A packed roof window product comprising a plurality of differently sized roof window related product components accommodated in a box, wherein the box in a supply condition has a bottom side and a top side, which bottom side and top side are spaced apart along a height axis, and side walls of the box extend between the bottom side and top side of the box in the height axis, said bottom side, top side and side walls delimiting an internal space of the box, and wherein a first side wall extends along a primary axis, which primary axis is perpendicular to the height axis, and said first side wall has an upper edge extending along the primary axis along the top side and an outer surface facing away from the internal space.
When installing windows in a roof it is vital to ensure that the roof window itself is securely attached to the roof structure and that the joint between the roof window and the roof structure is properly weather proofed. It is therefore important that all components of roof window products, such as the roof window itself or a flashing assembly for a roof window, are used and are used in the right way. To facilitate this, the components are typically arranged in the box in an intended order of use and small components, such as screws, are kept in plastic bags. Furthermore, blocks of expanded polystyrene or similar shock absorbing material are used for protecting the product and/or for keeping the components in the intended position within the box. An example of a packed roof window, where these principles are used, is known from EP2748071B1 and an example of a packed flashing assembly for a roof window is known from EP1710163B1. Traditionally small components have been attached to the box or to larger components, for example by means of an adhesive, to prevent them from becoming lost, either inside the box or when removed from the box, and/or they have been wrapped in plastic, thereby also preventing them from scratching or otherwise damaging other components. Larger components have traditionally been kept in place in the box by being attached to the box by means of an adhesive or by being fixated between blocks of expanded polystyrene (EPS), and some have been covered by a protective plastic film to prevent them from being scratched.
However, combined with an ever-increasing awareness of environmental considerations and the wish to reduce or even eliminate the climate footprint of products and their packaging, there is a need for delivering packed products that are more environmentally friendly.
With this background, it is an object of the invention to provide a packed roof window product, which has a smaller climate footprint and/or with improved recyclability, without increasing the risk of errors in the installation of the product and maintaining a good protection of the components of the product during handling and transportation.
These and further objects are achieved with a packed roof window product of the kind mentioned in the introduction, which is furthermore characterised in that a first of said components is carried by the first side wall.
By providing a packed roof window product wherein the first component is carried by the side wall, it may be possible to reduce the size of the box by employing previously unused space in the box, leading to reduced material consumption and climate footprint. As packed roof window products contain components of different sizes, including large components, such as insulation frames, and smaller components, such as collections of screws, the minimum dimensions of the box are determined at least in part by the largest dimensions among the components. Furthermore, as some components are fragile, they must be kept secure and apart in the packaging, making stacking of such components impractical without the use further protective packaging material or fastening means. Hence one component typically determines the height of the box along the height axis, leaving unused space in the box above other components of lesser height. By having the first component be carried by the side wall, the height dimension of the box may be used to a greater extent, allowing e.g. the width of the box to be reduced. Hence the material consumption can be reduced leading to a smaller climate footprint and potentially also to more flexibility in handling, storage, and transportation. Further, as the first component is carried by the side wall, auxiliary fastening means such as adhesives, tape or straps, may be eliminated, potentially rendering the packaging more suitable for easy recycling. It is presently preferred that the box is made from a paper-based material, such as cardboard, more preferably corrugated cardboard, all of which are is readily recyclable.
A further potential advantage may be that the strength and/or rigidity of the packed roof window product may be improved by the component serving as a reinforcement. This may especially be the case if the first component is a long component extending along a majority of the length of the side wall.
It is understood that the first component is carried by the first side wall without the use of fastening means beyond the box itself, such as straps, tape or adhesives, i.e. it may hang from or be suspended from the first side wall. The component may be said to the freely suspended from the first side wall. Hence, the first component is carried by the first wall by way of engagement between the first component and the side wall and possibly further panels of the box, such as a lid of the box when the box is closed. The first component may generally be carried by the first side wall by a part of the first component extending across the side wall.
The box may be of a rectangular configuration where the top side and bottom side extend in parallel and four side walls extend perpendicularly in between the bottom and top sides. In such a case the height axis is parallel with the side walls and two side walls extend along the primary axis and the remaining two side walls extend along a secondary axis, which is perpendicular both to the height axis and to the primary axis. The primary and secondary axis may be denoted a longitudinal axis and a transverse axis, respectively. While the first side wall of the box which carries the first component, is generally described herein as defining the length of the box, it is also possible for the first side wall to be shorter than the sidewalls extending in the secondary axis, whereby the first side wall may be said to define the width of the box, and thus for the first component to be carried by the shorter among the side walls.
The box may be a flat box, wherein the top side and bottom side form major sides of the box and the side wall are minor sides. Major and minor here refers to the area of the side. In flat boxes a height of the box is smaller than the other dimensions, i.e. length and width.
The term supply condition denotes the packed state of the roof window product, in which it is supplied to the user. The box is described herein with reference to a bottom side and a top side with side walls extending in between.
These terms are understood in terms of their function when packing the roof window product, the top side being the side which is open when packing the roof window product, allowing components to be packed in the box, and subsequently the top side is closed to provide the supply condition. The top side may also be denoted a lid of the box. The surfaces the box which face the internal space of the box in the supply condition are denoted as inner surfaces or faces, whereas surfaces or faces facing away from the internal space will be denoted as outer surfaces or faces.
The packed roof window product comprises a plurality of roof window related product components, and the first component is carried by the side wall, while at least some of, preferably a majority of, the other components are placed on the bottom side of the box, either directly or resting on top of one or more other components. Some of the other components may be glued to the bottom side or kept in place by positioning elements.
The packed roof window product may comprise additional components carried by the first or other side walls of the box.
In some embodiments the first component is suspended from the upper edge of the first side wall. The first component can be suspended from the upper edge by a part of the first component resting on the upper edge.
By having the first component rest on the upper edge it is suspended from the side wall providing a position toward the top side of the box in the supply condition. In addition, when the box is closed in the supply condition, the lid of the box will be in contact with the first component, preventing the first component from sliding along the side wall by increasing friction. In this way the first component is effectively fixed in the box without the use of auxiliary fastening means, beyond the box itself, reducing the amount of packaging material used.
The upper edge is a free upper edge of a panel of the box forming the side wall. The edge may the formed by a fold between two panels of the box or alternatively by being the extremity of the panel. The term “upper” denotes a position upwards along the height axis, i.e. toward the top side of the box. The first component may be suspended from the upper edge by extending along and engaging the upper edge thereby resting on the upper edge of the side wall.
In some embodiments, the first side wall comprises a receiving section, and the first component is carried by the receiving section.
The receiving section is a part of the side wall which has been modified e.g. by cutting and/or deformation, such that the first component can be carried therefrom, e.g. by being suspended from the receiving section. While it may be sufficient for some components to be carried by the side wall by resting on the upper edge, the attachment of the component to the side wall may be improved by providing a receiving section in the side wall, configured for receiving the first component. Boxes of a paper-based material such as corrugated cardboard are suitable for such embodiments as the material is easily cut or compressed to provide the receiving section, and cuts for the receiving section or perforations can be made at the same time as the cardboard box blank is cut.
In some embodiments, the receiving section comprises a recess in the upper edge of the first side wall.
The recess is formed in the upper edge such that the side wall has a non-uniform height. By providing a recess in the side wall the first component can be arranged in a retracted position in relation to top side of the box, allowing the box to close in a flush manner. Furthermore, the first component can be arranged in between ends of the recess, which ends keeps the first component in place, preventing it from sliding along the side wall in the direction of the primary axis. In such an embodiment the recess has a length corresponding substantially to a length of the first component.
In some embodiments, the receiving section comprises an aperture in the first side wall. The aperture is an opening in the side wall, the edge of which opening is delimited by the first side wall, i.e. it has no free edges. By providing an aperture a part of the first component can extend through the aperture allowing it to be carried by or suspended from the side wall. The aperture may extend along the primary axis, defining a support section of the first side wall between the upper edge and the aperture, wherein the first component is carried by from the support section. Such a support section is attached to the remainder of the side wall at longitudinal ends of the support section, as seen along the primary axis. The supporting section is possibly flexible and can be retracted slightly into the box, providing a retracted position of the first component, which can facilitate attachment of the lid of the box.
In some embodiments, the first component is elongate, having a component length extending between longitudinal ends of the first component, and the first component is carried by the side wall by being suspended at its longitudinal ends.
In such an embodiment the first component extends along the first side wall along the primary axis and is supported at its longitudinal ends by the first side wall thereby suspending the first component, while an intermediate part of the first component is free, the intermediate part extending between the supported longitudinal ends. This allows the intermediate part to extend along the inner side of the first side wall, reducing the area of a first part of the first component which is positioned at the outer surface of the first side wall. Minimizing the first part, can facilitate fastening of box lid and may protect the more fragile portions of the component, if any. This may be achieved e.g. by flaps or spaced apart recesses/cuts in the side wall. Being suspended from its longitudinal ends may also prevent the first component from sliding along the side wall in the direction of the primary axis.
The term “first part” here denotes one or more parts of the first component which is positioned on the outer surface of the first side wall.
In some embodiments, the receiving section comprises at least two flaps, and the first component is carried by the first side wall by being suspended from these two flaps at the longitudinal ends of the first component.
The flaps may be hinged in a manner allowing movement about the height axis. Such flaps can be inserted into openings or recesses at the longitudinal ends of the first component, thereby suspending the first component from the flaps of the side wall. The flaps may project in opposite directions along the primary axis. The flaps may be cut from a panel forming the first side wall and bends in the material of the box serves as hinges. In an alternative embodiment, a component having suitable openings or recess, which are not located at the ends of the component, is suspended by inserting flaps into such openings or recesses.
In some embodiments, the receiving section comprises at least two cuts in the first side wall from the upper edge, which two cuts are spaced apart along the primary axis. The two cuts form two end sections of the side wall between the ends of the side wall end the respective cuts, and an intermediate section is formed between the two cuts. The first component can then be suspended at the two end sections, while it is not suspended from the intermediate section. In this way the area of the first part, i.e. the parts of the first component positioned at the outer surface of the first side wall, will be minimized. The cuts can be simple straight cut lines in the side wall or have more complex shapes. In addition, or as an alternative to providing end sections from which the first component can be suspended, the cuts may carry the first component by supporting a lower edge of the first component.
The receiving section may comprise more than two of the flaps or cuts described above. For example, having three cuts may allow the same box to be used for different roof window products, allowing components of different length to be carried by the side wall by using the two cuts furthest from each other for a longer component and using the two cuts closest to each other for a shorter component.
The receiving section can combine several of the modifications described herein. For example, the receiving section can comprise flaps which also form recesses in the side wall, thus both providing a small first part of the first component, which is retracted in relation to the top side, and possibly where the recess ends prevent the component from sliding on the flaps. Similarly, cuts can be combined with a recess.
In some embodiments, the top side of the box is formed by a lid of the box, and the lid comprises an overlap panel, which overlap panel overlaps an outer side of the first side wall in the supply condition so that the first part of the first component is located between the first side wall and the overlap panel.
In this way the first part of the first component is covered by the overlap panel and friction between the overlap panel and the component will reduce the tendency of the component to slide on the first side wall. The first part may be said to sandwiched between the first side wall and overlap panel. The overlap panel may be a flap in the case of a 5-panel folder type cardboard box, or it may be a lid side wall in the case of telescope style cardboard box. In the closed state of the box the overlap panel may be fastened to the side wall, preferably by an adhesive.
A five-panel fold type box (sometimes referred to as five-panel-folder) is a standard box type, where fifth panel is provided to overlap with another panel in the closed state of the box. Telescopic boxes are also a standard box type, wherein the box comprises two pieces, which can be fitted to each other such that side walls of one piece are at least partly overlapped by side walls of the other piece.
In a further development, the overlap panel and/or the first side wall is provided with a zone of reduced thickness, such as a compressed zone, and this zone corresponds in size and shape at least to the first part of the first component. Typically, such overlap panel are attached to the outer surface of the side wall with which it is overlapping using adhesive to close the box as described above. However, as the first part is present on the outer surface, it may prevent the overlap panel from resting flush against outer surface and thus prevent the adhesive from attaching properly or breaking the adhesive connection by pressing the overlap panel away from the side wall. However, by reducing the thickness of the overlap panel or the side wall in the area of the first part, the contact between the outer surface and the overlap panel and in turn attachment is improved. For corrugated cardboard boxes the reduced thickness may be provided by compression of the corrugated cardboard.
In some embodiments, the first side wall of the box comprises an inwardly projecting panel projecting into the internal space of the box, and the first component is suspended from the inwardly projecting panel.
The panel preferably projects into the internal space of the cardboard box from the upper edge of the panel forming the first side wall. The panel may comprise an aperture and the first component being suspended from the aperture. Alternatively, or additionally the inwardly projecting panel may be provided with flaps from which the first component is suspended.
In some embodiments, the first component is a gutter-shaped component of a covering assembly or a flashing assembly for a roof window. Gutter-shaped components are typically used to drain off water, for example along the top of a roof window installed in an inclined roof, where a gutter drains water out onto one or more side flashing members extending along the side(s) of the window. The gutter-shaped component has a U-shaped cross-section formed by respective legs of the component, which allows it to be suspended from the side wall. Other components having projecting legs may be suspended from these legs. Another component which may be suspended from the side wall is a cover member of a covering assembly.
In some embodiments, the first side wall has a length L along the primary axis and the first component extends over 20 to 90% of the length L, preferably over 50 to 90% of the length L.
In some embodiments, the cardboard box is folded from one or more blanks, preferably a blank of the five-panel fold type or a blank of the telescopic type.
The roof window product may be an installation kit for use in the installation of a roof window system, such as a kit comprising flashing members and insulating members and possibly also an underroof collar.
Other embodiments and further advantages will be apparent from the subsequent detailed description and drawings.
In the following, embodiments of the invention will be described with reference to the schematic drawings in which
Referring initially to
In the supply condition the lid 11 is closed and in contact with the gutter element 3. In this way the gutter element 3 kept in place in the box 10, without the use of auxiliary fastening means.
Referring now to
Referring now to
Further details of the zone of reduced thickness 112 are shown in
Without the zone 112 the first component could tend to push the overlap panel 111 away from the first side wall 13, thus inhibiting efficiency of the glue.
Referring now to
The two flaps 22 delimit an intermediate section 23 of the first side wall 13. The intermediate portion 23 covers a majority of the gutter element 3, leaving only parts 34 at the ends of the gutter element 3 exposed when seen from the outer side of the box. These exposed parts embodies the first part(s) described above.
As the flaps 22 are integrated in the first side wall 13, the user only needs to recycle the box 10 itself, dramatically increasing the probability that it will be recycled compared to separate fastening members which should be collected and possibly sorted.
Referring now to
Referring now
Referring now to
In the embodiment of
The inwardly projecting panel 27 in
Referring now to
Number | Date | Country | Kind |
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PA 2021 70502 | Oct 2021 | DK | national |
Filing Document | Filing Date | Country | Kind |
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PCT/DK2022/050209 | 10/7/2022 | WO |