Packaging material having a cam lock

A packaging dunnage including a plurality of packaging columns having a pair of sidewalls, a bottom wall, a plurality of front transverse walls, and a plurality of rear transverse walls that cooperate to define a plurality of cells. Each of the cells is adapted to receive an article for shipment, and is associated with a cam lock assembly. The cam lock assembly includes a lock member that is movable between a first orientation and a second orientation. When the lock member is in the first orientation the cell is adapted to stably receive a first size article. When the lock member is in the second orientation, the cell is adapted to stably receive a second size article. The packaging dunnage is further adapted to receive articles having sizes between the first and second sizes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to packaging dunnage and shipping materials and, more particularly, toward such packaging dunnage and methods that are adapted to receive different sized parts.

2. Description of Related Art

In shipping sensitive electronic components, it is necessary to secure the parts against movement and excessive vibration. Conventionally, this is accomplished by custom designing shipping containers and packaging materials for each electronic component. However, this significantly adds to the shipping costs, especially when electronic components of varying sizes are shipped. Further, as product dimensions change between models, new packaging materials must be developed, which is expensive and time consuming.

Therefore, there exists a need in the art for a packaging dunnage that is adapted to accommodate similar articles having different sizes, and such packaging dunnage that is adapted for standardized shipping containers. There further exists a need in the art for packaging dunnage that may be readily changed to accommodate changes in article size as new article models are developed.

SUMMARY OF THE INVENTION

The present invention is directed toward a packaging dunnage that is adapted to accommodate and securely receive similar articles having different sizes. The present invention is further directed toward such packaging dunnage that is received in standardized shipping containers.

In accordance with the present invention, the packaging dunnage includes a plurality of packaging columns, each of the columns including a plurality of cells. The columns are defined by relatively rigid sidewalls that are secured to one another in a rectangular shape. The columns include relatively rigid transverse walls that separate the columns into a plurality of cells. Each of the cells includes a rotatable cam lock member that is mounted upon a shaft extending between the sidewalls of the packaging column. The cam lock has an irregular or semi-elliptical peripheral shape specially designed to change a spacing between a surface of the cam lock and one of the transverse walls facing the cam lock surface as the cam lock is rotated.

In further accordance with the present invention, the cam lock is movable between a first rotary position in which a side of the cam lock facing one of the transverse walls is at a first distance from the one transverse wall, and a second rotary position in which the side of the cam lock facing the one transverse wall is at a second distance from the one transverse wall. The first distance is essentially equal to an associated dimension of a first size article that is received in the cell, and the second distance is essentially equal to an associated dimension of a second size article that is received in the cell. Accordingly, by rotating the cam lock between the first and second rotary positions, similar articles of different sizes can be securely received in the cell.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference toFIG. 1, a packaging dunnage10incorporating a cam lock assembly36of the present invention is shown to include a series of packaging columns12,14, each of which comprise a series of cells20. In the illustrated embodiment, the packaging dunnage10is adapted for receipt in a standardized shipping container, which is sometimes referred to in the shipping art as an A1-style plastic container. Such A1-style containers are known to have standardized dimensions of 48 in.×45 in.×25 in.

Each packaging column preferably is rectangular in length and adapted to be received in the A1-style container. As such, each packaging column12,14will have a maximum length of about 48 inches, a maximum height of about 24-25 inches, and a maximum width of about 11.25 inches.

Each packaging column12,14has a pair of sidewalls24and a bottom wall26. Preferably, each of the walls is formed from corruplast, which is a well known relatively rigid, lightweight, and durable corrugated plastic material. Naturally, other materials are known in the art and may be used to form the walls without departing from the scope and spirit of the present invention.

The sidewalls24preferably integrally provide mounting tabs24athat receive a reinforcing bar32, which serves to strengthen or stiffen the associated column12,14against deformation. It will be appreciated that the basic structure of the columns12,14described to this point is generally known to those skilled in the art, and will not be described further hereinafter.

It is noted the columns12,14illustrated inFIG. 1are shown as having different heights, whereby a first column12is relatively shorter than a second column14, and that these columns12,14are placed next to one another so as to stagger the vertical location of laterally adjacent cells20. Providing adjacent columns at different vertical heights facilitates placement of articles therein. Preferably, the relatively shorter columns12are loaded with articles before the adjacent taller columns14. Further, relatively taller columns14are preferably unloaded before the adjacent relatively shorter columns12. As will be appreciated by those skilled in the art, this loading/unloading procedure minimizes any interference problems created by the close proximity of the cells of adjacent columns12,14.

In the packaging dunnage10illustrated inFIG. 1, sixteen possible cells20are provided. However, it is noted that one of the cells20has been designated as a storage compartment66wherein various replacement parts may be disposed. A top surface of the storage compartment66also preferably includes a graphical illustration of the preferred loading/unloading sequence for the cells20, described hereinbefore. Providing such replacement parts permits damaged cam lock assemblies, described hereinafter, to be readily repaired and placed back into service. Accordingly, in the illustrated embodiment of the packaging dunnage10fifteen cells are available to receive articles for shipment.

With reference toFIG. 2A, a representative packaging column12according to the present invention is illustrated, and is shown to further include a series of transverse walls28,30. The transverse walls28,30extend between the sidewalls24, as illustrated, and are referred to hereinafter as a front transverse wall28and a rear transverse wall30. The sidewalls24, bottom wall26, one rear transverse wall30and one front transverse wall28cooperate to define the four individual cells20for each column12,14. Each rear transverse wall30has a notched recess30aformed therein that is adapted to receive a portion of a cam lock member38, describe hereinafter.

Preferably, the front transverse wall28for each cell20is spaced from the rear transverse wall30of the next adjacent cell, and this space receives a reinforcing block34. The reinforcing block34has sufficient structural rigidity to support the front and rear transverse walls28,30so as to prevent their deformation in use, as will be appreciated by those skilled in the art and apparent from the following description. Preferably, the reinforcing block34is made from a closed cell foam material, although other materials may be used interchangeably.

A cam lock assembly36is provided for each cell20. With respect toFIG. 2A, the cam lock assembly36includes a cam lock member38, a cylindrical sleeve40, and a shaft42. The cam lock member38, which is preferably formed from a relatively dense, closed cell foam material, defines an offset bore44, a pair of generally planar sidewalls46, an outwardly extending tongue48, and a somewhat irregular or semi-elliptical peripheral surface.

The bore44extends through the sidewalls46and receives the cylindrical sleeve40in a press-fit fashion. The cylindrical sleeve40, which preferably is formed from a metal such as aluminum, serves as a bushing and slidably receives the shaft40so as to rotatably mount the cam lock member38to the shaft42. Opposite ends of the shaft42extend through the sidewalls24of the packaging column12,14, and are preferably retained thereon by push nuts50or the like.

It will be appreciated that the cam lock member38is especially adapted to be efficiently formed by molding. As such, production of the cam lock member38is cost effective, and modifications to the size and/or peripheral surface thereof, as may be desired to accommodate changes in the article dimensions, described hereinafter, may be economically provided. Naturally, the cam lock member38may be formed by other methods, such as extrusion, without departing from the scope and spirit of the present invention.

The cam lock member peripheral surface, which may be thought of as being semi-elliptical in shape, includes a flat first surface52and a curved second surface54. The cam lock member peripheral surface further includes a planar surface56opposite the flat first surface52, and a rounded surface58opposite the curved second surface54. A support surface60is provided by the extending tongue48, and serves to engage the rear transverse wall30when the cam lock member38is in a first orientation (FIG. 3). More specifically, the extending tongue48is adapted to fit within the notched recess30aof the rear transverse wall30, as will be apparent from the following description.

In the illustrated embodiment, each cell20is adapted to receive an article for shipment, and to stably support the article. More specifically, each cell20is specially adapted to receive similar articles having slightly different dimensions or sizes by frictionally receiving the article between the cam lock member38and the front transverse wall28while the cam lock member38frictionally engages the article and the rear transverse wall30.FIGS. 3-6illustrate use of the invention in securing two differently sized Central Module Units (CMU). Such CMU's are integrated electronic components that are to be installed in a vehicle dashboard, and typically include various controls for a vehicle climate control system as well as one or more audio and video components, such as a radio, CD player, and a navigation system and associated video screen. Generally, since the CMU must be installed in a predetermined space in the vehicle dashboard, the outer face of each CMU, regardless of the components installed therein, is generally identical. However, there may be small differences in the interior vertical height (as viewed when installed in the vehicle dashboard and sometimes referred to in the art as an ‘in-car position’) of different CMU's due to the different components that may be included in the CMU.

For example, a first CMU having a radio and a single disc CD player may have a first vertical height dimension, while a second CMU having a radio and a six-disc CD player may have a second vertical height dimension, while a third CMU having a radio, a six-disc CD player and a navigation system may have a third vertical height dimension. The differences in height between the first and second, and the second and third CMU's may be small (e.g., 0.125 inches) from a shipping perspective, and may be absorbed by the inherent resilience or compressibility of the packaging materials surrounding the CMU. However, the difference in height between the first and third CMU is significant (e.g., 0.25 inches) and has heretofore made shipping of the first and third CMU in common, identical packaging materials impossible. However, the present invention accommodates such differences in height, as will be apparent from the following description and with reference to the drawings, whereinFIGS. 3-4show placement of the first CMU (i.e., including radio and single disc CD player) in a cell20andFIGS. 5-6show placement of the third CMU (i.e., including radio, six-disc CD player, and navigation unit) in a cell20.

It is further noted that some CMU's (hereinafter called custom or premium CMU's) include additional add-on component blocks or boxes that protrude from the rear of the CMU and heretofore have made shipping of such premium CMU's problematic. However, with the present invention, the cam lock member38of the present invention may be adjusted laterally along the length of the shaft42so as to accommodate such special situations and thereby seamlessly permit stable and secure shipping of such premium CMU's.

With reference toFIG. 3, a first CMU62is shown disposed partially within the host cell20just prior to being pushed down into the accommodating space between the cam lock member curved second surface54and the front transverse wall28. In order to receive the first CMU62, the cam lock member38is disposed in a first orientation in which the support surface60of the extending tongue48is received within the notched recess30aof the associated rear transverse wall30and engaged with an upwardly facing surface of the rear transverse wall30. As such, the cam lock member38and the associated rear transverse wall30cooperate to properly orient the cam lock member curved second surface54to receive the first CMU62. As mentioned previously, should the first CMU be a custom CMU having additional components (not shown) that interfere with the proper rotary positioning of the cam lock member38, the cam lock member38may be slid along the shaft42to a position out of engagement with such additional components.

FIG. 4shows the cell20following insertion of the first CMU62therein. As will be appreciated, during insertion of the first CMU62into the cell20, the first CMU62engages the curved second surface54of the cam lock member38, causing the cam lock member38to rotate (clockwise in the drawing) such that the extending tongue48is moved out of engagement with the rear transverse wall30of the packaging column12,14. The spacing between the cam lock member second surface54and the front transverse wall28is chosen so as to securely frictionally receive the first CMU62therein. As such, and keeping in mind that the cam lock member38may be made of a slightly compressible closed cell foam material, the at-rest space (i.e., prior to insertion of the first CMU) between the cam lock member second surface54and the front transverse wall28may be equal to, or slightly smaller than, the relevant vertical height dimension of the first CMU62to be received therebetween. In this position, one surface of the cam lock member38is in engagement with the rear transverse wall30and the opposite surface of the cam lock member38is in engagement with the first CMU62, as illustrated. Accordingly, the first CMU62is frictionally held between the cam lock member38and the rear transverse wall30, while the cam lock member38is in frictional engagement with the first CMU62and the front transverse wall28.

FIG. 5schematically illustrates a third CMU64disposed partially within the host cell20just prior to being pushed down into the accommodating space between the cam lock member flat first surface52and the front transverse wall28. In order to receive the third CMU64, the cam lock member38is disposed in a second orientation (rotated approximately 90-120° relative to the position shown inFIG. 3) in which the extending tongue48is directed upwardly, and in which the flat first surface52is substantially parallel to and facing toward the front transverse wall28.

FIG. 6is a cross-sectional view schematically showing the cell20following insertion of the third CMU64therein. As illustrated, the third CMU64has a height dimension that closely matches the spacing between the flat first surface52and the front transverse wall28such that the third CMU64is snugly and stably received therebetween by friction. In this regard, it is again noted that the at-rest space (i.e., prior to insertion of the third CMU64) between the cam lock first surface52and the front transverse wall28may be equal to, or slightly smaller than, the height dimension of the third CMU64to be received therebetween. In this position, one surface of the cam lock member38is in engagement with the rear transverse wall30and the opposite surface of the cam lock member38is in engagement with the third CMU64, as illustrated. Accordingly, the third CMU64is frictionally held between the cam lock member38and the rear transverse wall30, while the cam lock member38is in frictional engagement with the third CMU64and the front transverse wall28.

As mentioned previously, should the third CMU be a custom CMU having additional components (not shown) that interfere with the proper rotary positioning of the cam lock member38, the cam lock member38may be slid along the shaft42to a position out of engagement with such additional components.

Further, as noted hereinbefore, there exists a second CMU (not shown) that has a vertical height dimension that is relatively larger than the vertical height dimension of the first CMU62and relatively smaller than the vertical height dimension of the third CMU64. Due to the compressible nature of the cam lock member38, the second CMU may be safely received within cell20with the cam lock member38in either of the previously described first and second orientations.

Accordingly, with the present invention, differently sized articles can be safely and securely received within a cell20of a packaging dunnage10. By simply rotating the cam lock member38between the first and second orientations the cells20are transformed from having a first sized space to accommodate a first size article to a second sized space to accommodate a second size article, such that differently sized articles may be conveniently and safely received in the cells20of the packaging column12,14.

In this regard it will be appreciated that the particular peripheral shape of the cam lock member38is exemplary and the present invention is not limited thereto. Rather, the cam lock member peripheral shape may be readily adapted to the particular articles being shipped, and may be easily changed as the size of such articles changes. Moreover, the present invention is not limited to the particular articles (i.e., CMU's) described herein, but rather may be adapted, by one skilled in the art, to many different articles.

In light of the foregoing, it will be appreciated that the present invention is capable of numerous modifications and changes in dimensions or configurations without departing form the scope and spirit of the present invention, as embodied in the claims attached hereto.