PALLET WRAPPING APPARATUS AND METHOD

Abstract

A wrap assembly for containing goods. The wrap assembly has a stacker wrap that has a first side, a second side, a back side, a first bottom flap, and a second bottom flap. The stacker wrap is configured to be folded into a folded configuration to provide a cavity for stacking goods within the cavity. The first bottom flap and second bottom flap have a plurality of coupling features that maintain the stacker wrap in the folded configuration while providing a substantially planar surface with both the first bottom flap and the second bottom flap.

Description

FIELD OF DISCLOSURE

The present disclosure relates to a pallet wrapping apparatus and more specifically to a pallet wrapping apparatus that provides a smooth coupling interface that allows product to slide there along without damage.

BACKGROUND

Pallets are often used to package and transport goods via conventional freight management systems such as planes, trains, and/or automobiles. The pallets are typically formed of a wood or synthetic material and provide a an upper and lower surface with a cavity therebetween. The cavity is sized so a conventional fork-lifting machine can easily position the corresponding forks in the cavity of the pallet to lift and move the pallet and any goods thereon. Often, the goods on the pallet utilize a wrapping to ensure the goods remain properly positioned over the pallet during transport.

Conventional pallet wrapping and packaging products utilize overlapped seems, mechanical fasteners such as staples, and other coupling configuration that are susceptible to damaging goods placed therein. Often, the conventional pallet wrapping covers all sides of the goods placed within the pallet wrapping. Accordingly, conventional pallet wrapping and packaging systems often inhibit exposure of the goods from the surrounding environment and can damage the goods when they are removed from the pallet.

SUMMARY

One embodiment is a wrap assembly for containing goods. The wrap assembly includes a stacker wrap that has a first side, a second side, a back side, a first bottom flap, and a second bottom flap. The stacker wrap is configured to be folded into a folded configuration to provide a cavity for stacking goods within the cavity. The first bottom flap and second bottom flap have a plurality of coupling features that maintain the stacker wrap in the folded configuration while providing a substantially planar surface with both the first bottom flap and the second bottom flap.

One example of this embodiment has a center bottom flap having a plurality of coupling features that are selectively coupleable to the first bottom flap and the second bottom flap, wherein the center bottom flap is aligned with the substantially planar surface of the first bottom flap and the second bottom flap.

In another example of this embodiment, the plurality of coupling features have at least one male dovetail defined in one of the first bottom flap or the second bottom flap and at least one female dovetail defined in the other of the first bottom flap or the second bottom flap. The at least one male dovetail is sized to be selectively positioned within the at least one female dovetail to maintain the stacker wrap in the folded configuration. In part of this example, the at least one male dovetail is coupled to the at least one female dovetail to provide a substantially planar transition there between. In another part of this example, the plurality of coupling features of the center bottom flap are selectively coupleable to corresponding coupling features of the first bottom flap and the second bottom flap. Further, the plurality of coupling features of the first bottom flap and second bottom flap selectively couple the first bottom flap to the second bottom flap.

Another example of this embodiment has a first outer flap defined from the first side and a second outer flap defined from the second side, the first and second outer flaps configured to be foldable onto the corresponding first and second side in the folded configuration. In part of this example, the first and second outer flaps are defined at an angle relative to a bottom edge of the corresponding first or second side, wherein the angle is not ninety degrees. Another part of this example includes an adhesive along the first outer flap and the second outer flap to maintain the first outer flap and the second outer flap in the folded configuration.

Yet another example of this embodiment has an adhesive on the bottom of one or more of the first bottom flap and the second bottom flap and configured to selectively couple the wrap assembly to a base.

Another embodiment of this disclosure is a method of assembling a wrap assembly. The method includes providing a stacker wrap having a first side, a second side, a back side, a first bottom flap, and a second bottom flap, folding the first side and second side ninety degrees towards one another relative to the back side, folding the first bottom flap ninety degrees towards second side, folding the second bottom flap ninety degrees towards the first side, and engaging a coupling feature between the first bottom flap and second bottom flap to maintain the stacker wrap in a folded configuration while providing a substantially planar surface along both the first bottom flap and the second bottom flap.

One example of this embodiment includes folding a center bottom flap extending from the back side ninety degrees towards the first bottom flap and the second bottom flap. Part of this example includes coupling the center bottom flap to both the first bottom flap and the second bottom flap such that the center bottom flap, first bottom flap, and second bottom flap are coupled to one another in a substantially planar configuration.

In another example of this embodiment the coupling feature comprises a male dovetail feature of the first bottom flap coupled to a female dovetail feature of the second dovetail flap. Part of this example includes coupling a center bottom flap to both the first bottom flap and the second bottom flap with separate dovetail coupling features.

Yet another example of this embodiment includes folding a first outer flap about 180 degrees relative to the first side and folding a second outer flap about 180 degrees relative to the second side to form respective first and second angled edges there along when in the folded configuration. In part of this example, the first and second angled edges are not perpendicular to the first and second bottom flap when in the folded configuration. Another part of this example includes applying an adhesive between the first outer flap and the first side and between the second outer flap and the second side to hold the first and second outer flap against the respective first or second side in the folded configuration.

Another example of this embodiment includes applying an adhesive to the bottom side of both the first bottom flap and second bottom flap such that the adhesive can selectively couple the wrap assembly to an underlying surface.

Yet another embodiment of this disclosure is a method of forming a planar stacker wrap cutout. The method includes cutting a flat material into a form that defines a first side, a back side extending from the first side, a second side extending from the back side opposite the first side, a first bottom side extending from the first side, a center bottom flap extending from the back side, and a second bottom flap extending from the second side, cutting a plurality of dovetail features into the first bottom flap, center bottom flap, and second bottom flap, the plurality of dovetail features configured to interconnect with one another to form a folded configuration of the planar stacker wrap cutout that has a substantially planar orientation of the first bottom flap, center bottom flap, and second bottom flap when interconnected to one another.

BRIEF DESCRIPTION OF THE FIGURES

The above-mentioned aspects of the present disclosure and the manner of obtaining them will become more apparent and the disclosure itself will be better understood by reference to the following description of the embodiments of the disclosure, taken in conjunction with the accompanying drawings, wherein:

FIG. 1a is an elevated perspective view of a stacker wrap assembly with goods positioned therein;

FIG. 1b is a front view of the stacker wrap assembly of FIG. 1a;

FIG. 1c is a side view of the stacker wrap assembly of FIG. 1a;

FIG. 2a is a top view of a stacker wrap in a planar configuration;

FIG. 2b is an elevated perspective view of outer flaps of the stacker wrap of FIG. 2a being folded inwardly;

FIG. 2c is an elevated perspective view of the stacker wrap of FIG. 2a illustrating adhesive strip locations;

FIG. 2d is an elevated perspective view of the stacker wrap of FIG. 2a in a partially folded configuration;

FIG. 2e is an elevated perspective view of bottom flaps of the stacker wrap of FIG. 2a aligning coupling features there between;

FIG. 2f is an elevated perspective view of the stacker wrap of FIG. 2a in the folded configuration illustrating a planar bottom surface of a cavity;

FIG. 3a illustrates a stacker wrap assembly having an outer wrapping applied;

FIG. 3b illustrates the stacker wrap assembly of FIG. 3a having a cap applied thereon;

FIG. 3c illustrates the stacker wrap assembly of FIG. 3a having bands holding the cap thereon;

FIG. 4a illustrates four stacker wrap assemblies from FIG. 3c arranged on a single pallet;

FIG. 4b illustrates the stacker wrap configuration of FIG. 4a with cross-bands holding the stacker wrap assemblies to the pallet; and

FIG. 4c illustrates an outer wrapping be applied around the stacker wrap configuration of FIG. 4b.

Corresponding reference numerals are used to indicate corresponding parts throughout the several views.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments described herein and illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated devices and methods, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.

Referring to FIGS. 1a-1c, one embodiment of a stacker wrap assembly 100 is illustrated. The assembly 100 may be formed of a stacker wrap 102 that has a folded configuration, as illustrated in FIGS. 1a-1c, that forms a cavity within which goods 106 may be placed. The stacker wrap 102 may sit on a skirt 104 that is selectively foldable in an up position wherein an underlying base is exposed, and a down position wherein the underlying base is substantially covered by the skirt 104 as illustrated in FIGS. 1a-1c. In one embodiment contemplated herein, the skirt 104 may have indicia thereon that is viewable in the down position to provide advertisements, instructions, graphics, or any other form of indicia.

The stacker wrap 102 may have a substantially U-shaped cross-section when viewed through a mid-height horizontal plane. This U-shaped cross-section allows the goods 106 to be easily stacked within the cavity of the stacker wrap 102 and the stacker wrap may substantially hold the goods 106 in a vertical stack therein. Further, the U-shaped cross-section also provides an open side that can prominently display the amount and type of goods positioned within the stacker wrap. Further still, consumers can easily remove goods from the stacker wrap from the open side. In one example contemplated herein, the goods 106 may be animal feed and the stacker wrap 102 may easily maintain stacks of the animal feed therein.

Referring specifically to FIG. 1c, the stacker wrap 102 may have tapered edges 108 on either side of the open side. The tapered edges 108 may extend from a bottom portion of the stacker wrap 102 to a top portion of the stacker wrap 102 at an angle that is not ninety degrees, or not perpendicular, to a plane defined by the bottom surface of the stacker wrap 102. In other words, the tapered edges have a taper that provides less coverage of the goods towards the top of the stacker wrap 102 than the coverage provided at the bottom of the stacker wrap 102. In this configuration, a consumer can more easily access the goods 106 and identify the number of goods remaining in the stacker wrap 102 from a side perspective as illustrated in FIG. 1c, among other things.

FIG. 2a illustrates the stack wrap 102 in a planar configuration. In one example of this disclosure, the stacker wrap 102 can transition from a planar configuration of FIG. 2a to a folded configuration 234 of FIG. 24. In the planar configuration the stacker wrap is substantially planar or flat. In the folded configuration the stacker wrap 102 is three-dimensional and defines a cavity 232 therein. The stacker wrap 102 may be formed of any material that can be folded and has a thickness. In on example, the material is a fluted cardboard. In another example, the material of the stacker wrap 102 is a foam-based material. In yet another example, the stacker wrap 102 is a plastic material. In yet another example, the material is any one or more material capable of achieving the described folded configuration.

The stacker wrap 102 may be cut or otherwise formed from a material to define a back side 207 having a first side 206 extending therefrom in one direction and a second side 208 extending therefrom in an opposite direction. A first outer flap 202 may extend from the first side 206 away from the back side 207. Further, a first bottom flap may extend downward from the first side 206 from the perspective of FIG. 2a. Similarly, a second flap 204 may extend from the second side 208 away from the back side 207. A second bottom side 212 may extend downwardly from the second side 208. Further, a center bottom flap 214 may extend downwardly from the back side 207 between the first bottom flap 210 and the second bottom flap 212.

Each of the first bottom flap 210, the second bottom flap 212, and the center bottom flap 214 may have coupling features thereon such that they may be interlocked with one another in the folded configuration to form a substantially planar top surface. That is to say, each of the first bottom flap 210, second bottom flap 212, and center bottom flap 214 can be coupled to one another without overlapping each other along the planar thickness of the material. More specifically, the first bottom flap 210 may have a first male dovetail 220 that aligns with a first female dovetail 216 defined in the center bottom flap 214 when in the folded configuration. Similarly, the center bottom flap may defined a second female dovetail 218 that corresponds with a second male dovetail 222 in the second bottom flap. The first bottom flap 210 may also define a third and fourth male dovetail 224, 226 configured to align with a third and fourth female dovetail 228, 230 of the second bottom flap 212. In the folded configuration, each male dovetail 220, 222, 224, 226 may be nested within the corresponding female dovetail 216, 218, 228, 230 to substantially maintain the stacker wrap 102 in the folded configuration.

Referring now to FIGS. 2b-2f, the process for transitioning the stacker wrap 102 from the planar orientation of FIG. 2a to the folded configuration of FIG. 2f is illustrated. In FIG. 2b, the first outer flap 202 is folded about 180 degrees inwardly towards the first side 206 and the second outer flap 204 is folded inwardly about 180 degrees towards the second side 208. This fold is intended to ultimately form the tapered edge 108 when in the folded configuration. In one aspect of this disclosure, an adhesive, such as two-sided tape, may be positioned between the outer flap 202, 204 and the corresponding side 206, 208 to hold the outer flaps 202, 204 in the folded position. Alternatively, a glue, staple, or other device or product may be used to hold the flaps 202, 204 in the folded position.

In FIG. 2c, adhesive 250 may be positioned on a bottom portion of the bottom flaps 210, 212. The adhesive may be a two-sided tape or the like such that one the bottom flaps 210, 212 are in the folded configuration the adhesive is adjacent to the underlying material. In this configuration, the adhesive 250 may be used to couple the stacker wrap 102 to the underlying surface so the stacker wrap 102 will not slide relative thereto.

Referring to FIG. 2d, the bottom flaps 210, 212 may be folded about ninety degrees relative to the adjacent side 206, 208 and the first and second sides 206, 208 may be folded about ninety degrees towards one another. In this configuration, the coupling features of the bottom flaps 210, 212 begin to align with one another as the stacker wrap becomes positioned in the folded configuration.

In FIG. 2e that center bottom flap 214 is folded about ninety degrees relative to the back side 207 to align the coupling features 216, 218 of the center bottom flap 214 with those of the first and second bottom flap 210, 212. In FIG. 2e, each male dovetail 220, 222, 224, 226 is being aligned with the corresponding female dovetail 216, 218, 228, 230.

Referring now to FIG. 2f, each male dovetail 220, 222, 224, 226 has been aligned and nested within the corresponding female dovetail 216, 218, 228, 230 to couple each of the first bottom flap 210, the second bottom flap 212, and the center bottom flap 214 to one another. Further, because of the nested relationship of the dovetail features, the flaps 210, 212, 214 define a substantially plan surface 236 along a top side. Once the dovetail features are coupled to one another, the stacker wrap 102 may be maintained in the folded configuration 234 because of the engagement of the dovetail features. Further, the cavity 232 defined therein can receive goods 106 without the goods being snagged or others caught on coupling features. In other words, because the flaps 210, 212, 214 utilize the dovetail features to couple to one another, the top surface where the goods 106 may be located is a planar surface 236. Accordingly, the goods can easily slide into, and out of, the cavity without the goods being damaged.

FIGS. 3a-3c illustrate further processing of the stacker wrap 102. More specifically, after the stacker wrap 102 I positioned in the folded configuration 234 and goods are positioned in the cavity 232, a plastic wrap or the like me encircle the stacker wrap 102 as illustrated in FIG. 3a to further hold the goods therein. Next, a cap 302 may be positioned over the top portion of the stacker wrap 102 and goods therein as illustrated in FIG. 3b. Finally, bands 304 may be wrapped around the skirt, stacker wrap 102, and cap 302 to create a sub packaged stacker wrap assembly 306 with the packaged goods therein.

In FIGS. 4a-4c, the four sub packaged stacker wrap assemblies 306 are packaged on a pallet 402. More specifically, as illustrated in FIG. 4a, each sub packaged stacker wrap assembly 306 may occupy a quarter of a standard pallet 402 such that four sub packaged stacker wrap assemblies 306 can be positioned on a standard pallet 402. Bands 404 may be wrapped around the sub packaged stacker wrap assembly 306 and the underlying pallet 402 such that they are substantially fixed relative to the pallet 402. Finally, a plastic wrap material may encircle the four sub packaged stacker wrap assembly 306 coupled to the pallet to provide further protection for transport.

While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character, it being understood that illustrative embodiment(s) have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. It will be noted that alternative embodiments of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the present invention as defined by the appended claims.

Claims

1. A wrap assembly for containing goods, comprising: a stacker wrap comprising a first side, a second side, a back side, a first bottom flap, and a second bottom flap;wherein the stacker wrap is configured to be folded into a folded configuration to provide a cavity for stacking goods within the cavity;wherein the first bottom flap and second bottom flap have a plurality of coupling features that maintain the stacker wrap in the folded configuration while providing a substantially planar surface with both the first bottom flap and the second bottom flap.

2. The wrap assembly of claim 1, further comprising a center bottom flap having a plurality of coupling features that are selectively coupleable to the first bottom flap and the second bottom flap, wherein the center bottom flap is aligned with the substantially planar surface of the first bottom flap and the second bottom flap.

3. The wrap assembly of claim 1, wherein the plurality of coupling features comprise at least one male dovetail defined in one of the first bottom flap or the second bottom flap and at least one female dovetail defined in the other of the first bottom flap or the second bottom flap, the at least one male dovetail sized to be selectively positioned within the at least one female dovetail to maintain the stacker wrap in the folded configuration.

4. The wrap assembly of claim 3, wherein the at least one male dovetail is coupled to the at least one female dovetail to provide a substantially planar transition therebetween.

5. The wrap assembly of claim 2, wherein the plurality of coupling features of the center bottom flap are selectively coupleable to corresponding coupling features of the first bottom flap and the second bottom flap.

6. The wrap assembly of claim 5, wherein the plurality of coupling features of the first bottom flap and second bottom flap selectively couple the first bottom flap to the second bottom flap.

7. The wrap assembly of claim 1, further comprising a first outer flap defined from the first side and a second outer flap defined from the second side, the first and second outer flaps configured to be foldable onto the corresponding first and second side in the folded configuration.

8. The wrap assembly of claim 7, wherein the first and second outer flaps are defined at an angle relative to a bottom edge of the corresponding first or second side, wherein the angle is not ninety degrees.

9. The wrap assembly of claim 7, further comprising an adhesive along the first outer flap and the second outer flap to maintain the first outer flap and the second outer flap in the folded configuration.

10. The wrap assembly of claim 1, further comprising an adhesive on the bottom of one or more of the first bottom flap and the second bottom flap and configured to selectively couple the wrap assembly to a base.

11. A method of assembling a wrap assembly, comprising: providing a stacker wrap comprising a first side, a second side, a back side, a first bottom flap, and a second bottom flap;folding the first side and second side ninety degrees towards one another relative to the back side;folding the first bottom flap ninety degrees towards second side;folding the second bottom flap ninety degrees towards the first side; andengaging a coupling feature between the first bottom flap and second bottom flap to maintain the stacker wrap in a folded configuration while providing a substantially planar surface along both the first bottom flap and the second bottom flap.

12. The method of assembling the wrap assembly of claim 11, further comprising folding a center bottom flap extending from the back side ninety degrees towards the first bottom flap and the second bottom flap.

13. The method of assembling the wrap assembly of claim 12, further comprising coupling the center bottom flap to both the first bottom flap and the second bottom flap such that the center bottom flap, first bottom flap, and second bottom flap are coupled to one another in a substantially planar configuration.

14. The method of assembling the wrap assembly of claim 11, wherein the coupling feature comprises a male dovetail feature of the first bottom flap coupled to a female dovetail feature of the second dovetail flap.

15. The method of assembling the wrap assembly of claim 14, comprising coupling a center bottom flap to both the first bottom flap and the second bottom flap with separate dovetail coupling features.

16. The method of assembling the wrap assembly of claim 11, further comprising folding a first outer flap about 180 degrees relative to the first side and folding a second outer flap about 180 degrees relative to the second side to form respective first and second angled edges there along when in the folded configuration.

17. The method of assembling the wrap assembly of claim 16, wherein the first and second angled edges are not perpendicular to the first and second bottom flap when in the folded configuration.

18. The method of assembling the wrap assembly of claim 16, further comprising applying an adhesive between the first outer flap and the first side and between the second outer flap and the second side to hold the first and second outer flap against the respective first or second side in the folded configuration.

19. The method of assembling the wrap assembly of claim 11, further comprising applying an adhesive to the bottom side of both the first bottom flap and second bottom flap such that the adhesive can selectively couple the wrap assembly to an underlying surface.

20. A method of forming a planar stacker wrap cutout, comprising: cutting a flat material into a form that defines a first side, a back side extending from the first side, a second side extending from the back side opposite the first side, a first bottom side extending from the first side, a center bottom flap extending from the back side, and a second bottom flap extending from the second side;cutting a plurality of dovetail features into the first bottom flap, center bottom flap, and second bottom flap, the plurality of dovetail features configured to interconnect with one another to form a folded configuration of the planar stacker wrap cutout that has a substantially planar orientation of the first bottom flap, center bottom flap, and second bottom flap when interconnected to one another.