Product Packaging that Remains with the Product and Functions as Acoustical and/or Thermal Insulation

Abstract

A shipping capsule for an electrical appliance comprises a blanket of insulating material and a layer of stretch wrap. Together these materials function as a durable shipping container eliminating the need for a corrugated cardboard outer carton currently in use. The invention further includes a method of reducing shipping costs and shipping waste associated with shipping an electrical appliance. The method includes the steps of covering at least a portion of the electrical appliance with insulation material that will remain with the electrical appliance after installation and providing a layer of stretch wrap over the insulation material whereby the combination of insulation material and stretch wrap form a shipping capsule.

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates generally to the product packaging field and, more particularly, to a shipping capsule for an electrical appliance as well as a method for reducing shipping costs and shipping waste associated with shipping an electrical appliance.

BACKGROUND OF THE INVENTION

Electrical appliances undergo significant handling and shipping prior to delivery and installation. Significant time, effort and expense is invested in shipping containers for electrical appliances such as dishwashers and built-in refrigerators, freezers, cook tops and ovens. For example, a dishwasher is typically held on a wood base and the front face is covered with a protective material. Corner boards of foam or cardboard are also typically provided to protect the corners and allow for stacking. Finally, an outer cardboard box encloses the dishwasher and completes the shipping container.

It should be appreciated that the outer cardboard box is typically made from corrugated cardboard material. Such material is relatively heavy thereby adding to shipping weight and shipping costs. The outer cardboard box is also a waste material that must be disposed of upon installation of the dishwasher. The material is relatively heavy and cumbersome to haul away and takes up substantial space in any landfill.

The present invention relates to a new and improved shipping capsule for electrical appliances such as dishwashers as well as to a new and improved method for reducing shipping costs as well as shipping waste associated with shipping such an electrical appliance.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a shipping capsule is provided for an electrical appliance such as a dishwasher or the like. The shipping capsule comprises a blanket of insulating material including a first portion covering a front face of the electrical appliance and a layer of stretch wrap extending around at least a portion of the blanket of insulating material and holding the first portion in place on the front face of the electrical appliance.

In accordance with an additional aspect of the present invention a shipping capsule is provided for an electrical appliance. The shipping capsule comprises a hood of insulating material. The hood of insulating material is provided in a shipping position covering a top wall, two opposing sidewalls and a front face of the electrical appliance. A layer of stretch wrap extends around the hood of the insulating material and holds the hood on the electrical appliance in the shipping position.

In accordance with still another aspect of the present invention, a shipping capsule for an electrical appliance comprises a five sided hood of insulating material. The hood is provided in a shipping position covering a top wall, two opposing sidewalls, a front face and a rear wall of the electrical appliance. A layer of stretch wrap extends around the hood and holds the hood on the electrical appliance in the shipping position.

In accordance with yet another aspect of the present invention, a method of reducing cost and shipping waste associated with shipping an electrical appliance is provided. That method comprises the steps of covering at least a first portion of the electrical appliance, including a front face of the electrical appliance, with insulation material that will remain with the electrical appliance after installation and providing a layer of stretch wrap over the layer of insulation material.

In the following description there is shown and described several different embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 is a top plan view of a blanket of insulating material used to construct the shipping capsule of the present invention;

FIG. 2 illustrates the blanket of insulating material of FIG. 1 in a shipping position with the flap folded so as to cover the front face of a dishwasher;

FIG. 3 is a view similar to FIG. 2 but showing the flap in an installation position with the flap folded so as to cover the rear wall of a dishwasher;

FIG. 4 is a perspective view of the blanket of insulating material incorporating pockets holding removable corner guards or corner protectors;

FIG. 5 a is a perspective view illustrating a four sided hood of insulating material used in the shipping capsule of the present invention;

FIG. 5 b is a view similar to FIG. 5a but showing the complete shipping capsule in the shipping position overlying a dishwasher supported on a wooden base;

FIG. 5 c illustrates the hood of FIGS. 5a and 5b in the installation position with the stretch wrap and wooden base removed;

FIG. 6 is a perspective view of a five sided hood including corner protector pockets used in the shipping capsule in the present invention;

FIG. 7 a illustrates the completed capsule incorporating the blanket or hood of insulation and an outer layer of stretch wrap for holding that insulation in place on a dishwasher or other electrical appliance

FIG. 7 b illustrates a section of the hood of FIG. 6 incorporating a T-shaped perforation allowing the section to be folded back to expose the front face of the dishwasher; and

FIGS. 8 a and 8b are perspective views illustrating yet another embodiment of the invention.

Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Reference is now made to FIGS. 1 and 8 illustrating a blanket 10 of insulating material used to construct the shipping capsule 12 of the present invention. As illustrated, the blanket 10 includes a first portion or flap 14 and a second portion or main body 16. The lines 18 define cut lines while the line 20 defines a fold line or hinge line extending between the cut lines.

The insulating material is made from a material selected from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethyleneterephthalate, polybutylene terephthalate and combinations thereof. The insulating material may also include reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations or mixtures thereof. In one particularly useful embodiment the blanket 10 of insulating material includes a densified outer skin as described and illustrated in issued U.S. Pat. Nos. 6,539,955 and 6,669,265, both to Tilton, et al and assigned to the assignee of the present invention. The full disclosure of these two patents is incorporated herein by reference. It should be appreciated that the densified skin provides a tough outer coating. It should be appreciated that the blanket 10 of insulating material including the densified skin is a non-laminate and, thus, it is not subject to potential de-lamination.

Advantageously, the tough densified outer skin is both flexible and tear resistant and, accordingly, will resist damage during handling of the shipping capsule including engagement with the paddles or forks of a lift truck. Such paddles commonly tear and damage corrugated cardboard cartons often leading to discounts in pricing for the electrical appliances contained in those cartons. In many instances, the blanket 10 of insulating material used in the shipping capsule 12 of the present invention will resist that damage thereby eliminating the need for “shipping damage” discounts. This saves the manufacturer significant money thereby increasing profitability. Similarly, while corrugated cardboard cartons or boxes may lose integrity and deteriorate when wet, the outer polymer film/stretch wrap of the shipping capsule of the present invention is water impervious. Thus, the shipping capsule maintains full integrity so undesirable potential shipping discounts are once again avoided.

FIG. 2 illustrates the blanket 10 of insulating material shown in FIG. 1 wrapped around a dishwasher with the flap 14 in the shipping position. More specifically, it should be appreciated that the main body 16 of the blanket 10 extends down and covers two opposing sidewalls of the dishwasher. The connecting portion of the main body 16 including the fold or hinge line 20 extends across the top wall T of the dishwasher D. In the shipping position the flap 14 is folded about the fold or hinge line 20 and extends down over the front wall or face of the dishwasher so as to protect the front wall or face from damage during shipping. If desired, corner protectors made from corrugated cardboard or other material may be provided at one or more corners and/or edges of the dishwasher. The dishwasher itself is supported on a wooden base for shipment. A layer of polymer film such as stretch wrap, (not shown for clarity of presentation) is wrapped completely around the blanket 10 including the flap 14 as well as the corner protectors in order to hold them in position on the dishwasher and complete the shipping capsule 12. It should be appreciated that the shipping capsule 12 includes an exposed layer of stretch wrap and there is no outer corrugated cardboard carton. Advantageously, the stretch wrap is less expensive than the corrugated cardboard outer carton used in state of the art packaging of dishwashers and other electrical appliances. It also weighs less so as to reduce shipping weight. Further, the shipping capsule 12 is more durable and tear resistant than an outer corrugated cardboard carton thereby reducing the discounting of product for outer carton damage commonly associated with corrugated cardboard cartons. In addition, the shipping capsule 12 of the present invention is green friendly as it is free of wood products. In contrast trees are used to produce the corrugated cardboard outer packaging of the prior art.

At the time of installation, the outer layer of stretch wrap and the corner protectors are removed. These are the only waste materials. The flap 14 is folded about the hinge line or fold line 20 so as to cover and insulate the rear wall of the dishwasher following installation (see FIG. 3). Thus, it should be appreciated, that the blanket 10 of insulating material serves a dual function. More specifically, the blanket 10 forms an integral part of the shipping capsule 12 and then remains permanently with the dishwasher after installation so as to perform an acoustical and/or thermal insulating function. Thus, the material is used far more efficiently and significant economic benefits are produced.

In an alternative embodiment illustrated in FIG. 4, the blanket 10 of insulating material has two pockets 22. When the blanket 10 is positioned over the dishwasher, the pockets 22 extend along the length of the front corners of the dishwasher formed between the front face of the dishwasher and the two sidewalls. The pockets are open at the top. A removable corner protector 24 is received in each pocket. Each corner protector 24 may be made form a material selected from a group consisting of cardboard, fiberboard, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof. This includes pultruded products and resin enhanced VersaMat materials available from Owens Corning. While pockets 22 holding removable protectors 24 are illustrated, it should be appreciated that the protectors 24 may, alternatively, be simply permanently affixed to the blanket 10 by adhesive or other means. In such an embodiment, the pockets 22 may be eliminated.

While two vertical pockets are illustrated in the blanket 10 in FIG. 4, it should be appreciated that any number of vertical pockets could be provided including one at each of the four corners or even one at any position along a sidewall, front wall or rear wall of the dishwasher if desired. Further, it should be appreciated that a horizontal pocket could be provided extending along any or all of the corners formed by the top wall of the dishwasher. Still further, one or more pockets and removable protectors could be provided running front to back or side to side at any midpoint along the top wall if desired.

The shipping capsule of the present invention illustrated in FIG. 4 comprises a blanket 10 of insulating material including multiple pockets 22 that hold removable corner protectors 24. A stretch wrap layer (not shown) is provided around the blanket 10 in order to complete the shipping capsule. Again, it should be appreciated that the there is no outer carton of corrugated cardboard required. This significantly reduces shipping costs and saves trees.

At the time of installation, the layer of stretch wrap and the removable corner protectors 24 are discarded. The portion 26 of the blanket 10 covering the front face of the dishwasher and providing protection during shipping may be folded back over the top wall and retained after installation as an integral part of the acoustical and thermal insulation of the dishwasher. More specifically, a series of perforations 26 may be provided along each sidewall of the dishwasher in order to allow the front face cover portion to be torn free and folded above the front face along the top wall of the dishwasher so as to overly the top wall and a portion of the rear wall following installation.

FIG. 5 a illustrates yet another embodiment of the present invention wherein the blanket of insulating material comprises a four sided hood 30. The four sided hood 30 includes a top wall 32, one sidewall 34, a second opposed sidewall 36 and a rear wall 38. Thus, as illustrated in FIG. 5, the hood 30 is open on two sides: one toward the viewer and one toward the bottom of the drawing figure.

When in a shipping position (see FIG. 5b), the hood 30 is positioned over a dishwasher D or other electrical appliance so that the rear wall 38 covers the front face of the dishwasher, the top wall 32 covers the top wall of the dishwasher and the sidewalls 34, 36 cover the opposed sidewalls of the dishwasher. The rear wall R of the dishwasher D and the wooden base or support W upon which the dishwasher rests are aligned with the two open sides of the hood 30. The hood 30 may include pockets 22 for receiving and holding removable corner protectors 24 as described above and illustrated in FIG. 4 if desired. A layer of stretch wrap 60 is provided over the hood 30 in order to secure the hood in the shipping position over the dishwasher D (see FIG. 5b).

At the time of installation, the stretch wrap 60 and wooden base W are removed and discarded. Similarly, any removable corner protectors 24 may be removed from the pockets and discarded. The hood 30 is then displaced or repositioned on the dishwasher in one of two ways (see FIG. 5c). In the first way, a perforation line is provided across the entire length of each sidewall 34, 36 and the top wall 32 adjacent the wall 38. The rear wall 38 is then removed from the sidewalls 34, 36 and top wall 32 by tearing along the perforations. This exposes the front face F of the dishwasher D. The wall 38 of the hood 30 may then be repositioned over the rear wall of the dishwasher prior to installation. As a result, the removable panel or wall 38 will function as an acoustical and/or thermal insulator for the dishwasher D during the service life of the dishwasher.

In an alternative approach, the entire hood 30 is removed from the dishwasher D and repositioned on the dishwasher so that the top wall 32 covers the top wall of the dishwasher, the sidewalls 34, 36 cover the two opposing sidewalls of the dishwasher and the rear wall 38 covers the rear wall of the dishwasher. This exposes the front face F of the dishwasher D. After installation of the dishwasher, the entire hood 30 functions as an acoustical and/or thermal insulator for the dishwasher for the entire service life of the dishwasher D.

In yet another alternative embodiment illustrated in FIG. 6, a five sided hood 40 of insulating material is provided. As illustrated, the five sided hood 40 includes a top wall 42 and four sidewalls 44, 46, 48 and 50 (two sidewalls are illustrated and two sidewalls are hidden in FIG. 6). In the illustrated embodiment a pocket 52 is provided at each corner of the sidewalls 44, 46, 48 and 50. Each pocket may receive a removable corner protector 54. The bottom of the five sided hood 40 remains open. In use, the five sided hood 40 may be positioned over the top of the dishwasher or other electrical appliance so that the top wall 42 covers the top wall of the dishwasher, the sidewall 44 covers the rear wall of a dishwasher, the sidewalls 46 and 48 cover the opposed sidewalls of the dishwasher and the sidewall 50 covers the front face of the dishwasher. A layer of polymer film such as stretch wrap 60 is provided over the five sided hood 40 in order to secure the hood in the shipping position over the dishwasher (see also FIG. 7a). This completes the shipping capsule 12.

At the time of installation, the stretch wrap 60 is removed and discarded. The wall or panel 50 covering the front face of the dishwasher is then cut away or folded to expose the front face. In the embodiment illustrated in FIG. 7b, the hood 40 includes a T-shaped perforation 70. When the hood 40 is torn along the perforation 70, the wall or panel 50 is divided into two sections 50a, 50b. Each section 50a, 50b may be folded as illustrated by action arrows A to expose the front face of the dishwasher with the two sections 50a, 50b overlying the sidewalls 44, 48 of the hood 40 covering the sides of the dishwasher. There these sections 50a, 50b form an integral part of the acoustical and/or thermal insulation of the dishwasher during the entire service life of the dishwasher.

In yet another embodiment illustrated in FIGS. 8a and 8b the shipping capsule 100 includes a six sided “box” of insulating blanket 102 and a covering film layer 104 of stretch wrap. The bottom wall of the blanket 102 includes two layers 108, 110 forming a pocket 112 for receiving a wooden support base 114 upon which the dishwasher D or other appliance product is supported during shipment. The wooden base 114 is removed from the pocket 112 and discarded at the time of installation. The blanket 102 also includes two rear corner posts 116 (either permanently attached plastic cornerposts as illustrated or disposable cardboard cornerposts held in pockets).

The front and top wall panels 120, 122 are connected to the main body 124 (i.e. the side wall panels, rear wall panel and bottom wall pocket 112) of the blanket 102 by a single fold line 126. The dishwasher D is inserted into the six sided blanket 102 through the opening formed by folding the front and top wall panels 120, 122 about the fold line 126. Once the dishwasher is positioned in the blanket on the wooden base 114, the front and top wall panels 120, 122 are folded back to overlie the top and front walls of the dishwasher. The layer 104 of stretch wrap is then applied to hold the blanket 102 in position over the dishwasher and provide a water impervious outer layer.

It should be appreciated that the blanket 102 may be attached to the dishwasher D at several points along the rear wall and sidewalls to ensure it remains properly positioned for long term service as an insulator. Adhesive, hook and loop fasteners, mechanical fasteners or other appropriate means may be used to complete the attachment.

At the time of installation, the layer 104 of shrink wrap is removed and discarded. The wooden base 114 is also removed and discarded. Next, the front wall panel 120 is folded back over the top wall panel 122 in order to expose the front face of the dishwasher. The dishwasher is then installed under the counter top with the insulation blanket 102 covering the top, two opposing sides, bottom and rear walls of the dishwasher D. Thus, the blanket 102 provides the desired acoustical and thermal insulation for the service life of the dishwasher D.

As should be appreciated, any of the shipping capsule embodiments 12 described are useful in a method of reducing shipping costs and shipping waste associated with shipping of an electrical appliance such as a dishwasher. The method may be broadly described as comprising covering at least a portion of the electrical appliance, including a front face of the electrical appliance, with insulation material 10 that will remain with the electrical appliance after installation. In addition, the method includes the step of providing a layer of stretch wrap 60 over the insulation material 10 whereby the combination of the insulation material and stretch wrap form a shipping capsule 12.

The method may further include providing a pocket 22 in the insulation material 10 and inserting a removable corner protector 24 in the pocket adapted to protect a corner of the electrical appliance during shipping. Advantageously, it should be appreciated that the method may also include eliminating an outer carton around the electrical appliance. This is because the shipping capsule 12 formed by the stretch wrap 60 and insulation material 10 is actually more durable than a corrugated cardboard carton. Advantageously, it is also lighter in weight and less expensive to produce. Further, at the time of installation, the only waste materials are the layer of stretch wrap 60 and any removable and disposable corner protectors 24 that might be provided as well as any wood base or other support structure upon which the appliance is shipped. In contrast, in state of the art shipping cartons waste materials include the corner protectors and the wood base as noted above and, in addition, the outer corrugated cardboard carton. It should be appreciated that the stretch wrap waste materials of the shipping capsule 12 of the present invention are less bulky, lighter in weight and consume far less space than the waste carton of the prior art. Accordingly, it costs less to haul the waste materials away and the waste materials consume a smaller space in any landfill. Further, no trees die to produce the stretch wrap and, accordingly, the shipping capsule is green friendly. In contrast trees are used in the production of corrugated cardboard for shipping containers of the prior art.

The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way.

Claims

1. A shipping capsule for an electrical appliance, comprising: a blanket of insulating material including a first portion covering a front face of said electrical appliance; anda layer of polymer film extending around at least a portion of said blanket of insulating material and holding said first portion in place on said front face of said electrical appliance.

2. The shipping capsule of claim 1, wherein said blanket of insulating material includes a densified outer skin.

3. The shipping capsule of claim 2, wherein said blanket of insulating material is a non-laminate.

4. The shipping capsule of claim 1, wherein said blanket of insulating material includes a protector.

5. The shipping capsule of claim 4, wherein said protector is held in a pocket so as to cover and protect said appliance.

6. The shipping capsule of claim 5, wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elostomer, neoprene, polyethylene terephthalate, composite material and combinations thereof.

7. The shipping capsule of claim 5, wherein said blanket of insulating material remains with said electrical appliance following installation and said corner protector is removed from said pocket prior to installation of said electrical appliance.

8. The shipping capsule of claim 7, wherein said first portion of said blanket of insulating material is displaceable from a shipping position wherein said first portion covers said front face of said appliance and an installation position wherein said first portion covers a rear face of said appliance.

9. The shipping capsule of claim 8, wherein said first portion is a flap of insulating material connected by a hinge line to a main body of said blanket of insulating material covering said electrical appliance.

10. The shipping capsule of claim 1, wherein said shipping capsule does not include an outer carton and said stretch wrap is exposed.

11. The shipping capsule of claim 1, wherein said blanket of insulating material is made from a material selected from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof.

12. The shipping capsule of claim 11, wherein said insulating material further includes reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof.

13. A shipping capsule for an electrical appliance, comprising: a hood of insulating material, said hood of insulating material provided in a shipping position covering a top wall, two opposing sidewalls and a front face of said electrical appliance; anda layer of polymer film extending around said hood of insulating material and holding said hood of insulating material on said electrical appliance in said shipping position.

14. The shipping capsule of claim 13, wherein said hood of insulating material is four sided and includes a densified outer skin.

15. The shipping capsule of claim 14, wherein said hood of insulating material is a nonlaminate.

16. The shipping capsule of claim 13, wherein said hood of insulating material includes at least one protector overlying said electrical appliance when said hood of insulating material is in said shipping position.

17. The shipping capsule of claim 16, wherein said protector is held in a pocket so as to cover and protect said electrical appliance.

18. The shipping capsule of claim 17, wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof.

19. The shipping capsule of claim 17, wherein said hood remains with said electrical appliance following installation and said corner protector is removed from said pocket prior to installation of said electrical appliance.

20. The shipping capsule of claim 19, wherein, prior to installation, said hood is displaced from said shipping position into an installation position wherein said hood covers said top wall, said two opposing sidewalls and a rear wall of said electrical appliance.

21. The shipping capsule of claim 13, wherein said shipping capsule does not include an outer carton and said stretch wrap is exposed.

22. The shipping capsule of claim 13, wherein said hood of insulating material is made from a group consisting of polyester, polyolefin, polyethylene, polypropylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof.

23. The shipping capsule of claim 22, wherein said insulating material further includes reinforcing fibers selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof.

24. The shipping capsule of claim 19, wherein said hood includes a removable panel covering said front face of said electrical appliance in said shipping position.

25. The shipping capsule of claim 24, wherein said removable panel is attached to a rear wall of said electrical appliance prior to installing said electrical appliance.

26. A shipping capsule for an electrical appliance, comprising: a five sided hood of insulating material, said hood provided in a shipping position covering a top wall, two opposing sidewalls, a front face and a rear wall of said electrical appliance; anda layer of polymer fiber extending around said hood and holding said hood on said electrical appliance in said shipping position.

27. The shipping capsule of claim 26, wherein said hood of insulating material includes a densified outer skin.

28. The shipping capsule of claim 27, wherein said hood of insulating material is a nonlaminate.

29. The shipping capsule of claim 26, wherein said hood of insulating material includes at least one protector overlying said electrical appliance when said hood of insulating material is in said shipping position.

30. The shipping capsule of claim 29, wherein said protector is held in a pocket so as to cover and protect said electrical appliance.

31. The shipping capsule of claim 30, wherein said protector is a corner protector made from a material selected from a group consisting of cardboard, fiber board, plastic, rubber, elastomer, neoprene, polyethylene terephthalate, composite material and combinations thereof.

32. The shipping capsule of claim 30, wherein said hood remains with said electrical appliance following installation and said corner protector is removed from said pocket prior to installation of said electrical appliance.

33. The shipping capsule of claim 32, wherein said hood includes a removable panel covering said front face of said electrical appliance in said shipping position.

34. The shipping capsule of claim 32, wherein said hood includes a substantially T-shaped perforation extending along one corner and down a section of said hood, where tearing along said perforation allows said section of said hood to be folded back to expose said front face of said electrical appliance.

35. A shipping capsule for an electrical appliance, comprising: a blanket of insulating material having a bottom wall, a top wall, a front wall, a rear wall, a right side wall and a left side wall;a base pocket provided in said bottom wall;a support base received in said base pocket;a first perforation line extending along a top rear corner and rear side corner of said blanket;a second perforation line extending along a top front corner and front side corner of said blanket;corner protectors provided along at least two corners of said electrical appliance; anda layer of polymer film provided overlying at least a portion of said blanket.

36. A method of reducing shipping costs and shipping waste associated with shipping of an electrical appliance, comprising: covering at least a portion of said electrical appliance, including a front face of said electrical appliance, with insulation material that will remain with said electrical appliance after installation; andproviding a layer of polymer film over said insulation material whereby said combination of insulation material and stretch wrap for a shipping capsule.

37. The method of claim 36, including providing a pocket in said insulation material and inserting a removable corner protector in said pocket adapted to protect a corner of said electrical appliance during shipping.

38. The method of claim 37, including eliminating an outer carton around said electrical appliance.