Patent Application
20120272621
A large variety of containers for shipping goods are available. Fragile goods or sensitive equipments are secured against mechanical impacts acting on the container during shipment. Therefore containers are commonly filled with packaging material to absorb an eventual impact, e.g. different kinds of foam arranged between container wall and goods. This packaging material is commonly a one-way-material. Currently, there is strong demand to save resources and consequently to provide containers and packaging material for frequent use. Simultaneously, the containers and/or packaging material may be light material in order to reduce the transport costs. Light containers made of foldable corrugated cardboard as cushioning structure have been recently introduced as packaging. To be able to ship fragile goods safely, the goods are placed in between two polyethylene (PE) foils fixed onto two corrugated cardboard frames. In closed transport vehicles, the temperature may raise significantly above room temperature. Occasionally, the temperature may exceed 40° C., especially in countries located in the tropical region. The packaging material is also exposed to a high humidity. PE foils are not suitable for transports under such conditions. However, there is a demand to provide shipping containers for safely transporting fragile goods in regions with transport temperatures occasionally exceeding 40° C. and a humidity of 80% and more.
The invention relates to a cushioning structure for transporting heavy, large and fragile goods, a container reducible in size comprising the cushioning structure, a method to load the goods into the container and a method to collapse the empty container.
This subject innovation provides a cushioning structure for safely transporting heavy, large and fragile goods comprising a main frame with at least one bearing surface, a carrier foil at least bonded to the bearing surface of the main frame, at least fully covering the at least one bearing surface, and covering the area between the bearing surfaces as a carrying surface for the goods, wherein the main frame comprises multiple foldable inner and outer side flaps able to be folded into multiple supporting elements to support the bearing surface of the main frame with a height defined by the dimensions of the outer side flaps, wherein the carrier foil comprises a first foil, preferably an urethane foil, and a second foil, preferably an urethane foil, and an air cushion between the first and the second foils. Besides multiple items to be transported, the term “goods” also refers to one single item to be transported.
Carrier foils, e.g. urethane foils, are known as foils providing a high loading capacity and a high tear-resistance, but single foils are only stable at temperatures below 40° C. and at low humidity. The structure of the carrier foil in an embodiment includes a first and a second foil with an air layer between the two foils that enlarges the applicable temperature and humidity ranges. With urethane foils as first and second foil, a temperature of 60° C. and a humidity of 90% are applicable without observing any stretch displacement of the carrier foil enabling the transport of heavy goods up to 50 kg under these environmental conditions.
In case of one bearing surface, a contiguous bearing surface is advantageous. Cushioning structures with a contiguous bearing surface supported by the supporting elements are able to carry heavier goods compared to other cushioning structures of similar dimensions with non-contiguous bearing surfaces with a carrier foil attached to the non-contiguous bearing surfaces. The load is distributed over a larger bearing surface in case of a contiguous bearing surface resulting in a lower load per bearing area. The term “contiguous” denotes a continuously connected area. Mathematically, this contiguous area is an area, where a first point inside this area can be connected to any other point inside this area by a continuous line without said continuous line leaving this area.
The foldable inner and outer flaps provide support for the bearing surface of the main frame if folded into the supporting elements having any suitable profile to carry weight, preferably a tubular shape with a rectangular cross section. The foldable inner and outer side flaps provide a foldable cushioning structure, which can be in a two-dimensional shape (structure) or a three-dimensional shape (structure) when folded as the supporting elements. The flexibility to provide the same cushioning structure as a flat structure or as three-dimensionally shaped structure enables a transport of non-loaded cushioning structure in a flat and therefore volume-saving manner. The term “folded supporting elements” denotes a three-dimensional structure established by the inner and outer side flaps in a folded manner. The terms “inner side flap” and “outer side flap” refer to the direction of the side flaps with respect to the contiguous bearing surface of the main frame in the non-folded status. The inner side flaps are fully enclosed by the contiguous bearing surface, when the main frame is in the two-dimensional shape. The outer side flaps direct to the opposite direction of the inner side flaps. The non-folded status denotes the cushioning structure being in a two-dimensional shape. Thus the empty two-dimensional cushioning structure (absent goods) can be transported and/or stored in a space saving manner. The carrier foil may extend over the bearing surfaces, e.g. also partly of fully covering the outer side flaps.
The shape of the main frame can be a shape to transport the desired good. The area between the bearing surfaces and therefore the area of the carrier foil may vary depending on the goods to be transported. As an example, the carrying surface of the carrier foil may have areas of 0.25 m2, 0.36 m2, 0.49 m2, 0.72 m2, 1.00 m2, however, other areas of the carrying surface may be used.
The lateral extension of the outer side flaps corresponds to the height of the supporting element in the folded status. For a safe transport of the goods preventing mechanical impacts from the outside acting on the transported goods, the height of the cushioning structure(=height of the supporting element) may be at least in the order of a few centimeters, e.g. 4 cm, 6 cm, 8 cm, 10 cm, or other heights. A too large height may result in a bulky container for transporting the goods on the cushioning structures.
The bearing surface and the inner and outer side flaps of the main frame may be made of a material for multiple uses. As an example, plastic material can be used as suitable material providing a cushioning structure. All components of the main frame, except the carrier foil, may be made of the same material. The previously mentioned components may be made of pressed paperboard providing a sufficient resilience to carry heavy goods and being able to be recycled after reaching the end of life as cushioning structure after multiple uses. Such cushioning structures of pressed paperboard can be used more than 100 times before replacement. The replaced cushioning structures can be easily recycled and re-used afterwards. Other materials may be for the main frame, and the inner and outer side flaps. Before recycling, the carrier foil is detached from the main frame.
In an embodiment, the carrier foil is bonded to the main frame by ultrasonic pressure bonding, without additional adhesives. Ultrasonic pressure bonding utilizes the exothermic effect of ultrasound to bond the foil to the main frame, and also to the outer side flap, even if these parts are made of pressed paperboard. The ultrasound process enables an easy peel-off of the carrier foil in case of cushioning structures to be recycled, eliminating the problem of the release of environmental hormones, also known as endocrine disturbing chemicals, thereby protecting the logistic workers. The absence of adhesives enables a quick break-down and separation of the components of the cushioning structure for an easier recycling.
In another embodiment the carrier foil extends to the outer side flaps to increase the bonding strength, especially in case of bonding without adhesives.
In another embodiment, the carrier foil comprises reinforcement patches to locally support the carrying surface. The patches are located in each corner of the carrying surface near the main frame. The reinforcement patches may be made of the same material as the carrier foil or alternatively made of single foils, e.g. of urethane and/or polyethylene. Reinforcement patches in the corners of the carrying surface are advantageous because the highest stress conditions during transport of goods occur in the corners of the carrier foils. To further fix goods on the carrier foils, magic tape (adhesive tape of 3M) may be used.
In an embodiment, the bearing surface of the main frame has a rectangular shape with a first, a second, a third and a fourth part, wherein the first part is opposite to the third part and the second part is opposite to the forth part and each of the parts comprise one of the foldable inner side flaps facing towards the foldable side flap of the opposite part in a non-folded status, preferably with inner side flaps having a triangular shape, more preferably with inner side flaps having a shape like a trapezium. The term “opposite” denotes the location of the parts within the main frame, not the orientation of the surfaces of the parts. Here, opposite parts are arranged essentially in one plane all facing upwards or downwards depending on the orientation of the main frame. A square shape of the main frame is a particular embodiment of the rectangular shape. As an example the rectangular area of the main frame may be 96 cm×65 cm, or other sizes. However, a rectangular shape consumes the smallest possible loading space (or volume) if this structure is loaded (stacked) together with other corresponding structures in a transport vehicle and/or container.
In another embodiment, the main frame comprises at least one corner element, such as an L-shaped corner element, fixed to the bearing surface of the main frame in at least one corner, or in each corner, of the main frame to strengthen the main frame. The corner element may be fixed to the main frame with mechanical and/or chemical fastening means, e.g. rivets riveted from both sides (side of corner element and lower side of main frame). In one embodiment, the main frame is sandwiched between the corner element on top of the bearing surface and a second corner element arranged on the opposite side of the main frame below the corner element to further improve the strength (loadability) of the main frame. Here, the rivets fix both corner elements to the main frame. The corner element as well as the second corner element may be made of a material to improve the strength of the cushioning structure, such as metal and/or plastic elements. In one embodiment, the corner element is made of pressed paperboard to be able to be recycled. The corner elements are L-shaped corner elements in case of rectangular bearing surfaces of the main frame.
In another embodiment, the areas, of the outer side flaps are smaller than the areas of the inner side flaps. Since the inner flaps can occupy the full area between the bearing structures of the main frame, the areas of the inner side flaps are designed larger than the areas of the outer side flaps in order to build the same supporting elements to achieve a cushioning structure occupying a smaller total area compared to cushioning structures, where the areas of the outer side flaps are larger than the areas of the inner side flaps. The space to transport non-folded two-dimensional cushioning structures is reduced, leading to a more efficient transporting.
In another embodiment, the supporting elements are established by the inner and outer side flaps, which are attached to each other by at least one first fixation means, such as hook-and-loop fasteners, per corresponding inner and outer side flaps. The term “established” denotes the folding-together (joining) of the inner and outer side flaps to build the support elements. The term “fixation means” (either first or second) denotes any kind of means able to connect (join) two parts, preferably a hook-and-loop fasteners comprising fasteners having hooks and loops, Velcro fasteners, fasteners with mushroom heads or the like. The first fixation means are attached to the inner and/or outer side flaps with suitable means such as rivets or adhesive tapes. The corresponding first fixation means of inner and outer side flap will hold the corresponding outer and inner side flaps together. The mounting of the first fixation means to the inner and outer side flaps has no influence on the bonding strength of inner and outer side flap established by the first fixation means. In alternative embodiemnts, other first fixations of the hook-and-loop-fasteners may be used. The first fixation means, e.g. the hook-and-loop fasteners, may be attached to the inner and/or outer side flaps at any suitable location, such as on the inner side flap at the largest distance to the main frame and aligned to the middle of the corresponding bearing surface. Depending on the dimensions of the inner side flap, the corresponding counterpart of the first fixation means, e.g. the hook-and-loop fastener, is be arranged on a location at the outer side flap. Alternatively, the corresponding counterpart may also be arranged on the bearing surface of main frame.
In an embodiment, the neighbored outer side flaps are connected to each other by at least one second fixation means, such as hook-and-loop fasteners, arranged on the outer surface of at least two outer side flaps, such as each of the outer side flaps. The term “outer surface” denotes the surface, which is facing away from the volume surrounded by the folded supporting elements in the three-dimensional status of the cushioning structure ready for being loaded with good. Alternatively, one or more second fixation means, such as hook-and-loop fasteners, may also be arranged on each outer side flap. In one embodiment, two opposite outer side flaps comprise foldable side areas to be folded around the corner of the supporting element in order to be connected to the corresponding neighbored outer side flap. Here, the second fixation means are arranged on the outer surface of the side areas and on the inner surface of the neighbored outer side flap, or vice versa. The term inner surface denotes the surface of the outer side flap opposite to its outer surface. The second fixation means to connect (join) neighbored outer side flaps may be attached to the outer side flaps in the same manner as previously described first fixation means for inner and outer side flaps.
In another embodiment the support elements have a rectangular tubular profile, which provides resilience against loaded weights.
In another embodiment, the cushioning structure further comprises reinforcement elements separate from the main frame to be inserted into the supporting elements to further increase the resilience of the main frame to carry goods with weights of more than 30 kg, 40 kg, or 50 kg. The reinforcement elements may be made of any material, such as the same material as the main frame and its components (inner and outer side flaps), or pressed paperboard in order to allow a recycling of damaged reinforcement elements. Pressed paperboard enableas use of the reinforcement element more than 100 times before replacement. The reinforcement elements may have a profile adapted to the profile of the supporting elements, such as a profile adapted to fit into the supporting elements in a snug fit manner. Profiles of supporting elements and reinforcement elements fitting together provide resilience, thereby increasing the loading capacity of the cushioning structure.
In another embodiment, the reinforcement elements are foldable into the profile adapted to the profile of the supporting elements and are collapsible into a two-dimensional structure. Reinforcement elements can be transported in a volume saving manner in a collapsed structure, when the non-loaded cushioning structure is transported. The term “foldable” comprises any kind of folding methods.
In one embodiment, the reinforcement elements in a folded status have a profile adapted to the profile of the supporting elements, such as a profile adapted to fit into the supporting elements in a snug fit manner. Profiles of supporting elements and reinforcement elements fitting together provide resilience, thereby increasing the loading capacity of the cushioning structure.
The subject innovation further relates to a container for safely transporting heavy, large and fragile goods comprising a bottom section, a midsection as a container side wall fitting into the bottom section, at least a first and a second cushioning structure according to the present invention with the first cushioning structure as a bottom element fitting into the midsection and for being placed on top of the bottom section with the carrier foil facing upwards to carry good and with the second cushioning structure for being placed on top of the goods with the carrier foil facing downwards to sandwich the goods between the carrier foils of first and second cushioning structures, and a top section fitting on top of the midsection to close the container. Here, the top section is placed on top of the midsection and the second cushioning structure if loaded with goods. During the transport of a container without goods inside, the volume of the container can be reduced and subsequently the top section is placed on top of the bottom section. The midsection may further comprise reinforcement sleeves at the upper and lower edges of the midsection enabling a stacking of the containers of at least 2 meter stacking height. The reinforcement sleeves further improve the reusability (multiple use) of the midsections.
In another embodiment, the bottom section, the top section and the midsection are made of pressed paperboard. Pressed paperboard provides a high resilience and the possibility of being easily recycled.
In another embodiment, the midsection is foldable fitting into the bottom section in a collapsed status, comprising at least one hook-and-loop fastener to be fixed to the first and/or second cushioning structures. In the case of empty containers (without goods inside), the containers can be transported having a reduced size, because the collapsed midsection is placed inside the container now defined by bottom and top section solely.
In another embodiment, the midsection comprises closing means to be fixed to the top section and/or bottom section in order to improve the robustness of the container during transport Closing means may include anchors, hooks, hook-and-loop fasteners, bolts, screws or the like. The closing means enable stacking of the containers of at least 2 meters stacking height.
The subject innovation further relates to a method for loading heavy, large and fragile goods for a safe transport into a container to the present invention comprising the steps of
The subject innovation further relates to a method for transporting a container without loaded goods
After transport, the goods 10 may be de-loaded from the container 8 and the empty container 8 returned to another loading facility to be loaded again. The collapsible cushioning structures 1 and a collapsible midsection 82 provide the possibility to reduce the size of the container 8 when being transported empty, see
While the invention has been illustrated and described in details in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments.
Pursuant to 35 U.S.C. §371, this application is the United States National Stage Application of International Patent Application No. PCT/EP2009/008042, filed on Nov. 11, 2009, the contents of which are incorporated by reference as if set forth in their entirety herein.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP09/08042 | 11/11/2009 | WO | 00 | 7/13/2012 |
