Abstract:
The present invention comprises an outer box comprising four sidewalls, a first end and a second end; a rat box comprising a crush zone, the rate box positioned at at least one end of the outer box; a half moon support fitting against the walls of the outer box comprising a surface in contact with a product surface and angled slots diverging interiorly from an outer edge of the half moon support; torpedo shield panels positioned inside of the outer box having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots of the half moon support; and an inner support having a plurality of contact points for contacting an inner product surface, the inner support extending beyond each end of the product and received by the rat box, thereby suspending the product within the outer box.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Application No. 61/093,714 filed Sep. 2, 2008. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to novel packaging for shipped objects and more particularly to packaging for chimney pipe. 
       BACKGROUND OF THE INVENTION 
       [0003]    Manufactured products are generally shipped or mailed to their final destination. One such product is chimney pipe. In many applications, chimney pipe is installed outside and visible to the public. As such, modern chimney pipes are plated or coated to make them aesthetically pleasing. 
         [0004]    It is not uncommon for chimney pipe to be scratched, dented or otherwise damaged during shipping, requiring the installer to ship the item back for replacement. This can cause project delays with resultant cost overruns, wasted time, effort and resources. 
         [0005]    Known packaging uses rectangular boxes in which the chimney pipe is placed. There may or may not be padding surrounding the chimney pipe. Most often the packaging is in direct contact with the pipe with no crush zones so that, for example, if a pointed object pierces the box, the chimney pipe is easily scratched or dented. 
         [0006]    Formed plastic has been used to encase and protect shipped items. However, this packaging method greatly the increases the packaging costs, is not environmentally sound, and is too expensive to be cost effective for lower priced items such as chimney pipe. 
         [0007]    Accordingly, there is still a continuing need for an economical, light weight, environmentally-friendly packaging which more effectively protects shipped products than does known packaging. The present invention fulfills this need and further provides related advantages. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    The present invention provides an improved package design for protecting a product during shipment. 
         [0009]    In a first embodiment, the present invention comprises:
   a) an outer box comprising four sidewalls, a first end and a second end;   b) a rat box comprising a crush zone, the rate box positioned at at least one end of the outer box;   c) a half moon support fitting against the inner wall of the outer box comprising a surface in contact with a product surface and angled slots diverging interiorly from an outer edge of the half moon support;   d) torpedo shield panels positioned inside of the outer box having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots of the half moon support; and   e) an inner support having a plurality of contact points for contacting an inner product surface, the inner support extending beyond each end of the product and received by the rat box, thereby suspending the product within the outer box.   
 
         [0015]    In a second embodiment, the at least one half moon support and the torpedo shields are omitted. 
         [0016]    It is an object of the present invention to provide packaging which protects shipped products from scratches. 
         [0017]    It is an object of the present invention to provide packaging which protects shipped products from dents. 
         [0018]    It is an object of the present invention to provide protective packaging which is economical. 
         [0019]    It is an object of the present invention to provide protective packaging which is environmentally-friendly. 
         [0020]    It is an object of the present invention to provide protective packaging which has reduced waste. 
         [0021]    It is an object of the present invention to provide protective packaging which is light weight. 
         [0022]    Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    The accompanying drawings are included to provide a further understanding of the present invention. These drawings are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention, and together with the description, serve to explain the principles of the present invention. 
           [0024]      FIG. 1  is a perspective view of the novel packaging according to the present invention. 
           [0025]      FIG. 2  is a side elevational view of the novel packaging according to the present invention. 
           [0026]      FIG. 3  is a cross-sectional plan view of the novel packaging according to the present invention shown in  FIG. 2 . 
           [0027]      FIG. 4  is a plan view of the cardboard cut outs which are folded into a rat box of the packaging according to a first embodiment of the present invention. 
           [0028]      FIG. 5  is a plan view of the cardboard cut outs which are folded into the inner support of the packaging according to the present invention. 
           [0029]      FIG. 6  is a plan view of the cardboard cut outs which are folded into the torpedo shield of the novel packaging according to the present invention. 
           [0030]      FIG. 7  is a cut out of several half moon supports. 
           [0031]      FIG. 8  shows a cross sectional view of a support according to the prior art. 
           [0032]      FIG. 9  shows a cross sectional view of a half moon support interlocked with the torpedo shield. 
           [0033]      FIG. 10  is a plan view of the cardboard cut outs which are folded into a rat box of the packaging according to a second embodiment of the present invention. 
           [0034]      FIG. 11  is a cross-sectional plan view of the novel packaging according to a second embodiment of the present invention. 
       
    
    
       [0035]    Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0036]    As required, detailed embodiments of the present invention are disclosed; however, it should be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessary to scale, and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. 
         [0037]    In the following exemplars, the present invention is fabricated of cardboard. Cardboard is economical, rigid, lightweight, offers protection against scratching and denting and is environmentally-friendly. However, the invention is not limited to cardboard. 
         [0038]    Turning now to the Figures,  FIG. 1  is a perspective view of the novel packaging according to a first embodiment of the present invention. An outer box  1100  shown with its front face removed, encloses a product  1  being shipped. In this embodiment, product  1  has an elongated cylinder shape, for example, a chimney pipe. However, the packaging is not limited to an elongated cylinder shape and may be used with slight modifications to package objects having various shapes and cross sections. 
         [0039]    An elongated package, such as packaging used to ship chimney pipe, is most prone to damage when it falls on an end, due to the substantial force concentrated on a relatively small surface area. To protect the ends of the product  1 , a ‘rat box’  1200  is constructed and used at either end of the package  1000 , each rat box  1200  having end crush zones  1210 . 
         [0040]    Two half moon supports  1500  hold product  1  in the center of the box  1100 . Each half moon support  1500  includes a product interface surface shaped to mate with the product  1 . Each half moon support  1500  has a corresponding half moon support  1500  on the opposite side of the product  1  thereby creating support around the perimeter of the product  1 . 
         [0041]    Each half moon support  1500  has an angled slot  1510  which receives an edge of a torpedo shield  1400 . Torpedo shields  1400  are shown in phantom for clarity. There are torpedo shields  1400  on opposite sides of product  1 . These torpedo shields  1400  are designed to provide additional protection to the product  1  should an object break the integrity of outer box  1100 . The elongated torpedo shield  1400  fits within the angled slots  1510  of the half moon supports  1500 . 
         [0042]    Preferably, each torpedo shield  1400  is comprised of a single piece having a center panel and two side panels diverging at an angle with respect to the center panel, the side panels at least partially fitting into the slots  1510  of the half moon support  1500 . The geometry of the torpedo shield  1400  serves to transfer/redirect an impact force away from the product  1  into the half moon support  1500 . This transfer/redirection of impact force is novel from the prior art which uses geometry that serves only to act as a physical block to an impact. Without the novel force redirection capability of the present invention, the prior art can suffer deformation of the product when receiving an impact, even if the prior art geometry prevents direct impact contact to the product. 
         [0043]      FIG. 2  is a side elevational view of the novel packaging according to the present invention. In this view, outer box  1100  is shown enclosing product  1 . Rat boxes  1200  containing crush zones  1210  are shown at either end of package  1000 . The two half moon supports  1500  are shown in cross section. Rigidity is achieved by, for example, several folded cardboard layers. Torpedo shield  1400  is shown in phantom for clarity. The torpedo shield on the opposite side of product  1  is not visible from this view. 
         [0044]      FIG. 3  is a cross-sectional plan view of the novel packaging according to the present invention shown in  FIG. 2 . 
         [0045]    Viewing  FIGS. 2 and 3 , the outer box  1100  is visible enclosing shipped product  1 . The rat box  1200  is shown at either end of the package  1000  each having end crush zones  1210 . The two half moon supports  1500  have a product interface surface shaped to hold product  1  in the center of the box  1100 . A torpedo shield  1400  is shown in phantom ( FIG. 2 ) over product  1 . The elongated torpedo shield  1400  fits within the half moon support  1500 . 
         [0046]    It is possible that an impact striking at an angle to the end of package  1000  could collapse the ends of a hollow product  1 , for example, a chimney pipe. In order to protect such hollow products  1 , an inner support  1600  is provided. Inner support  1600  has, for example a triangular cross sectional shape which fits snugly inside of the open ends of product  1 . Optionally, other cross sectional shapes that provide interior support to a hollow product may be used, for example, an octagonal cross sectional shape or any other geometric cross sectional shape that provides supporting contact points within the product  1 . 
         [0047]    Although inner support  1600  may span the entire length of product  1 , in a preferred embodiment, inner support  1600  comprises two separate end pieces. Regardless of whether inner support comprises two separate pieces or a single piece, inner support  1600  extends beyond the product  1  to engage a mating cutout in the rat boxes  1200 . In this manner, product  1  is suspended within package  1000 . 
         [0048]      FIG. 4  is a plan view of a cardboard cut-out pattern which is folded into a rat box  1200  of the novel packaging according to the present invention. The mating cutout, for example, triangular cut out  1211  in panel  1201 ,  1213  in panel  1203 ,  1251  in panel  1231  and  1253  in panel  1233  is provided. A panel  1202  connects panels  1201  and  1203 . Similarly, a panel  1232  connects panels  1231  and  1233 . 
         [0049]    Fold lines  1271 ,  1273  and  1275 ,  1279  indicate where panels  1201  and  1203  fold over each other making a box shape with the triangular cut outs  1211  and  1213  overlapping each other to make a single triangular hole. 
         [0050]    A portion  1285  between fold lines  1271  and  1273  becomes a side of the folded rat box  1200 . Similarly, a portion  1287  between fold lines  1275 ,  1279  becomes the other side of rat box  1200 . Notches  1281  overlap notches  1283  of panels  1202  and  1232  to create a recess to receive the top and bottom edges of torpedo shields  1400 . Tabs  1260  fold to make the other sides of the rat box  1200 . Rat box  1200  is now ready to receive and hold the inner support  1600 . 
         [0051]      FIG. 5  is a plan view of the cardboard cut-out which folds into the exemplar triangular shaped inner support  1600  of the novel packaging according to the present invention. 
         [0052]    Surface  1610  is one of the faces of the inner support  1600 . By folding on the fold lines  1651 ,  1610  becomes one of the triangular faces, panels  1620  become two of the other faces. Sections  1640  allow space for folding and provide a flattened apex of the triangular shape. Panels  1630  overlap each other. 
         [0053]      FIG. 6  is a plan view of the cardboard cut outs which are folded into the torpedo shield  1400  of the novel packaging according to the present invention. By folding torpedo shield  1400  cut out on center line  1423 , a double layer thickness with panels  1410  overlapping each other is formed. Panels  1420  each overlap as do panels  1430 . Notches  1433  overlap notches  1431  on one side and notches  1421  on the other side. These notches fit into slots  1510  of half moon support  1500  shown in  FIG. 7 . By partially folding panels  1420  and  1430 , the torpedo shield  1400  takes on its characteristic shape as shown in  FIG. 1 . 
         [0054]    Panels  1430  are partially folded on line  1411 . Panels  1420  are also partially folded at line  1413  to create the characteristic shape of torpedo shield  1400 . The upper and lower corners of the partially folded torpedo shield  1400  fit into the recesses created from notches  1281  and  1283  of  FIG. 4 . 
         [0055]      FIG. 7  is a cut out of several half moon supports  1500 . The cutout is cut on line  1515  to result in two identical mirror images. Each is folded into a half-moon support  1500 . 
         [0056]    For ease of reading, only one panel side  1520  of the cut out is described. Other sides are similarly formed. Panels  1517 ,  1519 ,  1521  and  1523  are connected to each other at fold lines  1511 . Depending upon the thickness of the materials used and the desired strength, the left set of panels  1520  may be folded into 1, 2 or 4 half moon supports  1500 . Panels  1517  may be folded onto panel  1519 . They may additionally be folded onto panels  1521  and  1523 . 
         [0057]    The panels are scored, or partially cut on line  1513  to allow easier folding. The panels are then folded on line  1513  to create the half moon shape. The inner surface  1517  is designed to fit against and support the product  1  ( FIG. 1 ). Optionally this inner surface may be covered with a material to further prevent scratching of the product. 
         [0058]    In this manner, the structure of the half moon supports  1500  and the torpedo shield  1400  fit together to make a structure which surrounds the product  1  perimeter, holds itself together without connectors, is rigid, and resists torsional forces. Due to the geometry of the half moon supports  1500 , the angled slots  1510  and the torpedo shield  1400 , a rigid structure is formed. 
         [0059]      FIG. 8  shows a cross sectional view of a support according to the prior art. A flat elongated piece  11  is shown with it folded at 90 degree angles to create side panels  13 . The slots  15  are perpendicular to the front edge  17  allowing the side panels  13  to slide into them. This allows for easy construction. Problematically, the side panels  13  slide out just as easily as they slide into slots  15 . 
         [0060]    Twisting elongated piece  11  causes the left edge  13  to move in the direction of arrow A into slot  15 . If left side panel  13  is fully inserted into slot  15 , then it does not move. However, the right edge panel  13  is forced to move in the direction marked by arrow B out of slot  15  causing it to partially disassemble. With the prior art design, if a force contacts elongated piece  11  in a direction marked by arrow “C”, the entire elongated piece  11  may be pulled out of slots  15 . These may progressively ‘creep’; moving further and further out until it is disassembled. Furthermore, as discussed above, the prior art does not allow for transfer/redirection of the impact force away from the product. 
         [0061]      FIG. 9  shows a cross sectional view of a half moon support  1500  interlocked with the torpedo shield  1400 . Due to the geometry of the present device, it is harder to disassemble. Center panel  1410  must be bowed to allow side panels  1420 ,  1430  to be inserted into slots  1510 . However, when a force is applied in the direction marked by arrow “D”, side panels  1420 ,  1430  resist being pulled out of slots  1510  and return to their original positions after the force is removed. This geometry only disassembles when force D is great enough to pull side panel  1430  entirely out of slots  1510 . In this manner, the present invention employs a more rigid internal structure, which is more resilient and better protects the product than does the prior art. 
         [0062]    The above embodiment of the present invention is envisioned for use with spans of product  1 , where without such rigidity, package  1000  could fold upon receiving a side impact thereby causing damage to product  1 . 
         [0063]    When shorter spans of product  1  are packaged, for example, spans of about twenty four inches or less, the added rigidity provided by half moon supports  1500  and torpedo shields  1400  become optional. Packages  1000  of such lengths have been found to be sufficiently rigid so a to not fold during a side impact. However, to better protect such shorter spans of product  1 , when half moon supports  1500  and torpedo shield  1400  are omitted, inner support  2600  ( FIG. 11 ) ideally comprises more contact points than a triangular cross-sectional geometric shape provides. Preferably, an octagonal cross-sectional geometric shape is utilized, although inner support  2600  is not limited to an octagonal cross-sectional geometric shape. 
         [0064]      FIG. 10  is a plan view of a cardboard cut-out pattern which is folded into a rat box  1200  of the novel packaging according to a second embodiment. The mating cutout, for example, octagonal cut out  2211  in panel  2201  and  2213  in panel  2203  is provided. A panel  2202  connects panels  2201  and  2203 . 
         [0065]    Fold lines  2271 ,  2273  and  2275 ,  2279  indicate where panels  2201  and  2203  fold over each other making a box shape with the octagonal cut outs  2211  and  2213  overlapping each other to make a single octagonal hole. 
         [0066]    A portion  2285  between fold lines  2271  and  2273  becomes a side of the folded rat box  1200 . Similarly, a portion  2287  between fold lines  2275 ,  2279  becomes the other side of rat box  1200 . Notches  2281  overlap notches  2283  of panel  2202  to create a recess to receive the top and bottom edges of optional torpedo shields  1400 , should they be utilized. Tabs  2260  fold to make the other sides of the rat box  1200 . Rat box  1200  is now ready to receive and hold the inner support  2600 . 
         [0067]      FIG. 11  is a cross-sectional plan view according to the second embodiment. The optional two half moon supports  2500  have a product interface surface shaped to hold product  1  in the center of the box. An optional torpedo shield  2400  is shown over product  1 . The optional elongated torpedo shield  2400  fits within the optional half moon support  2500 , received by slots  2510  of optional half moon support  2500 . Inner support  2600  fits snugly inside of the open ends of product  1 . 
         [0068]    Although the present invention has been described in connection with specific examples and embodiments, those skilled in the art will recognize that the present invention is capable of other variations and modifications within its scope. These examples and embodiments are intended as typical of, rather than in any way limiting on, the scope of the present invention as presented in the appended claims.