Abstract:
A support for receiving and supporting stacked tiers of cylindrical roll stock is provided. The support can be either located below a first tier of the roll stock, placed between tiers of roll stock, or secured above the top tier, all to provide a stacked arrangement of the roll stock that is especially suited for storage or transport. The roll support is preferably formed from a resinous plastic, polymeric material, such as PET that includes a plurality of curved cradles and each curved cradle is sized for receiving a roll of cylindrical stock. A multiple of the support bodies combine to support a multiple of the rolls of cylindrical stock in a tiered array. Each support body can substantially support the weight of each roll of cylindrical stock received within its curved cradles. The roll supports are manufactured in thin, nestable configurations, and can be stored with a minimum of nested stack height.

Description:
PRIORITY, RELATED APPLICATIONS  
       [0001]    This application is a Continuation-In-Part of prior pending application Ser. No. 09/613,652, filed Jul. 11, 2000, now U.S. Pat. No. 6,322,034, issued Nov. 27, 2001, which was a Continuation-In-Part of prior pending application Ser. No. 09/330,536, filed Jun. 11, 1999, now U.S. Pat. No. 6,209,839, issued Apr. 3, 2001, the disclosures of which are incorporated herein in their entirety by this reference. 
     
    
     
       TECHNICAL FIELD  
         [0002]    The invention relates to stacking supports for roll stock, and more particularly to nestable stacking supports for roll stock.  
         BACKGROUND  
         [0003]    “Roll stock” is a term that is commonly used to describe cylindrical rolls or tubular rolls of a selected width of thin materials. Such items include paper products, plastic film products, thin gauge metals, roofing sheets, and various other thin materials. Many cylindrical or tubular shaped rolls are packed on pallets for shipping and storage. Such packing is often provided in tiers of rolls, and commonly, the rolls are horizontally oriented above the pallets. Consequently, in order to stabilize and support the cylindrical or tubular rolls, stacking supports have typically been employed.  
           [0004]    Various materials and structures have been suggested, attempted, or actually used for receiving stacked rolls of materials. Some disclosures have suggested the use of a support and spacing member for roll stock formed from expanded polystyrene foam. However, certain characteristics of polystyrene foam make it less than ideal for use in roll stock supports. This is because expanded polystyrene is rather rigid, relatively brittle, and thus has a minimum of structural flexibility. Additionally, polystyrene foam rolls supports do not typically compactly nest together and thus storage of roll supports manufactured of polystyrene or similar plastic materials usually takes up considerable space.  
           [0005]    One alternative to polystyrene foam roll supports has been the development and use of roll supports made from papier-mâché. Unfortunately, in many circumstances, papier-mâché is inadequate for roll stock supports. For example, the strength of papier-mâché roll stock supports rapidly degrades which they get wet. Consequently, papier-mâché roll sock supports must be protected from the weather, and even cannot be used in many humid environments. Such weather protection is especially difficult during transport, and requires that such supports be shipped within a fully enclosed container or trailer. Further, even though roll supports manufactured from papier-mâché have improved stackability over foam type roll supports, the papier-mâché roll stackers must be of substantial thickness to support the weight of many materials.  
           [0006]    Therefore, it can be appreciated that there still remains a need for an improved roll stacker design which can be manufactured utilizing a material that would reduce the storage space requirements of roll supports, so as to free up warehouse space. And, there remains a need for a strong, weather-proof, preferably recyclable material which can be utilized in the production of compactly stackable roll supports. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0007]    In order to enable the reader to attain a more complete appreciation of the invention, and of the novel features and the advantages thereof, attention is directed to the following detailed description when considered in connection with the accompanying drawings, wherein:  
         [0008]    [0008]FIG. 1 is a perspective view of a plurality of roll supports, shown in working arrangement to support stacked layers of roll stock on a shipping pallet.  
         [0009]    [0009]FIG. 2 is a perspective view of a pair of roll supports situated side-by-side, showing pairs of roll supports nested and stacked for shipping and storage.  
         [0010]    [0010]FIG. 3 is a perspective view of one embodiment of a pair of roll supports provided in a back-to-back configuration, for use in stacking roll stock in the manner illustrated in FIG. 1 above.  
         [0011]    [0011]FIG. 4 is a vertical cross sectional view, taken as through line  4 - 4  of FIG. 3, illustrating the generally stadium shaped support platforms as well as the alignment locks utilized to register one of a pair of roll supports to another.  
         [0012]    [0012]FIG. 5 is a first end view of a pair of roll supports, showing the first end view of a pair of roll supports as shown in FIG. 2 above.  
         [0013]    [0013]FIG. 6 is a second end view of a pair of roll supports, showing the second end view of the pair of roll supports shown in FIGS. 2 and 5 above.  
         [0014]    [0014]FIG. 7 is side elevation view, taken along one of the opposing sidewalls of a first of a roll support.  
         [0015]    [0015]FIG. 8 is a side elevation view, taken along the opposite side of a roll support as the view first provided in FIG. 7.  
         [0016]    [0016]FIG. 9 is a top plan view, taken looking downward on a pair of roll supports situated side by side.  
         [0017]    [0017]FIG. 10 is a perspective view of the embodiment of a pair of roll supports as just shown in FIG. 9, showing the roll supports with structurally enhancing flutes in opposing sidewall portions, and structurally enhancing flutes in the sloping sidewalls of the first and second end portions located at opposing ends of a roll support portion.  
         [0018]    [0018]FIG. 11 is a partial top plan view of the embodiment of a pair of roll supports as just illustrated in FIGS. 9 and 10 above, now showing in detail the raised strengthening bars between adjacent first and second end wall portions between roll support portions.  
         [0019]    [0019]FIG. 12 is a top plan view of a second embodiment of two side-by side roll supports, now provided with the raised strengthing bars between first and second end wall portions, where the strengthening bars are spread apart transversely beyond the structurally enhancing flutes in each of the first and second end wall portions.  
         [0020]    [0020]FIG. 13 is a partial perspective view of the second embodiment of a roll support as just illustrated in FIG. 12 above, now showing strengthening bars between first and second end wall portions, where the strengthening bars are spread apart transversely beyond the structurally enhancing flutes in each of the first and second end wall portions.  
         [0021]    [0021]FIG. 14 is a partial top plan view of the embodiment of a pair of roll supports as just illustrated in FIGS. 12 and 13 above, now showing in detail the raised strengthening bars between adjacent first and second end wall portions, with the strengthening bars located outside of the structurally enhancing flutes in each of the first and second end wall portions.  
         [0022]    [0022]FIG. 15 is a “footprint” view of a portion of a single unit of a support apparatus of the type set forth in FIGS. 2 and 4 above, now showing the footprint of such a single unit, as when it contacts a support pallet, or when used against another support unit in back-to-back fashion, showing in particular the “footprint” of the various reinforcing flutes, as well as the footprint of the bottom support foot of a “stadium shaped” support platform. 
     
    
       [0023]    In the various figures, it should be noted that the use of subscripts, such as in reference to support cradle portions  62   A  or  62   B , still generally refers to the structure so named without the subscript (such as roll support structure  62 ), but such subscripts are merely used for convenience with addressing similar structures either side-by-side or back-to-back pairs of roll supports, to distinguish similar structures in roll supports formed and/or used together.  
         [0024]    The foregoing figures, being merely exemplary, contain various elements that may be present or omitted from actual implementations depending upon the circumstances. An attempt has been made to draw the figures in a way that illustrates at least those elements that are significant for an understanding of the various embodiments and aspects of the invention. However, various other elements of the roll supports are also shown and briefly described to enable the reader to understand how various features, including optional or alternate features, may be utilized in order to provide a compact, efficiently nestable, reliable material structure for a roll stacking support.  
       DETAILED DESCRIPTION  
       [0025]    Attention is now directed to FIG. 1, wherein one embodiment of an improved, novel roll support is illustrated. Here, a pair  20  of roll supports are oriented in back-to-back configuration as used to provide spacing and support to a number of pieces of roll stock  22  situated on a pallet  24 . As illustrated in FIG. 1, the roll support pair  20  is provided as a pair of single roll supports  26  oriented in a back-to-back configuration. However, a single roll support  26  can be utilized as necessary below a first or lowest layer  28   1  of N layers  28  of roll stock  22  above pallet  24 . Then, a back-to-back pair of roll supports  20  can be used between lower layer  28   1  and the next layer  28   2 , repeating between layers up to the Nth or upper layer  28   N  in a series of layers  28   1  through  28   N . Note however, that in this FIG. 1, only the next to last layer, layer  28   N-1  of roll stock  22  is illustrated. If desired for packing and strapping, the configuration shown at the bottom, next to the pallet  24 , utilizing a single roll support  26 , could be repeated, reversed in mirror image fashion, above the last layer  28   N .  
         [0026]    Roll supports  26  may be manufactured singularly, or as noted in FIG. 2, may be manufactured in pairs  20   A  and  20   B  which may be flexibly joined or “hinged” along adjacent edge portions  34  and  36  of the respective base portions  38  and  40  of pairs  20   A  and  20   B . If pairs are provided in manufacture, a flexible joint  42  is formed by further thinning the material of construction and allowing only a very thin portion of material to connect the pairs  20   A  and  20   B . Alternately, a plurality of longitudinally extending thin transverse strips can be used to connect the adjoining sections  20   A  and  20   B  of a roll support pair  20 .  
         [0027]    In FIG. 2, note that reference arrow  50  shows how a first one  20   A  of a pair of roll supports is folded under a second one  20   B  of the pair of roll supports, to transform the pair from a side-by-side configuration to a back-to-back configuration.  
         [0028]    As better seen in FIG. 4, regardless of whether the roll supports are provided in singular or half-portions  26 , or in pairs  20 , when situated in a back-to-back configuration a first alignment lock  52  in first roll support section  26  (or  20   A ) is folded over in close fitting interlocking fashion with a second alignment lock  54  in second roll support section  26  (or  20   B ). In one embodiment, the pair of alignment locks  52  and  54 , are configured as mating dimples as shown in this FIG. 4. Note that in this configuration, alignment locks  52  and  54  provide for registration detents that serve to register first and second roll supports  26 , (or portions  20   A  and  20   B  if manufactured together, even if in this latter case such sections become disconnected along joint  42  during continued use of the roll support pair  20 ).  
         [0029]    As also noted in FIG. 2, the roll support design  26  (or roll support pairs  20  when provided in hinged pairs  20   A  and  20   B ) allows for compact nesting, which thus allows compact storage. In order to take maximum advantage of this feature, the roll supports can be manufactured from a resinous plastic polymeric material. Resinous plastics which may be utilized for the roll support include high-density polymers that produce a strong, yet flexible final product. A resinous plastic polymer material that can be thermoformed be utilized to provide a desired final shape. On suitable resinous plastic material found to be useful is polyethylene terephthalate material, commonly known by the abbreviation “PET”.  
         [0030]    Instead of providing a cushioning support, as would be desired when protecting a fragile article such as glass, or light bulbs or the like, supports for much roll stock must be strong and resistant to deformation. Such applications are ideal for PET, since PET resin forms a high strength product with good strength in all directions. Also, many businesses now prefer that materials be manufactured from recycled materials. The disclosed roll supports are easily fabricated from recycled plastic materials. Also, use of recycled plastic material is a great advantage over most prior art cellulose materials, since recycling of cellulose materials suitable for packaging roll supports is considered more complex and difficult than manufacture of plastic materials from recycled materials. In the manufacture of roll supports, suitable recycled plastics are relatively easy to reprocess. PET, as with a great variety of plastic materials, is initially segregated at time of disposal, after which it is typically kept clean and uniform during the entire recycling process. This process substantially enhances the likelihood of retaining desirable material properties in a finished roll support made from recycled materials.  
         [0031]    Another important property which is achieved by the use of PET is that paired roll supports  20  can easily stack over a previous pair with only a slight increase in height. As shown in FIG. 2, the thickness T of the roll support can be as little as from approximately 40 Mils to approximately 60 Mils (or from about 0.04 inches to about 0.06 inches). In one embodiment, the thickness T can be limited to not exceed the lower end of this range, or 40 Mils (0.040 inches). Thus, with such manufactured thickness, roll supports  26  could be stacked from approximately 16 per inch, to about 20 per inch, and even up to as dense as about 26 per inch. Of course, it is desirable from a storage and nesting perspective that thicknesses be provided which occur at the lower end of the stated thickness range. This very small thickness, when nested, is a significant advantage over the stacked pairs of prior art papier-mâché material, since papier-mâché material prohibits such a close nested stacking of new or used roll supports. For example, about an eight to one advantage in stacking of PET roll supports is provided over commercially available fabricated in prior art papier-mâché materials. In one test, it was found that a vertical stack of 1280 roll supports  20  could be situated within the same vertical height in which only about 160 prior art papier-mâché roll supports occupied. In another test, it was found that about 960 prior art papier-mâché roll supports will occupy, volumetrically, roughly six times the warehouse volume that which is occupied by 1280 of the roll supports provided herein (when measured comparably, either in pairs or singularly). Moreover, it as been found that about 1280 roll supports  20  occupy, volumetrically, roughly 12 times the warehouse volume of that occupied by one brand of prior art polystyrene foam roll supports. Thus, the nesting compactness of the present invention provides a substantial and significant savings in shipping and storage space, as compared to prior art papier-mâché or other foam or plastic materials. Thus, it is important to note that warehouse space saved in the storage of nested and still unused roll supports can be allotted to other storage needs. Alternatively, the saved storage or shipping space can be used to store or transport additional roll supports and allow the purchase of higher quantities to realize bulk rate cost savings and substantially reduce freight costs.  
         [0032]    As earlier described in conjunction with FIGS. 2 and 4 above, each member  20   A  and  20   B  of a pair of roll supports  20  may be provided joined to the other in a flexible, foldable edge hinge  42  that provides the connected pair  20   A  and  20   B  with the ability to fold together and form a back-to-back support configuration as shown in FIGS. 1, 3 and  4 . Additionally, the flexible hinge  42  can be utilized as a separation edge, for detaching the pair  20   A  and  20   B  from each other and forming two separate, detached roll supports portions, as noted in conjunction with the discussion of FIG. 1 above.  
         [0033]    A pair of roll supports  26  (or portions  20   A  and  20   B  taken together as a joined roll support pair  20 ), are suited for receiving and supporting one or more pieces of roll stock of a selected diameter D and radius R. Each of the roll supports  26  have a first elongated upper surface  60 , with a plurality of roll support cradle portions  62  thereon. Similarly, each of the roll support portions  20   A  and  20   B  have a first elongated upper surface  60   A  and  60   B , respectively, each having a plurality of roll support cradle portions  62   A  or  62   B  thereon. Each of the roll support cradle portions  62   A  and  62   B  have an outward surface  64   A  or  64   B  shaped in an arcuate segment of pre-selected dimensions adapted for securely receiving a piece of roll stock  22  of substantially complementary shape, i.e., preferably complementary diameter D or radius R. To support the roll support cradle portions  62   A  and  62   B , a pair of longitudinally running opposing sidewall portions  66   A1  and  66   A2 , and  66   B1  and  66   B2  (see FIG. 4) are provided in each of portions  20   A  and  20   B , respectively. When viewed in the side-by-side configuration (see FIG. 5, for example), each of the opposing sidewall portions ( 66   A1 ,  66   A2 ,  66   B1 ,  66   B2 ) slope inwardly and upwardly toward the shaped outward surface  64   A  or  64   B , respectively, or the roll support cradle portions  62   A  or  62   B .  
         [0034]    Roll support  26 , or portions  20   A  and  20   B , have a base,  38  and  40 , respectively in the latter case, each of which provides structural support to the adjacent opposing sidewall portions ( 66   A1 ,  66   A2 ,  66   B1 ,  66   B2 , as applicable). These opposing sidewall portions, in turn, each provide structural support to the applicable roll support cradle portions  64   A  or  64   B . Within the opposing sidewall portions  66   A1 ,  66   A2 ,  66   B1 , and  66   B2 , strengthening flutes  66   F  are provided. These flutes  66   F  may be provided in the shape of arc portions of a length of cylinder, where the cylinder has a preselected diameter. One suitable diameter ranges from about 0.25 inches to about 0.50 inches. Preferably at least one strengthening flute  66 F is provided along a selected opposing sidewall  66   A1 ,  66   A2 ,  66   B1 , or  66   B2 , on either side (longitudinally) of the bottom  96  of the roll cradle support portion  64   A  or  64   B . More preferably, two strengthening flutes  66   F  are provided on either side (longitudinally) of the bottom  96  of the roll cradle support portion  64   A  or  64   B  along the respective opposing sidewall  66   A1 ,  66   A2 ,  66   B1 , or  66   B2 .  
         [0035]    At opposing ends of the roll support cradle portions  64   A  or  64   B , a first end wall portion  67  and a second end wall portion  68  are provided. These first and second end walls slant inwardly and downwardly toward the respective intervening base portion between roll support cradle portions  64   A  or  64   B . As illustrated, this angle is provided equal to an incline of about twenty degrees (20°) from the vertical (or alternately stated, is at a seventy degree (70° incline). Within the first and second end wall portions  67  and  68 , strengthening flutes  67   F  and  68   F , respectively, are provided, preferably oriented along the plane of the respective first or second end wall portion. As illustrated (but not necessarily limited thereto) the flutes  67   F  and  68   F  each are provided in a long, rounded groove in their respective first end wall portion or second end wall portion. These flutes  67   F  and  68   F  may be provided in the shape of arc portions of a length of cylinder, where the cylinder has a preselected diameter. One suitable diameter ranges from about 0.25 inches to about 0.50 inches. At least one flute  67   F  is provided in end wall portion  67 , and more preferably, at least three flutes  67   F  are provided. Likewise, at least one flute  68   F  is provided in second end wall portion  68 , and more preferably, at least three flutes  68   F  are provided in second end wall portion  68 . Also note by reference to FIG. 15 that a foundation support  66   s ,  67   s , or  68   s , is provided at each flute  66   F ,  67   F , or  68   F , respectively.  
         [0036]    To enhance structural strength, one or more support platforms  70  is provided in each of the roll support cradle portions  64   A  or  64   B . Each of the support platforms  70  has first  72  (or long) and second  74  (or short) inwardly and downwardly sloping sidewall portions, each having a lower end portion  76  and  78 , respectively. Also, the support platforms have opposing wall portions  80  and  82 . A bottom support foot  90  is located adjacent the lower end portions  76  and  78  of the first  72  and second  74  inwardly and downwardly sloping sidewall portions. As indicated in FIG. 7, the inwardly sloping sidewall  72  is at an angle alpha (α) of about 20 degrees from the vertical (or, alternately stated, is at a seventy degree incline). Also as indicated in FIG. 7, the inwardly sloping wall  74  is at an angle beta (β) of about 20 degrees from the vertical (or, alternately stated, is at a seventy degree incline).  
         [0037]    The bottom support foot  90  extends laterally across a portion of the respective roll support cradle portion  64   A  or  64   B . Also, the bottom support foot  90  extends downwardly, when the roll supports are viewed in a side-by-side configuration, to a location substantially even with the height or plane of the respective base  38  or  40 . This is confirmed by the footprint illustrated in FIG. 15, as well as shown in FIG. 4. When a back-to-back configuration is utilized, the bottom side  92  of support foot  90  of first roll support portion  20   A  and the bottom side  92  of a second support foot  90  in the second roll support portion  20   B  are in opposing contact for strong structural support. As depicted in the various figures, one advantageous shape for the support platforms  70  is a “stadium bowl”, broadly concave shaped configuration having a flat bottom and sloped sidewalls.  
         [0038]    As can be seen in various figures, and evident in the side view shown in FIG. 7, each of the roll support cradle portions  64   A  or  64   B  has a bottom portion  96  (at the bottom of the curve), wherein the bottom portion  96  is elevated above the respective base. As illustrated, the bottom portion  96  of the roll support cradle portion is elevated a height H about 0.25 inches above the base  38  or  40 .  
         [0039]    Also, I the embodiment illustrated in FIGS. 5 and 6, opposing sidewall portions  66   A1 ,  66   A2 ,  66   B1 , and  66   B2  can be provided angled upward and inward at an angle sigma (Σ) of about twenty degrees (20°), i.e., to allow a seventy degree (70°) slope on the selected opposing sidewall, when viewed from above.  
         [0040]    As shown in the various figures, between adjacent first  67  and second  68  end wall portions, at least one strengthening ridge  100  is provided. Preferably, two or more outwardly protruding strengthening ridges  100  are provided. In FIGS. 12, 13, and  14 , strengthening ridges  102  are illustrated, differing from ridges  100  only in that ridges  102  are spaced apart, transversely, beyond an outer strengthening flute  67   F  and  68   F  along the bottom  104  of end wall  67 , or the bottom  106  of end wall  68 . As illustrated, and as appropriate to achieve compact nesting, the strengthening ridges  100  are shown with a trapezoidal cross-sectional shape, when viewed transversely.  
         [0041]    The roll stock  22  supported by the illustrated roll supports can be any one of a variety of materials typically wrapped around a spool or core. This rolled material is conventionally placed in the cylindrical or tubular roll for storage, transport and eventual use. The rolled material can be any web material, plastic or film, such as polyethylene or cellophane. As an example, the packaging manufacturing and printing industry employs rolls of plastic film, typically polyethylene, to fabricate bags that receive a printed design or label.  
         [0042]    It is also possible to blend the material that forms the roll support  20  of the present invention from other, non-resinous materials, such as fibrous materials, line carbon fiber, or other high strength materials. Also, for certain applications, forming roll supports in the configuration described herein can be advantageously accomplished with wood fiber product compositions. Preferably, any blended or composite materials would be formulated to maintain the thin-walled, thermoformed, advantages as described herein.  
         [0043]    The roll support disclosed herein is designed for use both (1) singularly, as to support a first layer of roll stock above a substrate, and (2) in roll support pairs, so that a downward oriented roll support secures a layer of roll stock below, and so that a second, upturned roll support is registered with the downturned one of the pair, for secure mating engagement therewith, so that yet another layer of roll stock can be supported. Thus, pairs of roll supports can be used in a back-to-back fashion and located between tiers or roll stock. Roll supports as taught herein can be manufactured in foldable pairs, or singularly. When manufactured in pairs, they can also be placed in a side-by-side configuration and orientated downwardly facing above a top tier of roll stock, all in order to provide a secure, stacked arrangement of the roll stock that is suited for storage or transport. Alternately, a single roll support can be used where appropriate at the base or at the top of a stack of roll stock.  
         [0044]    Importantly, successive singles or pair sets of roll supports in pile of such roll supports will nest tightly within a prior single or lower pair set, thereby substantially reducing the storage space required for both new or for used roll supports.  
         [0045]    The roll supports described herein are configured to receive and support horizontally stacked tiers of roll stock. The roll support cradle surface is sized for receiving a preselected diameter of roll stock. The roll support functions to stabilize the tiered array of roll stock, usually located on a shipping pallet. Each roll support is structurally able to support distributed portion of the weight of the roll stock that is received within its roll support cradle portions. Thus, the strong roll stock stacking support design provided is an important improvement in roll supports for roll stock materials.  
         [0046]    It is to be appreciated that the various aspects and embodiments of the roll stock stacking supports as described herein are an important improvement in the state of the art of structures and materials for roll stock stacking supports. Although only a few exemplary embodiments have been described in detail, various details are sufficiently set forth in the drawings and in the specification provided herein to enable one of ordinary skill in the art to make and use the invention(s), which need not be further described by additional writing in this detailed description. Importantly, the aspects and embodiments described and claimed herein may be modified from those shown without materially departing from the novel teachings and advantages provided by this invention, and may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Therefore, the embodiments presented herein are to be considered in all respects as illustrative and not restrictive. As such, this disclosure is intended to cover the structures described herein and not only structural equivalents thereof, but also equivalent structures. Numerous modifications and variations are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention(s) may be practiced otherwise than as specifically described herein. Thus, the scope of the invention(s) , as set forth in the appended claims, and as indicated by the drawing and by the foregoing description, is intended to include variations from the embodiments provided which are nevertheless described by the broad interpretation and range properly afforded to the plain meaning of the claims set forth below.