Patent Application
20140353199
The present disclosure relates to a packaging system and method, and more particularly relates to an improved packaging system and method for shipping and handling of all types of doors, glass doors, doors with glass inserts, mirrors, framed art, etc.
Protective packaging is often used to protect products or articles from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile and/or valuable, it is often desirable to cushion the article inside a box to protect the article from a physical impact with the inner walls of the box that might be caused by shocks imparted to the box during loading, transit, unloading, etc.
Often times, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures can include paper or plastic packaging materials, structured plastic foams, foam-filled cushions, and the like. In some instances, the article to be packaged is suspended within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.
Items or articles that are sometimes shipped in this manner include doors, such as cabinet doors, which can be formed of glass or with glass inserts, mirrors, framed art, etc. One prior art shipping container includes a relatively thin rectangular box which receives the suspended shipping item between a pair of large foam sheets. Frame members can be disposed along upper and lower ends of the box and/or right and left side ends of the box. Typically the box requires the application of an adhesive, such as glue, at multiple locations to secure the box in a closed position with the product to be shipped interposed between the foam sheets within an opening defined by the frame members.
A major drawback of this type of shipping arrangement is the cost of materials required for each item to be shipped. Other drawbacks include increased shipping weight due to the large foam sheets and the frame members. Also, the item being shipped is prone to movement or migration within the box, particularly migration toward one of the ends (e.g., upper or lower ends) of the box. This can be reduced or eliminated by exact sizing of the box, the frame members and the foam sheets to correspond to the item being shipped, but then a large inventory of boxes, frame members and foam sheets is required to accommodate varying sizes of items being shipped.
As another issue, many cushioning packaging structures and techniques are designed in a manner that limits their use to single items. Although this is fine in many circumstances, in other situations similar items that are nevertheless of different sizes (e.g., two sizes of cabinet doors) require separate, differently sized containers and cushions. This increases complexity (and thus cost) and reduces packaging efficiency.
According to one aspect, an improved packaging method is provided for a product. More particularly, in accordance with this aspect, a shipping container appropriately sized for the product is provided. At least one shock absorption member is attached to the shipping container for serving as a locator for the product relative to the shipping container. The product is positioned on the shipping container with the at least one shock absorption member. At least another shock absorption member is attached to the shipping container to secure the product on the shipping container. The shipping container is closed about the product with the shock absorption members suspending the product within the enclosed shipping container.
According to another aspect, an improved packaging system is provided for a product. More particularly, and in accordance with this aspect, the packaging system includes a shipping container appropriately sized for the product and at least a first shock absorption member attached to the shipping container for serving as a locator for the product and for positioning the product on the shipping container. The packaging system further includes at least a second shock absorption member attached to the shipping container for, together with the at least a first shock absorption member, securing the product on the shipping container. The product is suspended by the at least a first shock absorption member and the at least a second shock absorption member within the shipping container when the shipping container is closed about the product for shipping.
According to still another aspect, an improved packaging method is provided for securing a product within a shipping container. More particularly, in accordance with this aspect, a first shock absorption clip is attached to the shipping container for positioning the product relative to the shipping container. The product is installed onto the shipping container. A second shock absorption clip is attached to the shipping container for securing the product relative to the shipping container. The shipping container is assembled about the product with the first and second shock absorption clips suspending the product within the shipping container.
In another aspect, the invention is the combination of a box; at least first and second planar objects in the box; and at least first and second shock absorbing (foam) clips attached to the planar objects in the box. At least one of the first clips is fastened to the first planar object and the clip is positioned between one wall of the box and the second planar object. A least one of the second clips is fastened to both planar objects and is positioned between opposite walls of the box.
In another aspect, the invention is a package precursor that includes a box blank; a first C-shape clip fixed on one panel of the box blank; and at least one E-shaped clip fixed on the same panel of the box blank. A first planar object is inserted into the E-shaped clip and the C-shape clip; and a second planar object is inserted into the E-shape clip and a second C-shape clip, with the second C-shape clip gripping the first planar object.
In another aspect, the invention is a cushioning clip formed of a resilient material. The cushioning clip has a base wall and three clamping walls oriented generally perpendicularly to the base wall. The clamping walls form two exterior clamping walls and one interior clamping wall and defining two gripping slots between the respective exterior clamping walls and the interior clamping wall. An adhesive strip is positioned along one of the exterior clamping walls immediately adjacent the base wall.
In yet another aspect, the invention is a packaging station. The packaging station includes an elevated horizontal work surface and a switch-based taping machine substantially coplanar with the work surface so that packages on the work surface can engage the switch without requiring lifting the packages from the work surface. A supply container is mounted on one edge of the horizontal work surface; and a tape dispenser is adjacent the supply container. Packages assembled on the horizontal work surface can include items from the supply container taped inside the packages and the exterior of packages can be taped by moving a package against the switch-based taping machine and without lifting the package.
The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the followed detailed description taken in conjunction with the accompanying drawings.
Referring now to the drawings, wherein the showing are for purposes of illustrating one or more exemplary embodiments,
In the illustrated embodiment, shock absorption member 14 is alone attached to the shipping container 10 for serving as the locator for the product 12 and for positioning the product 12 on the shipping container 10, and shock absorption member 16, along with shock absorption clips or members 18, 20, 22, 24, are attached to the shipping container 10 for securing the products 12 on the shipping container 10 together with the shock absorption member 14. That is, the shock absorption member 14 locates and positions the product 12 on the shipping container 10, while all of the illustrated shock absorption members 14-24 secure the product 12 on the shipping container 10. It will be appreciated by those skilled in the art that more than a single shock absorption member, such as member 14, can be used for locating the product 12 on the shipping container 10 and for positioning the product 12 on the shipping container 10. Likewise, the number of shock absorption members securing the product 12 on the shipping container 10 can vary from the illustrated embodiment (e.g., more or fewer shock absorption members can be used to secure the product 12 on the shipping container 10). As will be described in more detail below, and as best illustrated in
The shock absorption members 14-24 can be extruded polyethylene, though other materials could also be used. Structurally, all the shock absorption members can be similarly constructed; accordingly, only shock absorption member 14 will be described in further detail herein, but its description is applicable to the other shock absorption members 16-24. The shock absorption member 14 is attached to the shipping container by at least one adhesive strip. More specifically, and with specific reference to
As shown, the shock absorption member 14 includes a base wall 34 and a pair of clamping walls 36, 38 extending from spaced apart locations of the base wall 34 to form a slot 40 therebetween and into which the product 12 can be received for securement thereof. In the illustrated shock absorption member 14, the clamping walls 36, 38 converged toward one another as the walls 36, 38 extend away from the base wall 34. That is, the slot 40 defined between the converging walls 36, 38 is wider adjacent the base wall 34 than adjacent distal ends 36a, 38a of the converging walls. The first side 28 on which the first adhesive strip 26 is provided is defined by the clamping wall 36. Likewise, the second side 32 to which the second adhesive strip 30 is attached is defined by the clamping wall 38. As will be described in further detail below, the first adhesive strip 26 on the first side 28 allows the shock absorption member 14 to be attached to the shipping container 10, whereas the second adhesive strip 30 on the second side 32 allows the shipping container 10 to be attached to the shock absorption member 14 when the shipping container is folded into a box about the product 12. Each of the adhesive strips 26, 30 can have a peelable liner 42 disposed thereon to prevent the adhesive strips from inadvertently adhering to an undesirable object and/or location.
With additional reference to
As best shown in
The next step (S202) in the packaging method is to attach at least one or a first shock absorption member to the shipping container 10 for serving as a locator for the product 12 relative to the shipping container 10. In the illustrated embodiment, as shown in
In addition to attaching to shock absorption member 14 to the shipping container 10, one or more foam pads can be attached to the shipping container 10. Specifically, as shown in the illustrated embodiment, foam pads 70, 72 can be respectively attached at locations 84, 86 to the first and second main sections 50,52, which respectively form first and second sides of the box when the shipping container 10 is folded into its box form. As will be described in more detail below, the foam pads 70, 72 are positioned or interposed between the sides 50, 52 of the shipping container 10 and the product 12 carried within the shipping container 10. The foam pad 70, 72 can be formed by polyester foam, though this is not required.
Next, with reference to
With the product 12 positioned or installed on the shipping container 10, at least another or a second shock absorption member is attached to the shipping container 10 in step S206 for securing the product 12 relative to the shipping container 10. In the illustrated embodiment, with reference to
The steps S202 and S206 of attaching the shock absorption members 14-24 to the shipping container 10 can include removing the peelable liners 42 from the adhesive strips 26, 30 of the shock absorption members 14-24 and adhering each of the shock absorption members 14-24 to the shipping container 10 via the adhesive strips 26, 30. Adhering each of the shock absorption members 14-24 to the shipping container 10 can include installing each member 14-24 at respective locations 80, 88, 90, 92, 94, 96 on the shipping container. Specifically, as shown in
Similarly, before closing the shipping container 10 about the product 12, peelable liners 42 can be removed from the second adhesive strips 30 disposed on the second sides 32 of the shock absorption members 14-24 (S214). Accordingly, when the shipping container is closed or assembled about the product 12, the shipping container 10 is adhered to the shock absorption member 14-24 via their respective adhesive strips 30 (S216). When the shipping container 10 is folded into a box about the product 12 and adhered to the shock absorption members 14-24, the foam pad 70 rests against an upper surface of the product 12 and is interposed between the product 12 and the second main section 52 of the shipping container 10 forming the second side of the shipping container 10.
Closing the shipping container 10 in step S208 includes folding the shipping container 10 into a box about the product 12 with an inner surface of a first side (i.e., first main section 50) adhered to respective first sides 28 of the shock absorption members 14-24 and inner side of the second side of the box 10 (i.e., second main section 52) adhered to respective second sides 32 of the shock absorption members 16-24. Advantageously, the shipping container 10 includes at least one adhesive strip disposed thereon that adheres to another portion of the shipping container to maintain the shipping container in its box form. This allows the shipping container 10 and the packaging system and method disclosed herein to be used without further adhering products, such as glue, tape, etc.
In particular, adhesive strips 98 can be provided or disposed on the shipping container 10, particularly alongside tab 58 and end flaps 100,102 of the end tabs 60, 62 respectively. Peelable liners 104 can be provided over the adhesive strips 98 for preventing inadvertent adherence of the adhesive strips to an undesired object and/or location. This shipping container 10 and the adhesive strips 98 are particularly configured and/or oriented to permit ready folding and assembly of the shipping container 10 into a box as shown in
More specifically, the end flaps 60, 62 are first folded along the fold lines 106,108. Similarly, side tab 66 can be folded along folding line 110. Next the second main section 52 and the side tab 64 can be folded over about respective fold lines 112,114 with end tabs 54,56 and side tab 58 tucked inside corresponding tabs 60,62,66. The peelable liner 104 can be removed from adhesive strip 98 on side tab 58 and the adhesive strip 98 of side tab 58 can be adhered to the side tab 66. Then, peelable liner 104 can be removed from adhesive strip 98 on end flap 100; then, end flap 100 adhered via adhesive strip 98 to the second main section 52 on an outer side thereof as shown in
Similarly, as shown in
As used herein, the term “planar” is not limiting, but instead refers to three dimensional objects for which the area is significantly greater than the thickness. Such objects are often, but not always, rectangular in shape. The difference between the size of an object in different dimensions is referred to as the “aspect ratio.” In three dimensional items such as the planar objects described herein, the aspect ratio is still defined as the ratio of two of the three dimensions. For example, cabinet doors typically have an aspect ratio of at least 10:1, often at least 20:1, and sometimes 30:1 or greater. Stated differently, a cabinet door that is about 1 inch thick and 20 inches long on it's longest side has an aspect ratio of about 20:1.
Two types of shock absorbing polymer foam clips are attached to the planar objects 122 and 121 in the box 120. The first are the C-shape gripping clips illustrated in
Additionally, at least one (and preferably several) of the second E-shape clips 124 are fastened to both of the planar objects 121 and 122 and are positioned between the opposite walls 123 and 125 of the box 120.
As
If desired in some circumstances, the C-shape clips 20 can be made relatively thick so that they have a width (i.e., across-the-box) dimension substantially similar to the width of the E-shape clips.
The C-clips 20 and E-clips 124 are formed of a material that is compressible and resilient, typically polymer foam. Appropriate foams for the package are well understood in the art and can be selected by the skill person without undue experimentation. Exemplary polymers include polyurethane, polyolefin, polyvinylchloride, styrene, polyimides, and silicone.
The invention can accordingly be understood as a package precursor that includes the box blank 120, the C-shaped clip (or clips) 20 fixed on one panel (here 125) of the box blank 120, an E-shaped clip (preferably several) fixed on the same panel 125 of the box blank 120, and the planar objects 121 and 122. The first planar object 121 is inserted into at least one E-shape clip 124 and at least one C-shaped clip 20, and the second planar object 122 is inserted into at least one E-shaped clip 124 and a second C-shape clip with the second C-shape clip gripping the first planar object.
As
In most circumstances, the box 120 is formed of corrugated board because of its wide availability, appropriate cost, and well understood properties and strengths. Other materials could be incorporated, however, including combinations of board and polymer. An advantage of the invention, however, is that it provides a very secure cushioning package within a generally otherwise conventional corrugated board box.
As in earlier described embodiments, the box blank 120 can be assembled and closed using respective adhesive strips 136 (on end panel 127), 137 (on end panel 126), and 140 (on tab 133).
As further illustrated in
The term “box” is, of course, well understood in this and other arts, and generally refers to a six sided solid rectangle. This is the sense in which it is generally used herein. Formal geometry terms for such shapes include “orthotope” or “hyperrectangle.”
Each clip 124 includes a base wall 144 and three clamping walls 145146 and 147. The clamping walls are oriented generally perpendicularly to the base wall 144 and comprise two exterior clamping walls 145 and 147 and one interior clamping wall 146. These clamping walls define two gripping slots each numbered at 150 between the respective exterior clamping walls 145, 147 and the interior clamping wall 146. In other words, the gripping slots 150 are on either side of the interior wall 146.
The shape and orientation of the walls and the slots can be similar to those described with respect to the C-shaped embodiments 16, 18, 20, 22 and 24. The shape and relationship of the base wall 144 and the clamping walls 145, 146, 147 is such that the designation “E-shape” is a convenient and illustrative manner of referring to the clip.
The cushioning and gripping clip 124 also includes an adhesive strip 151 along at least one of the exterior clamping walls, and preferably both of the exterior clamping walls, immediately adjacent the base wall 144. Each of the adhesive strips 151 typically include a peelable release liner 152 covering the adhesive strip 151 which protects the adhesive from contacting anything other than an intended item until the clip 124 is ready for use. Adhesive strips of this type are well known in the art, and are typically formed of a material that will stick to the adhesive strip 151, but will either minimize or entirely avoid removing any of the adhesive as the release liner is removed. Release liner materials can be selected by those of skill in this art without undue experimentation. Appropriate adhesives suitable for joining both paper and polymer foam are generally well understood by persons of skill in this art and thus can be selected and used without undue experimentation.
As set forth with respect to the other illustrated embodiments, the cushioning gripping clip 124 is preferably formed of polymer foam, and the foam is typically selected from the group consisting of polyurethane, polyolefin, polyvinylchloride, styrene, polyimides, and silicone.
The foam is selected to have a desired density, and in some cases is selected to have as low a density as possible consistent with the required mechanical strength. Depending upon the application, the foam can have an open or closed cell structure. In this regard, in an “open cell” foam essentially all (i.e., at least about 90 per cent), of the cells are intercommunicating. Rigid foams may have varying density values and usually have a closed cell structure.
The packaging station 153 includes a horizontal work surface 154 elevated (i.e. with respect to a floor) on four legs, three of which are illustrated at 155, 156, and 157 in
A switch-based taping machine broadly designated at 155 is substantially coplanar with the work surface 154 so that packages on the work surface 154 can engage a switch 156 on the taping machine 155 without requiring lifting packages from the work surface 154.
Other than its specific orientation, the tape machine 155 can be a commercial device of which a number of choices are available to the skilled person without undue experimentation. Without going into unnecessary detail, a basic tape machine 155 will include an axle to hold a tape roll 157, the previously noted switch 156, a knife or functional equivalent to cut discrete portions of tape from the roll 157, and a motor to feed a cut piece of tape on to an adjacent package when the package bears against the switch 156.
A supply container 164 is mounted on one edge of the horizontal work surface 154. A second tape dispenser illustrated by the two rolls 165, 166 and the pulley 167 is adjacent the supply container 164 and typically is used to keep items being packaged convenient for the packaging station operator. In the context of (e.g.) cabinet doors or related furniture which will later be assembled into a larger structure, the supply container 164 typically holds a plurality of fasteners or small hardware items which in many circumstances are conveniently packaged in small sets in small plastic bags. Thus, when packaging items such as cabinet doors, the operator can quickly obtain a bag of parts from the supply container 164, apply tape from the rolls 165, 166, and tape the bag into a package being assembled on the work surface 154.
Although all of the functions of the packaging station 153 and the associated items illustrated in
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.
This is a continuation in part of Ser. No. 12/406,436 filed Mar. 18, 2009, and now U.S. Pat. No. 8,752,703.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12406436 | Mar 2009 | US |
| Child | 14305748 | US |
