Patent Application
20110186473
Products such as mechanical equipment including, for example, lawn mowers, electrical generators and the like, outdoor recreational equipment such as, for example, outdoor grills, smokers, swing sets and the like, electrical appliances such as, for example, dishwashers, cook tops, ovens, built-in refrigerators, built-in freezers and the like and other bulk construction products like prefabricated windows, doors and the like undergo significant handling and shipping prior to delivery and installation. Significant time, effort and expense are invested in shipping containers for such products. 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 box or container encloses the dishwasher and completes the state of the art shipping container.
It should be appreciated that the outer box or carton 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 cardboard material is relatively heavy and cumbersome to haul away and takes up substantial space in any landfill. Further, the outer cardboard box is not green friendly as it is typically made from harvested trees removed from the environment.
The present invention relates to shipping capsules for various products as well as to methods of packaging a product for shipment which can reduce waste production, are lighter in overall weight, less expensive and environmentally friendly.
In accordance with embodiments of the present invention described herein, a shipping capsule is provided comprising a lattice blanket that is expandable and contractible so as to allow size adjustability and a covering layer. In one particularly embodiment, the lattice blanket forms an expandable and contractible sleeve that is received around a product being shipped in the shipping capsule and the covering layer is a polymer film such as stretch wrap.
In accordance with an additional embodiment, a method is provided for packaging a product for shipment. In embodiment, the method comprises the step of positioning an expandable and contractible lattice blanket around the product and covering at least a portion of the lattice blanket with a covering layer.
In accordance with yet another embodiment, a method of making a reusable shipping capsule, comprises securing a covering layer to an expandable and contractible lattice blanket when that lattice blanket is in an expanded position. This allows the covering layer to stay with and cover the lattice blanket when that blanket is expanded or contracted as well as anything in between. In addition, the invention includes a shipping capsule comprising an expandable and contractible lattice blanket and a covering layer connected to that blanket at least one point so that the covering layer covers the blanket in both an expanded position and a contracted position.
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, aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
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:
Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.
Reference is now made to
An alternative embodiment of lattice blanket 20 is illustrated in
In yet another alternative embodiment illustrated in
It should also be appreciated that the lattice blanket 20 illustrated in
In either of the embodiments of the lattice blanket 12, 20, the lattice blanket may be made from a material selected from a group consisting of non-woven synthetic material, non-woven natural material and mixtures thereof. The material may include thermoplastic fiber material, thermosetting fiber material, bicomponent fiber material and mixtures thereof. Various polymers are also particularly applicable as lattice blanket material. Still more specifically, the material may be selected from a group consisting of polyolefin, polypropylene, polyethylene, polyester, nylon, rayon, polyethylene terephthalate, polybutylene terephthalate, cotton, kenaf, silk, cellulose, hemp, shoddy and mixtures thereof. If desired, the lattice blanket material may incorporate reinforcing fibers selected from a group consisting of glass fibers, metal fibers, mineral fibers, carbon fibers, graphite fibers, natural fibers and mixtures thereof.
The lattice structure of the blankets 12, 20 may be made by slitting or honeycombing in the manner set forth in United States Patent Application Publication No. US2007/0042156 A1 to Rockwell published on 22 Feb. 2007, the full disclosure of which is incorporated herein by reference. As described in that document, such a lattice structure allows for selective expansion and contraction of the material.
It should further be appreciated that the material utilized to construct the lattice blanket 12, 20 may include a densified outer skin or layer 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 patents is incorporated herein by reference. The densified skin or additional outer layer can made from a relative soft composition(s) including polypropylene, glass reinforced polypropylene or polyester (scrim), polyester, polyolefin, polyethylene, rayon, nylon, acrylic, hemp, kenaf, cotton, polyethylene terephthalate, polybutylene terephthalate and combinations thereof. Use of reinforcing fibers includes those selected from a group consisting of glass fibers, polypropylene fibers and combinations thereof. It should further be appreciated that the densified skin provides a tough outer coating in a non-laminated product that, therefore, is not subject to de-lamination. It should also be appreciated, that while not necessary, the densified skin or outer layer provides enhanced acoustic and thermal insulation, abrasion resistance, and added strength during shipment.
Advantageously, the blanket 12, 20 is both flexible and resilient. Further, the densified outer skin is tough and tear resistant. Accordingly, the blanket 12, 20 resists damage during handling of the shipping capsule 10 including, for example, engagement with the paddles or forks of a lift truck. Such paddles commonly tear and damage corrugated cardboard boxes/cartons often leading to discounts in pricing for products contained in those boxes/cartons. In many instances the shipping capsule 12 will resist that damage thereby eliminating the need for “shipping damage” discounts. This saves the manufacturer significant money thereby increasing profitability.
In any of the embodiments of the shipping capsule 10 including either the lattice blanket 12 illustrated in
In any of the embodiments the lattice blanket 12, 20 is reusable again and again to ship different products multiple times. The covering layer 14 may be made from any of a number of appropriate materials including but not limited to a polymer film, polypropylene film, polyethylene terephthalate film, nylon film, polyethylene film, rayon film, polybutylene terephthalate film, stretch wrap and combinations thereof. Where stretch wrap is used as the covering layer 14, it is the only waste material following shipping. Since the completed shipping capsule 10 comprises the lattice blanket 12, 20 and the exposed covering layer 14, it should be appreciated that there is no need for an outer corrugated cardboard box or carton. Advantageously, the covering layer 14 is less expensive than a corrugated cardboard outer carton used in state of the art packaging. It also weighs less so as to reduce shipping weight. Further, the shipping capsule 10 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. The shipping capsule 10 includes a water impervious covering layer 14 that withstands moisture. In contrast, a corrugated cardboard box that gets wet loses its integrity. In addition, the shipping capsule 10 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.
In contrast, when other films are used for the covering layer 14, the covering layer becomes a permanent and reusable part of the shipping capsule 10. More specifically, the film covering layer 14 is attached to the expanded lattice blanket 20 at one or more spaced points by adhesive or other appropriate means.
In use, the shipping capsule 10 is expanded to fit over the product being shipped. The lattice blanket 20 may be in its fully expanded state or partially expanded state. Once in place, the resilient properties of the lattice blanket 20 cause the blanket to return to its relaxed state and draw up around the product. The covering layer 14 crumbles or accordions down as the lattice blanket contracts, providing a water impervious barrier to protect the product from water damage. Following shipping, the entire capsule 10, including both the lattice blanket 20 and attached covering layer 14, is returned to the manufacturer and reused to ship another product.
In one embodiment, a method for packaging a product for shipment is shown in
In accordance with yet another embodiment, a method 600 illustrated in
Advantageously, the present invention reduces the weight and cost of shipping materials as well as the bulk and weight of the waste materials produced by the shipping process all to the financial benefit of the manufacturer/shipper. The reusable nature of the polymer lattice blanket 12, 20 along with the size adjustability of the blanket provided by the lattice structure allows for great versatility and shipping efficiency.
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. Modifications or variations are possible in light of the above teachings. For example, the shipping capsule 10 could include an optional fifth or top wall if desired covering the top wall of the dishwasher in
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.
This application claims priority to U.S. Provisional Patent Application No. 61/292,304, filed Jan. 5, 2010, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61292304 | Jan 2010 | US |
