Abstract:
A two piece packing system usable for packing artifacts, including plate glass, which utilizes a two part trapezoidal body construction, with removable holders, which holder can be rectangular or trapezoidal pyramids, in shape, to protect the artifact and/or restraint an artifact against damage, even in the face of vibration, jarring, and careless handling of the artifact.

Description:
[0001]    This invention is a continuation-in-part application of co-pending application Ser. No. 09/544,049 filed Apr. 6, 2000. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to novel, improved two-piece packing device for artifacts, particularly flat artifacts made from plate glass or a similar heavy and breakable substance.  
           [0003]    In another aspect, the present invention relates to novel, improved packing systems for protecting the secured artifact or artifacts from damage during shipping, particularly freight shipping.  
         DEFINITIONS  
         [0004]    “Artifact” is used herein in a perhaps somewhat special sense to include aggregations of objects such as sheets of glass or components of a framework as well as individual objects such as a single sheet of glass, a window, a piece of furniture, a canvass artwork or similar object.  
         BACKGROUND OF THE INVENTION  
         [0005]    The transporting of artifacts often requires that the artifacts be tied to the bed of a vehicle or vehicle-mounted support and/or that artifacts be bundled to facilitate handling and transport. Typically, a flexible restraint such as a rope or strap is employed for these purposes. The rope may be wrapped around the artifact and fixed to the transport device.  
           [0006]    Particularly where the restraint is tight on the artifact, this may result in breakage, denting, abrasion, and other forms of damage to the artifact. Also, if the rope is instead, a wire cable, and the artifact is hard such as a sheet of glass, for example, the artifact may be damaged from abrasion with the cable or bouncing against a hard object.  
           [0007]    These problems are particularly acute in the transportation of artifacts. These problems are perhaps universally encountered in moving vehicles. These problems lead to movement between the artifact and the typical restraint systems, such as in a sawing fashion. These problems cause the artifact to shatter, or become damaged if only secured with a rope or cable.  
           [0008]    A variety of devices for protecting an artifact have been described in issued patents.  
           [0009]    In particular, see U.S. Pat. No. 5,518,348, which is incorporated herein by reference. Also, note U.S. Pat. No. 4,639,977 issued Feb. 3, 1987 to Howard for COMBINATION ROPE GUARD AND ROPE BUNDLE KEEPER; in U.S. Pat. No. 5,056,664 issued Oct. 15, 1991 to Demers for CORNER PROTECTOR APPARATUS; and in those patents cited and discussed in column 1 of Demers.  
           [0010]    The Howard device has all the disadvantages of Demers&#39; including susceptibility to damage except for slits which allow the device to be assembled to an associated restraint without threading the latter through the protective device. However, the thin leather or comparable material from which the Howard device is made would allow it to be easily dislodged from the associated restraint both in tying down or bundling artifacts and in the subsequent removal and handling of the flexible restraint.  
           [0011]    U.S. Pat. No. 5,775,753 equipment for loading containers, U.S. Pat. No. 5,685,437, device for storing glass plates or insulating glass panes, U.S. Pat. No. 3,990,576 transparent container for glass panels, U.S. Pat. No. 3,939,780 apparatus for shipping flat glass without packing cases, and U.S. Pat. No. 3,596,755, method and apparatus for shipping flat glass without packing cases all relate to the present invention and are incorporated by reference.  
           [0012]    Drawbacks of the character discussed above also exist in available systems, which employ complex machinery to hold the glass, and increase the cost of shipping. Still other disclosed devices do not enable multiple panes of glass to be shipped in the same container without severe damage possibilities.  
           [0013]    A need has long existed for an inexpensive, protective packing system designed to eliminate damage to bundled, assembled, or tied down artifacts which can be handled in air cargo, ship holds, and other containers without concern for the size of the artifact in the container, and that damage could occur to the artifact, particularly if it is glass plate. In addition, a long need has existed for an environmentally friendly device of this type, made of recyclable materials. Finally, the present invention overcomes a long felt need for a packing system which is easily assembled in the field, and is strong, easy to lift, and easy to ship.  
         SUMMARY OF THE INVENTION  
         [0014]    The present invention relates to a packing system for packing flat objects comprising: a body comprising a first end and a second end, a base and a top; and the body comprising at least a two part construction secured together, wherein said two part construction comprises: a first component with a first component base extension a first component side, and a first component top; and a second component with a second component base extension, a second component side, and a second component top and wherein the body is assembled such that the first component base extension is layered on the second component base extension; and the first component top is layered on the second component top, and further wherein the first component side further has a first component interior surface and a first component exterior surface and the second component side further has a second component interior surface and a second component exterior surface; a first end cap removably attached to the first end and a second end cap removably attached to the second end; a holder engaging opposite ends of an object wherein the holder comprises a slot into which the object can be removably inserted, and wherein the holder has a center portion which extends to and fits against the first component interior side and the second component interior side, and the holder has a first holder extension, second holder extension, third holder extension and a fourth holder extension and wherein each extension is secured to an interior side of the body for securing the holder tightly in place.  
           [0015]    The objects and features of the present invention will be apparent from the foregoing and the appended claims and as the ensuing detailed description and discussion of the invention in conjunction with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a side view of the body portion of the present invention.  
         [0017]    [0017]FIG. 1A is another side view of the body portion of the present invention.  
         [0018]    [0018]FIG. 2 is a cross sectional view of the body of the present invention.  
         [0019]    [0019]FIG. 2A is a perspective view of the interior of the box of the present invention.  
         [0020]    [0020]FIG. 2B is a side view of a holder of the present invention.  
         [0021]    [0021]FIG. 3 is a view of an object contained in the two holders of the present invention.  
         [0022]    [0022]FIG. 4 is a front view of a holder containing a slot.  
         [0023]    [0023]FIG. 4A is a side view of a holder containing a slot.  
         [0024]    [0024]FIG. 5 is a perspective view of an end cap used in the present invention.  
         [0025]    [0025]FIG. 6 is an end view of the packing system.  
         [0026]    [0026]FIG. 6A is a perspective view of a base of the packing system.  
         [0027]    [0027]FIG. 7 shows the same view of the invention as in FIG. 6 with footpads.  
         [0028]    [0028]FIG. 8 shows a cross sectional view of the body of the present invention with footpads, and an object or artifact contained in the holders.  
         [0029]    [0029]FIG. 9 is another cross sectional view of the body of the present invention with casters, with the object or artifact contained in the holders being of different size than the device shown in FIG. 8.  
         [0030]    [0030]FIG. 10 shows how the packing system can hold multiple artifacts or objects.  
         [0031]    [0031]FIG. 11 is a front view of a holder with a slot and the backtop disposed on one side.  
         [0032]    [0032]FIG. 12 is a side view of the packing system having  3  holders, with one holder having two backstops in an alternating arrangement. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0033]    [0033]FIG. 1 shows the body ( 16 ) of the unique packing system ( 2 ) having a first wall ( 6 ). The body ( 16 ) has a first end ( 18 ), a second end ( 20 ), a base ( 4 ) and a top ( 10 ). The first holder ( 26 ) for engaging the artifact or flat object to be transported in the packing system is shown as a dotted line. The second holder ( 28 ) for engaging the artifact or flat object is shown as a second dotted line. The packing system is assembled when the body ( 16 ) is closed with first end cap ( 22 ) and a second end cap ( 24 ) which are removably attached in formed cavities which are created by the first and second wall, top and base of the body.  
         [0034]    In the most preferred embodiment, the body ( 16 ) is in the shape of a trapezoidal pyramid as are the end caps.  
         [0035]    The body as shown in FIG. 1A has a first component ( 15 ) with a first component base extension ( 19 ) and a first component top ( 100 ). The body also comprises a second component ( 17 ) with a second component base extension ( 21 ) and a second component top ( 102 ) and wherein the body is assembled such that the first component base extension is layered in a sandwich like-manner on the second component base extension. Similarly, the tops can be layered in a sandwich-like manner.  
         [0036]    In an alternative embodiment, the end caps can be disposed over the edges of the body and secured to the body with any conventional device, including but not limited to, staples, glue, brads, bolts, hinges, rivets, straps, tape, nails or a combination thereof. In the preferred embodiment, adhesive is used.  
         [0037]    The present invention is designed for supporting weight from 1 to 500 pounds.  
         [0038]    [0038]FIG. 2 shows a preferred embodiment of the present invention. Base ( 4 ) is attached to first wall ( 6 ) and a second wall ( 8 ). The body has an interior side ( 30 ) and an exterior side ( 32 ). The top of the body ( 16 ) is formed from a first wall extension ( 12 ) integral with first wall ( 6 ), which is folded over a second wall extension ( 14 ) that is integral with second wall ( 8 ) forming the top ( 10 ) in an overlapping or sandwich-like embodiment. The first wall extension can be on top of the second wall extension or it can be under the second wall extension, and the wall extensions can then be removably secured together, such as with adhesive. In the cross section of FIG. 2, the first holder ( 26 ) is shown having a first slot ( 36 ) into which an object is typically inserted.  
         [0039]    In still another embodiment of the invention shown in FIG. 2A, the packing system for packing flat objects comprises: a body comprising a first end and a second end, a base and a top; and the body comprises at least a two part construction secured together, wherein the two part construction comprises: a first component with a first component base extension, a first component side, and a first component top; and a second component with a second component base extension, a second component side, and a second component top, and wherein the body is assembled such that the first component base extension is layered on the second component base extension; and the first component top is layered on the second component top, and further wherein the first component side further has a first component interior surface ( 104 ) and a first component exterior surface ( 106 ) and the second component side further has a second component interior surface and a second component exterior surface (not shown in FIG. 2A. In this embodiment, the first end cap is removably attached to the first end of the body and a second end cap is removably attached to the second end of the body. A holder ( 108 ) is shown capable of engaging and object using a slot ( 110 ) into which an object, such as plate glass can be removably inserted. The holder ( 108 ) has a center portion which extends to and fits against the first component interior side ( 104 ) and the second component interior side (not shown). The holder ( 108 ) may have flaps or extensions, as shown in FIG. 2B. The first holder extension ( 112 ), second holder extension ( 114 ), third holder extension ( 116 ) and a fourth holder extension ( 118 ). Each holder extension is secured to an interior side of the body ( 108 ), such as with adhesives or rivets for securing the holder tightly in place in the body of the box.  
         [0040]    The packing system can be made from single scored sheets of materials or two sheets of materials connected together or multiple laminate structures. The key to the material selection for the body is strength of the body once assembled and the weight of the overall structure so that it works for shipping.  
         [0041]    [0041]FIG. 3 depicts a typical artifact or object ( 34 ) having a first end ( 40 ) which passing through first slot ( 36 ) of first holder ( 26 ) and a second end ( 42 ), which passes through second slot ( 38 ) of second holder ( 28 ).  
         [0042]    [0042]FIG. 4 shows first holder ( 26 ) having a slot ( 36 ) for holding the artifact. The slot preferably is rectangular, but may be square, or of another shape to accommodate the artifact. For example, if the artifact is cylindrical, the slot may be cylindrical. In the preferred embodiment, the size of the body is at least about ⅛ inch to about 3 inches thick. The typical holders are between about ¼ inches and about 3 inches thick. The overall body preferably has a height of 48 and ¼ inches, but can range from about 12 inches to about 6 feet in height. A preferred body has a width at the base of 24 and {fraction (9/16)} th  inches, preferably in a range of from about 3 inches in width to about 3 feet in width at the base. The width at the top is preferably 7 and {fraction (7/16)} th  inches, but can range from 3 inches to about 3 feet in width. The preferred side height is 48 and ¼ inch long and can range from 12 inches to 6 feet in length. The preferred depth of the body is 67 and ⅞ th  inches, but can range from 12 inches to 10 feet in depth.  
         [0043]    [0043]FIG. 4A shows a slot  112  which has a T shape construction in the holder  108 . The T shaped slot has a vertical opening and a horizontal opening. The object is dispoed in the vertical opening and an additional base support  114  is disposed in the horizontal opening. A plurality of holders and be used in the body of the box, and in some embodiments, two holders are adequate, but three or more may be needed for certain very heavy applications.  
         [0044]    The invention has been designed to use a holder with a slot opening, which is preferably rectangular and ideally 4 and ¼ inches wide. However, the slot could be as narrow as ½ inch and up to 6 inches wide. The height of the slot in the most preferred embodiment is 40 inches in height, but can range from 6 inches up to any height, which still provides strength to the holder form, which the slot is constructed.  
         [0045]    This most preferred slot is cut to accommodate a 40×60 inch plate glass object. The most preferred structure of the holder is a 7 ply laminate structure made from cardboard. However, the holder could be useful if it had anywhere from 1 to 20 plies in thickness, and the thickness would depend on material selection for the holder and the artifact to be transported.  
         [0046]    [0046]FIG. 5 shows an end cap having a cap body ( 52 ), with a first engagable edge ( 54 ), a second engagable edge ( 56 ), a third engagable edge ( 58 ) and a fourth engagable edge ( 60 ). The end caps create “lid like” construction.  
         [0047]    In the preferred embodiment, the end caps are not fitted over the openings created in the body ends, but instead are fitted snugly inside, creating strength and a secure packing system.  
         [0048]    With the end caps inserted into the body in this manner, the end caps are recessed. This type of end cap assembly enables faster assembly of the system in the field than any known packing system. The end caps can be fastened to the body using any of a variety of conventional techniques, which include the use of staples, adhesives, bolts, rivets, tape, and screws. This version of use of the end caps also provides a significant advantage compared to other system with regard to lifting. The end caps, assemble on the body in this way, provide a ledge like construction, which is strongly reinforced by the layering of the body, and the use of the folds in the material, such that lifting become only easier, by providing a surface, but more reliable, because the edges which are lifted have been reinforced by the overlaid construction and the folded effect. The unique end cap insertion moves the structural line of support closer to the centerline of the body. In a preferred embodiment, this end cap provides a third layer of on top of the layered sandwich like structures of both the body&#39;s top and base.  
         [0049]    Alternative embodiments of the end cap configuration on the body contemplate that the end cap to be inserted into the body, with the end cap engagable edges,  54 ,  56 ,  58  and  60 , adhered to the interior walls of the body, creating a smooth surface, which resists the accumulation of dirt, mice, or other items when stored. In this configuration, the end cap provides a larger volume for the interior of the body, which enables a larger artifact to be transported using the packing system. Also, this version of the end cap usage enables printing, such as origin or destination information or shipping contents to be on an easily viewable exterior surface of the body.  
         [0050]    An embodiment of the invention involves disposing the edges of the end cap on the body ( 52 ) so that the engageable edges,  54 ,  56 ,  58  and  60  of the end cap overlay the exterior of the body effectively providing additional protection to the edges of the body, and encapsulating the body on each end.  
         [0051]    [0051]FIG. 6 shows the body ( 16 ) with the top constructed to form a laminate or sandwich design and the base constructed to form a laminate, or sandwich design. The base is further enhanced with a base support ( 44 ) attached to the base of the body to keep the body from touching a floor or similar surface and to facilitate lifting, such as by a forklift. In still another embodiment, the base supports extend the length of said base. For another embodiment, the base supports are disposed at various intervals along the length of the base, enabling a forklift to slide between the base supports to easily lift the packing system without damaging the base or the base supports. FIG. 6B shows an embodiment where the base support ( 44 ) extends the entire length of the base ( 4 ).  
         [0052]    In yet another embodiment, the body can be made even more useful by adding a first handle ( 62 ) and second handle ( 68 ) which can be attached to first wall ( 6 ) and second wall ( 8 ) respectively. It is contemplated that the handles can be of a variety of materials and forms, and can even be cut from the walls of the body, creating slots for lifting the body. These slots could be of any useful shape. At least one slot per wall of the body is contemplated as useful in this embodiment.  
         [0053]    [0053]FIG. 7 shows body ( 16 ) having at least two-foot pads, a first foot pad ( 48 ) and second foot pad ( 50 ). Three or more footpads or base supports could be used within the invention. The footpads are designed to enable the packing system to be lifted, such as by a forklift without damaging the artifact. The packing system, in a preferred embodiment, could use removable footpads or base supports, ones that are attached with a removable adhesive or a similar material, such as a bolt. Additionally, the foot pads or base supports are preferably positioned at least under the first and second holders, although it is contemplated that additional foot pads could also be located along the base ( 4 ) for additional support. The foot pads can be made of wood, cardboard, plastic, corrugated cardboard, Styrofoam or combinations thereof.  
         [0054]    [0054]FIG. 8 shows a cross section of the body ( 16 ) wherein the artifact or object, ( 34 ) is in a first position, inserted into the slot of a first holder at a first position ( 70 ) and into the slot of a second holder at a first position ( 74 ). The distances from the holder to the end of the body are noted as distances “a” and “b” respectively. Also, this embodiment shows the base supports ( 44 ) and ( 46 ) disposed directly under the holders ( 26 ) and ( 28 ) respectively. The slots may be engineered to hold one or more artifacts, however, if additional space remains in the slot area once the artifact is inserted, it is contemplated that spacers or packing material could be used as a buffer to prevent any movement of the artifacts in the slot which would cause damage or warpage. In the preferred embodiment, it is contemplated that rectangular spaces would be used, made from cardboard in a multi-ply construction.  
         [0055]    [0055]FIG. 9 shows a body ( 16 ) with a small artifact engaged in the holders of body ( 16 ). In FIG. 9, the body ( 16 ) is also presented as resting on a set of casters, hereafter referred to as first wheel set ( 66 ) and second wheel set ( 68 ). These casters could be removably attached, or, alternatively, holes could be punched into the base of the box, and the wheel sets could then be set into those holes and secured, such as with a cotter pin on the interior side of the box.  
         [0056]    In this Figure, the object ( 35 ) is shown to be held by first and second holders ( 26 ) and ( 28 ) respectively, however, the distance from first holder ( 26 ) in this figure, which is at the first holder&#39;s second position ( 72 ), is shown as distance “a′” to signify that the distance is different than the distance “a” shown in FIG. 8. Also, second holder ( 28 ) in this Figure is positioned at second holder&#39;s second position ( 76 ) and is shown as being at a distance of “b′” to signify that first and second holders can be moved, slid, and repositioned to accommodate smaller objects inside the body.  
         [0057]    [0057]FIG. 10 shows the body ( 16 ) wherein the first holder ( 26 ) contains an object or artifact ( 34 ) and a second additional object ( 80 ) is shown adjacent the object ( 34 ) and a third additional object ( 82 ) is shown adjacent the object ( 80 ) and all three objects are restrained with a restraining band ( 78 ). It is contemplated as within the scope of the present invention to use one or more restraining bands depending on the weight of the artifact or artifacts being secured for transit. In an alternative embodiment, these additional objects ( 80 ) and ( 82 ) could be inserted into the slots of the holder. It is also contemplated that if there is extra room in the slots, permitting the objects to slide, then wedges, such as a wedge made from cardboard, could be inserted into the slot to prevent jarring or movement of the additional objects in the slots. Wedges could be used to hold objects in the slots where the object invented for shipping is significantly less in width than the slot opening.  
         [0058]    [0058]FIG. 11 shows holder ( 26 ) with a backstop ( 84 ). The backstop ( 84 ) prevents the object ( 34 ) from sliding through the slot in the holder.  
         [0059]    [0059]FIG. 12 shows a body ( 16 ) with a holder ( 26 ) disposed in the center of the body ( 16 ). A portion of the slot of holder ( 26 ) is backstopped to prevent a first object ( 34 ) from sliding through the holder and a second portion of the same slot is backstopped on the opposite side to prevent and object ( 35 ) from sliding through the slot ( 26 ). Two additional holders are shown, ( 100 ) and ( 102 ) with slots which the objects passing through.  
         [0060]    The packing system is contemplated as a reusable system, making it environmentally friendly. It is also contemplated that the packing system is made of post consumer paper, which is recyclable, reducing the environmental impact to the creation, use and disposal of this packing system.  
         [0061]    Handles can be disposed on the walls of the body for ease of lifting of the packing system. In a preferred embodiment, a first handle ( 62 ) is integral with first wall ( 6 ) and a second handle ( 68 ) is integral with second wall ( 8 ). The handles can be any number of forms, such as punched out handholds, or attached straps, which could be made from rope, nylon, or leather or any similar material. Preferably, the straps are removably attached to the walls, such as through two holes punched into the walls of the body. Handles could also be plastic handholds, such as self-attaching or metal handles which are riveted or bolted onto the walls. Even a cardboard handhold is contemplated as possible with this invention such a handhold could be punched out of the wall of the body, and used for lifting.  
         [0062]    The object or artifact ( 34 ) could be any number of types of objects, including but not limited plate glass, stained glass, panels, mirrors, artwork, decorative doors, ceramic plates, frames, large plate-like fragile materials, molding, windows, and china.  
         [0063]    The body can be a unitary structure fabricated from cardboard or by molding from a rigid or semirigid polymer, such as polyvinyl chloride or comparable material.  
         [0064]    In the preferred embodiment, body  16  has a trapezoidal cross-sectional configuration defined by integral, walls and overlapping extensions that form a laminate structure for the top and base.  
         [0065]    Alternative embodiments contemplate that the walls could be secured, such as with hinges or similar attaching means and the top, base and walls could all be independent, structures which are their affixed together.  
         [0066]    The body of the present invention could comprise one or more of a variety of lightweight, impact resistant materials. Contemplated materials include cardboard, corrugated paper, lightweight plywood, sheet metal, sheet tin, thin stainless steel, wood, high impact plastic, metal/plastic laminate materials, graphite composites, fiberglass, fiberboard or combinations thereof. Cardboard is the preferred material of the packing system of the present invention.  
         [0067]    The invention may be embodied in many forms without departing from the spirit or essential characteristics of the invention.  
         [0068]    The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes, which come within the meaning and range of equivalency of the claims, are therefore intended to be embraced therein.