; an upper tray that covers a top portion of the item; a plurality of impact-dampening pieces that are placed on an exterior surface of the item and a transparent cover that covers the lower tray, the upper tray and the plurality of impact-dampening pieces, wherein the exterior surface of the item is visible from outside the packing structure.
The impact-dampening piece may include a polystyrene foam piece. The impact-dampening piece may further include a fabric layer placed between the polystyrene foam piece and the exterior surface of the item. The fabric layer may be a fabric pocket that contains the polystyrene foam piece.
The upper tray and the lower tray may include corrugated fiberboard. The lower tray may include a bottom wall and a plurality of sidewalk extending upwardly from edges of the bottom wall, and the upper tray may include a top wall and a plurality of sidewalk extending downwardly from edges of the top wall. The bottom wall of the lower tray and the top wall of the upper tray may have substantially the same shape and size. One or more of the plurality of impact-dampening pieces may be placed on the tower tray and the upper tray.
The plurality of impact-dampening pieces may include a corner piece that extends vertically along a side corner of the item. The corner piece may extend between the lower tray and the upper tray. The plurality of impact dampening pieces may further include at least one of a horizontal crossbar that may extend between two of the corner pieces; and a vertical crossbar that may extend between the tower tray and the upper tray.
The plurality of impact-dampening pieces may include a lower corner piece that is placed on a corner of the lower tray and extends upwardly to cover a lower portion of a side corner of the item; and an upper corner piece that is placed on a corner of the upper tray and extends downwardly to over an upper portion of the side corner of the item.
The transparent cover may be a single piece comprising an opening. The transparent cover may provide a vertical compression force that pushes the lower tray and the upper tray towards each other and a horizontal compression force that pushes the impact-dampening pieces placed on side exterior surfaces of the item inwardly.
According to another aspect of the disclosure, a method of packing an item includes placing the item on a lower tray to cover a bottom portion of the item; placing a plurality of impact-dampening pieces on portions of an exterior surface of the item; placing an upper tray on the item to cover a top portion of the item; and covering the lower tray, the upper tray and the plurality of impact-dampening pieces with a transparent cover.
The method may further include placing a plurality of impact-dampening pieces on the lower tray and the upper tray. The plurality of impact-dampening pieces may include at least one of a corner piece that covers a side corner of the item; and a vertical piece that covers a side surface of the item, wherein the corner piece and the vertical piece may extend between the lower tray and the upper tray.
The method may further include at least one of placing a horizontal crossbar that may extend between two corner pieces; and placing a vertical crossbar that may extend between the lower tray and the upper tray.
The transparent cover may be a single piece including an opening. The covering with the transparent cover may include stretching the transparent cover to enlarge the opening; inserting the upper tray, the lower tray and the plurality of impact-dampening members inside the stretched cover via the enlarged opening; and allowing the transparent cover to shrink and compress the upper tray, the lower tray and the plurality of impact-dampening members, wherein the transparent cover may provide a vertical compression force that may push the lower tray and the upper tray towards each other and a horizontal compression force that may push the in pact-dampening pieces placed on side exterior surfaces of the item inwardly.
Additional features, advantages, and embodiments of the disclosure may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure as claimed.
The accompanying drawings, which are included to provide a further understanding of the disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the detailed description serve to explain the principles of the disclosure. No attempt is made to show structural details of the disclosure in more detail than may be necessary for a fundamental understanding of the disclosure and the various was in which it may be practiced.
The embodiments of the disclosure and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the embodiments of the disclosure. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the disclosure, which is defined solely by the appended claims and applicable law. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
The disclosure describes a packing structure and packing method that may be used for packing a large item for shipment or storage. Particularly, the packing structure and method described in this disclosure may be used with articles of furniture that vary widely in size, shape and/or weight. The article may be boxy pieces (e.g., dressers, nightstands, etc.) or flat pieces (e.g., mirrors, headboards, etc.). Additional furniture types may include, without limitation, beds, bunk beds, cribs, case goods, mirrors, accessories, and the like.
The bottom wall of the lower tray 210A and the top wall of the upper tray 210B may have the same shape and size. For example, the bottom wall of the lower tray 210A and the top wall of the upper tray 210B may have the same rectangular shape and size, as seen in
The impact-dampening pieces may be strategically placed on various portions of the exterior surface of the dresser 100 to protect the dresser 100 from impact, shock, vibration, and the like, to the dresser 100 and prevent the dresser 100 from moving within the packing structure 200A. Further, the impact-dampening pieces may be shaped and arranged strategically in the packing structure 200A to provide a clear view of the dresser 100 while providing sufficient protection to the dresser 100 without compromising the structural integrity of the packing structure 100. Such a clear view may be advantageous for marketing and display purposes. In addition, shipping and handling personnel may be more likely to take additional care and caution when they can see the dresser 100, as opposed to simply dealing with a large and heavy cardboard box. The impact-dampening pieces may be formed of a material that is structurally strong, easy to shape, light and inexpensive. For example, the impact-dampening pieces may be formed of polystyrene foam or other materials having similar characteristics. The impact-dampening pieces may be covered by a layer of soft material, such as, e.g., fabric, plastic, or the like, since, during transport, the impact-dampening pieces may scratch or damage the exterior surface of the dresser 100. In an embodiment, the impact-dampening piece may be a fabric pocket that contains a polystyrene foam piece.
Referring to
Additional impact-dampening pieces may be used to cover other portions of the dresser 100. For example, the packing structure 200A may further include one or more vertical pieces 222. One of the vertical pieces 222 may be arranged between the corner pieces 220A and 220B on the front side surface 130A of the dresser 100 as shown in
The combination of the trays 210 and the impact-dampening pieces may be covered by the transparent cover 250. The transparent cover 250 may be pre-fabricated to fit the packing structure 200A. The transparent cover 250 may be applied to the packing structure 200A using a stretch hood wrapping machine (shown in
Once the dresser 100 is placed on the lower tray 210A (at 530), a plurality of impact-dampening pieces may be strategically placed on the exterior surface of the dresser 100. For example, as shown in
After the upper tray 210B is placed on the dresser 100 (at 560), the packing structure 200A may be wrapped by the transparent cover 250 (at 570). For example, the packing structure 200A may be moved below a stretch hood wrapping machine 600 shown in
The packing structures 200A, 200B and 200C described in
The packing process 500 described in
A “computer”, as used in this disclosure, means any machine, device, circuit, component, or module, or any system of machines, devices, circuits, components, modules, or the like, which are capable of manipulating data according to one or more instructions, such as, for example, without limitation, a processor, a microprocessor, a central processing unit, a general purpose computer, a super computer, a personal computer, a laptop computer, a palmtop computer, a notebook computer, a desktop computer, a workstation computer, a server, or the like, or an array of processors, microprocessors, central processing units, general purpose computers, super computers, personal computers, laptop computers, palmtop computers, notebook computers, desktop computers, workstation computers, servers, or the like. Further, the computer may include an electronic device configured to communicate over a communication link. The electronic device may include, for example, but is not limited to, a mobile telephone, a personal data assistant (PDA), a mobile computer, a stationary computer, a smart phone, mobile station, user equipment, or the like.
The terms “including”, “comprising” and variations thereof, as used in this disclosure, mean “including, but not limited to”, unless expressly specified otherwise.
The terms “a”, “an”, and “the”, as used in this disclosure, means “one or more”, unless expressly specified otherwise.
Devices that are in communication with each other need not be in continuous communication with each other, unless expressly specified otherwise. In addition, devices that are in communication with each other may communicate directly or indirectly through one or more intermediaries.
Although process steps, method steps, algorithms, or the like, may be described in a sequential order, such processes, methods and algorithms may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described does not necessarily indicate a requirement that the steps be performed in that order. The steps of the processes, methods or algorithms described herein may be performed in any order practical. Further, some steps may be performed simultaneously.
When a single device or article is described herein, it will be readily apparent that more than one device or article may be used in place of a single device or article. Similarly, where more than one device or article is described herein, it will be readily apparent that a single device or article may be used in place of the more than one device or article. The functionality or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality or features.
A “computer-readable medium”, as used in this disclosure, means any medium that participates in providing data (for example, instructions) which may be read by a computer. Such a medium may take many forms, including non-volatile media, volatile media, and transmission media. Non-volatile media may include, for example, optical or magnetic disks and other persistent memory. Volatile media may include dynamic random access memory (DRAM). Transmission media may include coaxial cables, copper wire and fiber optics, including the wires that comprise a system bus coupled to the processor. Transmission media may include or convey acoustic waves, light waves and electromagnetic emissions, such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with pieces of holes, a RAM, a MOM, an EPROM, a FLASH-EEPROM, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
Various forms of computer readable media may be involved in carrying sequences of instructions to a computer. For example, sequences of instruction (i) may be delivered from a RAM to a processor, (ii) may be carried over a wireless transmission medium, and/or (iii) may be formatted according to numerous formats, standards or protocols, including, for example, WiFi, WiMAX, IEEE 802.11, DECT, 0G, 1G, 2G, 3G, 4G or 5G cellular standards, Bluetooth, or the like.
While the disclosure has been described in terms of exemplary embodiments, those skilled in the art will recognize that the disclosure can be practiced with modifications in the spirit and scope of the appended claims. These examples given above are merely illustrative and are not meant to be an exhaustive list of all possible designs, embodiments, applications or modifications of the disclosure.
This application claims the benefit from U.S. Provisional Application No. 61/391,394 filed on Oct. 8, 2011, which is hereby incorporated herein by reference for all purposes as if fully set forth herein.
Number | Date | Country | |
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61391394 | Oct 2010 | US |