PALLET-TYPE PACKAGE SYSTEM CONTAINING A PLURALITY OF BOBBINS OF YARN

Abstract: A pallet-type package and system and tray therefore are provided that utilize reusable structural components of bob­ bins and trays. The pallet-type package has a bottom pellet layer on top of which is located at least one tray constituting the first tray layer on top of which is a layer of a plurality of nestable bobbins of yarn where subsequent layers of trays and bobbins of yarn alternate to allow the bobbins to nest through apertures in the tray. The tray of the pallet-type package positively positions the base of each bobbin in a re­ cess having one aperture for each bobbin of yarn through which the top of the bobbin from the underlying layer of bob­ bins of yarn penetrates to nest with the cavity in the base of the overlying layer of bobbins of yarn. In addition, the tray also has material handling receiving means and has reinforc­ ing means sufficient to provide longitudinal and transverse strength to the tray. The pallet-type package system has the pallet-type package along with a material handling means and a tray delivery means. The material handling means has a griping means to associate with the material handling re­ ceiving means of each tray, an attachment means to attach the griping means to bobbin top stabilizing means, the bobbin top stabilizing means having at least one channel per row of bobbins, connecting means to connect the material handling means to a mechanical focal point means and a mechanical focal point means whereby the material handling means can be lifted. The tray delivery means has a plurality of wheels attached to a frame to convey trays that are unloaded from the pallet-type package that are full of bobbins of yarn to the yarn utilizing machine.

Description: The present invention relates to a pallet-type package and packaging system for bobbin yarn to transport bobbin yarn from the yarn manufacturer and, if desired, all the way to the yarn utilizing machine. Also the present invention is directed to a tray structural component of the pallet-type package and of the packaging system that is one of the package's reusable structural components. Textile yarns have been shipped from yarn manufacturers to their customers in sundry types of packages. US-A-2,185,920 from 1936 describes a shipping container for wound yarns made from corrugated cardboard. The cones of rayon yarns are arranged in several superimposed layers, each layer comprising 12 cones of yarns. The layers are separated by trays and the wound yarns are secured against shifting or movement under the usual handling during shipment by holes in the cardboard trays which engage the tubes on which the yarns are wound. This cardboard container is only suitable for shipment of smaller bobbin yarns and can only be used once. The bobbin yarns have to be unloaded by hand. BE-A-556 712 from 1957 describes a packaging system for small tubes consisting of a box in which the tubes are arranged in layers separated by trays with recesses from the bottom side which form protuberances at the top side. The tubes are secured between two trays in a spaced relation by the fact that the bottom of the tubes engage with the protuberances of the lower tray and the top of the tubes fit into the recesses of the upper tray. In such a way several layers of tubes can be stacked upon each other. The whole stack of tubes can be handled as a unit by virtue of a cord running transversely through the center of the tray layers and connecting all trays. Though this packaging system already provides means for handling the complete layer stack it does not allow to remove a single layer of tubes from the stack for further processing. US-A-3,094,211 from 1963 describes a shipping support for textile packages designed to facilitate handling of textile bobbins in shipping and processing. Here again the yarn bobbins are transported in a box. The yarn bobbins are arranged in layers which are separated by rigid double wall platforms and the bobbins are secured in spaced relation by mounting posts projecting through apertures in the top wall of the double wall platform and receiving the apertured bottom of the bobbins. The platforms of this packaging system are still not rigid enough for the heavy bobbin yarns used nowadays and material handling receiving means are missing for safe handling of the single platforms. Also, the empty containers still occupy the same space as the loaded ones so that no cost effective return of the empty container is possible. The pallet-type package, which is multiple tiered with a plurality of wound yarn units per tier, and which is structured for conveyance by a forklift, is a popular packaging scheme. For instance, bobbin yarn having plastic spools with superimposed layers of wound textile yarn have been shipped in the pallet-type packages with nesting bobbins. These bobbin spools extend above and below the layers of wound yarn and allow for the bobbin tops of an underlaid layer to insert into the base of the bobbins of an overlaid layer. Packages with nesting bobbins have corrugated fiberboard interlayers between the nesting bobbins and have exterior corrugated fiberboard wrapping. With the pallet-type package, the bobbins with the wound yarn are generally: removed by hand, placed on some type of conveyance vehicle, and delivered to the utilizing machine. At this point they are unloaded and placed in some type of feeding mechanism. Present-day, pallet-type packages for yarn may present hazards in unloading the yarn from the packages, and problems in disposal of packaging materials. Recently, bobbins with wound yarn have gotten larger and heavier. The weight of the bobbin yarn, rapidly gaining acceptance in the marketplace today, is around 20 pounds. Unloading the heavier bobbin yarn by hand presents an increased risk of injury to the individuals doing the unloading. The individuals might reach and stretch into a pallet to obtain, hold and remove the heavier bobbin yarn. If the bobbin yarn is lifted improperly or dropped, injuries to backs, feet and legs may result. In addition, dropping bobbin yarn can damage the yarn because of denting and soiling. Any fingerprints, dirt or dust placed on the yarn can be damaging or lead to quality control problems for yarn like glass fiber yarn that nicks and abrades easily. Also, the traditional corrugated fiberboard interlayer and exterior packing used with the pallet-type package are cumbersome for disposal purposes because they occupy large volumes, especially after a number of pallet-type packages have been unloaded. It is an object of the present invention to provide a pallet-type package for bobbin yarn which requires less manual handling of bobbin yarn in loading and unloading of the bobbin yarn and which reduces the possibility of contamination from dirt, dust, fingerprints and the like, and which provides for a safer method of removing the bobbin yarn from the pallet-type package, and which provides a pallet-type package with reusable structural components as opposed to expendable exterior support material. SUMMARY OF THE INVENTION The aforementioned objects and other objects gleaned from the following disclosure are accomplished by the pallet-type package, tray, and system of the present invention. Thus, the present invention provides a pallet-type package system containing a plurality of bobbins of yarn, said system comprising reuseable constructional packaging elements for the transport and the storage of said plurality of bobbins of yarn said system enabling the unload of discrete package units of said plurality of bobbins of yarn, said system consisting of (a) a plurality of layers of bobbins of yarn, each bobbin of yarn having a reuseable bobbin which is wound with a plurality of superimposed annular layers of yarn on a core between a base and an annular shoulder portion, the base portion having a cavity extending into the core said cavity being dimensioned to accomodate a top portion of an underlying bobbin of yarn, said top portion extending beyond said annular shoulder portion (b) a plurality of layers of trays with at least one tray per layer, where a tray layer is interspersed between each layer of bobbins of yarn and wherein each tray layer has a plurality of mutually aligned top and bottom planar surfaces having aligned apertures in a grid-like fashion through both top and bottom planar surfaces, the cavity of each bobbin of yarn being aligned with said aperture so that the top portion of each bobbin of yarn from the layer of bobbin of yarn, underneath the tray protrudes through said aperture and into said cavity of the superimposed bobbin of yarn, said annular shoulder portion of each bobbin of yarn resting on said bottom planar surface of the superimposed tray, said base portion being positively positioned in cavities forming said top planar surfaces of said tray, (c) a lid tray layer having a plurality of bobbin top portion receiving means to securely receive the top portions of the topmost layer of bobbins of yarn (d) a bottom pallet layer with at least one positioning means, the lowest tray layer of said plurality of tray layers being associated with said bottom pallet layer through that layer's positioning means, and (e) a unitizing means to hold said different layers of trays and bobbins of yarn together, thereby forming a unit package. The multiple-layered, pallet-type package of the present invention has: a bottom pallet layer; a plurality of layers of trays with at least one tray per layer; a plurality of layers having multiple nestable bobbins with wound yarn, where one tray layer is interspersed with one layer of nestable bobbins; lid; protective covering and unitizing means for bottom layer, tray layers, bobbin yarn layers, and lid. The trays have top and bottom planar surfaces and a plurality of row recesses formed on the top planar surface, a plurality of walls projecting vertically from the top planar surface, some in a peripheral position and some in an internal position on the tray. The walls of the tray provide for positive positioning of at least one bobbin of yarn in each recess. Also the tray has a plurality of apertures aligned in a grid-like pattern on the tray. One aperture is present for each bobbin yarn occupying each recess to enable overlaying bobbin yarn to nest with underlaying bobbin yarn. Nesting is accomplished by the tops of the nestable bobbins in the underlaying layer beneath a tray passing through the vertically aligned apertures and occupying the cavities in the base of the bobbin yarn in the layer on the tray. The tray also has reinforcement means for effective longitudinal and transverse reinforcement and material handling receiving means to allow the tray to be lifted. The lid and bottom layer of the pallet-type package can have the same or a different shape ad structure. However, the bottom pallet layer has a positioning means for the first tray layer, and the lid has means adapted to receive the tops of the bobbin yarn for the last layer of bobbin yarn and to support the unitizing means. The protective film in the pallet-type package can be comprised of individual film wrappings around each bobbin yarn, around each layer of a plurality of bobbins on a tray and/or an external film wrapping around the pallet-type package. The pallet-type package system has: the pallet-type package, a materials handling means and tray delivery means. The materials handling means has a griping means to attach to the material handling receiving means on the trays and to remove the trays from the pallet-type package and to place one or more of them on the tray delivery means. The tray delivery means conveys the one or more trays to a location around the yarn utilizing machinery to be directly or indirectly fed into the utilizing machinery. Indirect use occurs by removing the bobbins from the individual tray delivery means and placing them on a feeding device for the utilizing machinery. The tray utilized in the pallet-type package has the row recesses that are continuous or discontinuous across and/or longitudinally along the tray. The sidewalls can have reinforcement means to provide rigidity to molded polymeric trays and to provide for the material handling receiving means. The apertures form a grid-like pattern in the tray and are of a dimension to allow a portion of the top of a nestable bobbin to penetrate the aperture, but also to allow for the tray to rest on shoulders or flanges near the top of the bobbin further down a longitudinal neck at the top of the bobbin. The tray rests on the bobbin shoulders or flanges to avoid the tray contacting the multiple layers of yarn wrapped around the bobbin. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic view of a exemplary pallet-type shipping package according to the present invention showing layers of bobbins of yarn separated by tray layers along with a bottom layer, lid, protective wrap and unitizing means. Also Figure 1 shows a partial broken away view to illustrate the nesting of bobbins of yarn in the pallet-like package; Figure 2 is a perspective view of one-half of a layer of bobbins of yarn and a tray from a two-tray, tray layer with one bobbin of yarn removed from the tray to show the recess and aperture portion of the tray; Figure 3 is a perspective view of stacked trays from a pallet package that has two-tray, tray layers after all of the bobbins of yarn have been removed from the pallet-type package; Figure 4 is an isometric view of the bobbin utilized in the instant invention laying on its side and resting on the flange to show the core, base which is a flange, and top which includes shoulder, neck and upper portion; Figure 5 is an isometric view of the top planar surface of a tray having only internal traversing walls and four peripheral walls to form row recesses, where each recess has a plurality of spaced-apart apertures; Figure 6 is an isometric view of the bottom pallet layer with two positioning means per tray and a capacity of two trays for the tray layer, where the bottom pallet layer has one tray of Figure 5 positioned on it; DETAILED DESCRIPTION AND PREFERRED EMBODIMENT OF THE INVENTION In the embodiment of the invention shown in Figure 1, numeral 10 indicates the pallet-type package for a plurality of bobbins of yarn which is comprised of layers of at least two reusable structural elements. At the bottom of the package 10, a pallet layer 11, has a plurality of legs, 12 whereby access to the underside of the pallet layer by the tines or forks of a lift or truck is possible between the legs 12. On top of the pallet layer 11 is at least one positioning means 13 (not shown in Figure 1 but shown in Figure 7). The positioning means associate one or more trays 15 with the bottom layer 11. The positioning means encompass the bottom tray molded into the pallet layer or the one or more trays 15 as separate articles from the pallet layer. A plurality of trays 15 are arranged in multiple tray layers 16 in package 10. Each tray layer 16 may be comprised of at least one tray, but preferably is comprised of two trays 15. Interspersed between the tray layers 16 are layers 17 of a plurality of nestable bobbins of wound yarn. For the nestable bobbin of wound yarn 18, any nestable bobbin known to those skilled in the art can be utilized. In the cutaway in Figure 1, the nestable relationship between the bobbins of yarn 18 is shown. The top portion 19 of one bobbin passes through an aperture 20 (described later) in the tray 15 and enters a cavity 21 in the bottom of the overlaying nestable bobbins of yarn. On the last layer 22 of plurality of bobbins of yarn 18 is lid 23 which can be the same as tray 15 as in the other tray layers 16 or which can be at least one solid rectangular article having a top and bottom planar surface with bobbin top receiving means which are formed by the recesses 69 shown in Figure 7. Recesses 69 accommodate the bobbin tops 19 of the bobbins in the last bobbin layer 22. The lid 23 also has a plurality of side panels 25 to extend down the sides of package 10 to protect the yarn 26 on the upper portion of the bobbins 18. All of the sides of the pallet-type package 10 except for the bottom can be and preferably are covered with a protective film 27. It would be possible also to have the film 27 cover the bottom of the pallet package although this is not necessary to protect the cleanliness of the yarn on the bobbins in the pallet-type package 10. The protective film can be any plastic film known to those skilled in the packaging art and having a thickness up to around 101.6 µm (4 mils). Nonexclusive examples of such films are polyethylene film and shrink wraps and/or stretch wrap films and the like. In lieu of or in addition to film 27, it is possible to have film coverings on the individual bobbins of yarn 18 and/or layers of bobbins of yarn 17 or any portions thereof. The pallet package can be secured by unitizing means 28 which can be any strappings to facilitate handling of the pallet-type package as a unit. Any strapping known to those skilled in the art of packaging pallets can be used such as plastic or metal strapping. The strapping can encompass the package in any manner known to those skilled in the art. In the pallet-type package 10, three reusable structural units are bottom pallet layer 11, and the nestable bobbins 18 arranged in multiple layers, the interspersed layers 16 of reusable trays 15. Figure 2 depicts a single tray 15 which preferably constitutes one-half of a tray layer 16 in Figure 1. Also Figure 2 depicts the disposition of one-half of a layer of bobbin yarn 17 of Figure 1. When more than one tray 15 is used to make up a tray layer in the palletized package 10, no special device is needed to interlock the trays when unitizing means 28 is used about a pallet-type package 10 in Figure 1. In lieu of or as the unitizing means 28, interlocking mechanisms could be used between a plurality of trays making up a tray layer 16. As shown in Figure 2, one bobbin of yarn 18 has been removed from the tray to show some of the features of the tray 15. The nestable bobbin of yarn 18 has the bobbin top 19 for nesting and a shoulder 29 on which rests the overlaying tray of the next tray layer. In this fashion the overlaying tray or trays do not contact the wound yarn 26 on the bobbin of yarn 18. The tray 15, which is generally of a solid rectangular shape with a top planar surface 30 and a bottom planar surface 31 has a plurality of recesses 32. In the embodiment of Figure 2, each recess has an aperture 20 centered in the bottom layer, of the recess. The recess 32 is defined by the bottom layer which is the top planar surface 30 and peripheral walls 33. The walls 33 can be arranged in any geometry to accommodate the bottom of one or more bobbins of yarn 18. Generally the walls can be arranged to form cylindrical recesses or rectilinear recesses. The tray 15 can have the plurality of recesses 32 arranged in rows so that there is one recess 32 for each bobbin of yarn 18 so that the bobbins of yarn 18 are positively positioned and secured in the tray. With one bobbin of yarn 18 for each recess 32, each recess 32 has one aperture 20. The aperture 20 is of a dimension to accommodate the bobbin top 19 to allow the nesting of the bobbin top 19 with the cavity 21 in the bottom of the bobbin of yarn 18 of an overlaying layer of bobbin yarn 17 directly above the bobbin yarn of the underlaying layer beneath tray 15. One of the walls for all of the recesses which have a peripheral position of the tray is formed by a longitudinal wall 34 or a traverse wall 35 along tray 15. In addition, the interior recesses 36 are formed by interior longitudinal walls 37 running through the interior of tray 15 on the top planar surface 30, or interior traverse walls 38 running through the interior of the tray 15 on the top planar surface 30 from which both the longitudinal and traverse walls vertically project. Where the interior longitudinal walls 37 meet the interior traverse walls 38, an intersection point 39 is formed. Only one internal or external longitudinal wall and only one internal or external (peripheral) wall on the tray need be near continuous. These walls would have metallic reinforcement means (shown in subsequent figures) to provide effective longitudinal and transverse reinforcement for the tray. All the other longitudinal and transverse walls can be discontinuous through the tray to act more as stops for the recesses. Also the type of internal wall, i.e., whether longitudinal or transverse can be varied where the walls are arranged to form recesses that have more than one aperture and where the walls of the recess positively position more than one bobbin of yarn. Hence, the tray could have only internal traverse walls or internal longitudinal walls or a mixture thereof. As shown in Figure 2, each bobbin 18 can be individually wrapped with a film covering 40 to provide cleanliness for each bobbin. The film covering 40 can be any polymeric film known to those skilled in the art for use in packaging such as polyethylene film having a thickness from about 12.7 up to 38.1 µm (0.5 up to around 1.5 mils). The film covering cannot be so thick as to retard the nesting of the bobbin top 19 into cavity 21 of the base of the adjacent overlaying bobbins of yarn. Therefore, the thickness of the film must allow for movement of the film to allow for proper nesting. Various structures of the trays are further shown in Figure 5. Referring to Figure 3, some of the features already described for the tray 15 are shown along with several additional features. Figure 3 indicates the nestability of trays 15 when the bobbins of yarn 18 have been removed from the trays. This nestability assists in returning the trays for reuse with other bobbins of yarn at the yarn manufacturer. In Figure 3, the nestability is for the trays 15 which are structured so that it takes two trays to make a tray layer 16 for the pallet package 10. In Figure 3 the bottom pallet layer 11 is indicated as being a separate article from the first tray 15 as opposed to a single unit. Generally the bottom layer 11 is of sufficient dimensions to accommodate at least one tray 15and preferably two trays 15, each tray having fifteen recesses in a honeycomb pattern where each recess 32 securely holds one bobbin of yarn as shown in Figure 2. As indicated, the recesses are adjacent to each other and are separated by interior longitudinal and transverse walls 37 and 38, respectively, or are bounded by exterior longitudinal and transverse walls 35 and 35, respectively of the tray 15. The tray 15 can be formed of any moldable material, such as polyethylene, particularly high density polyethylene. The shape of the tray is a solid rectangle, and the tray can be perceived as having two planar surfaces, a top planar surface 30 and a bottom planar surface 31. The top planar surface 30 has the rectangular grid 41 of walls composed of a plurality of external and internal longitudinal walls, 34 and 37, respectively, and external and internal transverse walls 35 and 38, respectively. Beneath the grid 41 is the top planar surface 30 which comprises the bottoms of the recesses 32. Although the grid 41 has been described as being formed with rectilinear walls, the walls can be circular to define a circular recess which will accommodate the circular flange (to be described) of the bobbin of yarn 18. The walls of grid 41 should have a sufficient height to positively position at least the flange of bobbin of yarn 18. Although the tray 15 has been defined as having a grid and top and bottom planar surfaces, the tray is one solid rectangular piece which can be manufactured from the polymer by any method known to those skilled in the art including: compression molding, injection molding and the like. The apertures 20 in the tray 15 are of a dimension to receive the tops of the bobbins of yarn 19 in Figure 1, where the bobbins of yarn are aligned directly below the tray and the tray rests on the shoulders of the tops of the bobbins of yarn of the underlaying layer of bobbins of yarn. The shaped and dimensioned apertures 20 securely maintain the tops of the bobbins of yarn of the underlaying bobbin layer in conjunction with the tray or trays on which bobbins of yarn of the underlaying layer of bobbin yarn are placed, where the tray effectively and securely holds the bottoms of the bobbin yarn. In Figure 4 there is shown a bobbin generally indicated as 44 which is comprised of a core 45. The core 45 terminates at one end at a circular flange 46 and at its other end at a top member generally indicated as 19. The core 45 can be a barrel or a tube or can also be a solid except at the base near the flange where the body has a cavity 21. If the body is tubular, the cavity 21 is the lower portion of the hollow or lumen of the tube. Figure 4 is one example of a nestable bobbin although any nestable bobbins known to those skilled in the art can be used in the present invention. Another nonexclusive example of a suitable nestable bobbin is given in U.S. Patent No. 3,860,194, hereby incorporated by reference. Preferably the bottom flange 46 has a plurality of spaced supports 47 that are intimately molded to the inner walls of flange 46 and to the outer wall of core 45 which extends a distance into the flange and to the upper inner surface of flange 46. A plurality of the flange supports 47 are spaced so as to effectively divide the bottom of flange 46 into a plurality of segments 48. Located in each of the segments 48 are vertical support members 47 which are molded to the upper inner surface and inner wall of flange 46. The vertical supports 49 extend along the inner surface of the flange 46 about 10 to 13 millimeters and along the surface of the inner wall of flange 46 about 8 to 11 millimeters and are generally triangular in shape. If the core 45 of the bobbin 44 is not solid with a cavity 21 near the flange 46, but is a barrel, the lumen can have vertical supports 49 to provide structural stability for the bobbin. The surface of the core 45 can have any type of roughened surface such as ribs or knobs and the like or can be a smooth surface. The top member 19 of the bobbin 44 is provided with a base which connects it to the core 45 and shoulder 29 with a neck 51 rising from the shoulder 29 and terminating in a circular collar 52. For nesting, the neck 51 and circular collar 52 of the top 19 can insert into the cavity 21 at the flange of a vertically adjacent bobbin in the next higher layer of bobbins of yarn in the pallet-type package 10. Figure 5 illustrates the preferred embodiment of tray 15 that have row recesses capable of positively positioning a plurality of bobbin yarn in each recess. The row recesses 53 have a plurality of apertures 20 to accommodate one bobbin yarn per aperture 20. The grid-like pattern of the apertures is seen on the top planar surface 30. The embodiment of this tray 15 has only traverse walls 55 as the internal walls on the top planar surface 30. There is no grid of walls as for the tray of Figure 3. Here the walls forming the row recesses yield a ladder-like pattern on the top planar surface 30 of tray 15 where the ladder is capped with a top and bottom rung. The ladder-like pattern is formed by the two external longitudinal walls 54, the rungs are the internal traverse walls 55 and the capping top and bottom rungs are the external traverse walls 56. The height of the transverse walls and external longitudinal walls are the same as the walls in Figure 3. The recesses formed by the walls have the same depth as the recesses in the tray illustrated in Figure 3 and the grid-like pattern of apertures is the same as for the tray illustrated in Figure 3 except now a plurality of apertures 20 reside in each recess 53. To positively position the plurality of bobbin yarn 18 within each recess, 53 the transverse walls 55 have arcuate shaped segments 57 to contact the flange 46 of Figure 4 of the bobbin yarn 18 at Figure 1. The transverse walls 55 do not have to be continuous across the width of the tray but they can be discontinuous between the arcuate shaped segments 57 except that at least one of the transverse walls 55 should be continuous across the tray in order to provide sufficient strength for the tray in that direction. The external longitudinal walls 54 can be continuous to discontinuous rectilinear walls although preferably they are continuous walls. The external longitudinal walls 54 project below the surface of the bottom planar surface 31. The transverse walls 55 are hollow from the underside of tray 15 where they correspond to sections other than the arcuate segments 57 of the top planar surface 30. The bottom planar surface 31 also has the grid-like pattern 43 of apertures. The section of the external longitudinal walls that project below the plane of the bottom planar layer 31 forms a type of lip running lengthwise on both sides of the tray. Within this lip or channel, the reinforcing means for the tray can be located. The tray 15 also has one or more reinforcement means that provides effective longutidinal and transverse support or strength for the tray. The reinforcement means can be strong support material like metals such as stainless steel, steel or aluminum in the shape of a T, bar, angle, or a flat plate. The reinforcement means is installed along at least one exterior longitudinal wall 54 and/or installed along one or more of the internal longitudinal walls, if any, within a hollow inside wall. In addition, the tray can have transverse reinforcement means along the external traversing wall 56. The longitudinal reinforcement means are preferably attached to the tray along the two exterior longitudinal walls 54 behind the lengthwise running lip. It is also preferred that the external traversing walls 56 have a lip. It is possible if lips are not present for the reinforcement means to constitute the external walls of the tray 15. In addition, the tray has two material handling receiving means so that a material handling device can securely lift the tray and remove it from the pallet-type package. Any receiving means known to those skilled in the art for lifting solid objects can be used such as hooks, metal eyelets and the like. Preferably the receiving means are the lips along the external traversing walls 56. The receiving means could be along the external longitudinal walls although removing the trays from a pallet-type package in this manner would be burdensome. It is preferred to have a tray 15 as shown in Figure 5 which has 5 row recesses in each tray positively positioning 3 bobbins of yarn per recess. Also it is preferred to have two trays to make up a layer of trays in a pallet-type package to give 4 layers of trays. Preferably the tray has the dimension of 66.04 x 114.3 cm (26 x 45 inches) and the pallet-type package has dimensions of 1.14 x 1.32 x 1.88 m (45 x 52 x 74 inches). Preferably the tray has a total height or thickness of around 5.08 to 7.62 cm (2 to 3 inches). Figure 6 shows the bottom pallet layer 11 having one tray 15 positioned on it, where it takes two trays to constitute one tray layer in the pallet-type package 10 of Figure 1. The tray 15 is positioned on bottom pallet layer 11 by two positioning means 13 occupying the apertures 20 of the tray 15. The positioning means 13 can occupy any of the apertures 20 in tray 15, and more than two positioning means can be used. The positioning means 13 for a second tray are shown in Figure 6 at 13b. Although the bottom pallet layer 11 in Figure 6 has a grid-like pattern, such a pattern is not necessary except such a pattern may be useful in molding the bottom pallet layer. Figure 7 shows the lid 23 for the pallet-type package 10 of Figure 1. Figure 7 shows the bottom planar surface of the lid. The top planar surface of the lid (23) has a raised grid of rectilinear walls connected at their intersection by knobs. Also the lid has higher rigids at each corner and has side panels 25. Figure 7 shows the recesses 69 in the bottom planar layer 65 of lid 23 that correspond to the nobs on the top planar surface of lid 23. The channels 70 running between the recesses 69 on the bottom planar surface 65 correspond to the rectilinear walls on the top planar surface of lid 23. The recesses positively position the tops 19 of bobbins of yarn 18 shown in Figure 1 for the last layer of bobbins of yarn. Although the rectilinear walls and channels shown connecting the recesses and knobs are preferred for adequately supporting the knobs and recesses in a molded article, the knobs and recesses are not absolutely necessary. Also the recesses could be apertures and the lid could essentially be another tray 15 or two trays where a tray layer is comprised of two trays where the two trays are linked together in some fashion. The knobs at the corners of the lid along with the rigids provide securing means for the unitizing means 28 of Figure 1. Preferably the side panels 25 have a height of around 5.08 to 10.16 cm (2 to 4 inches) to adequately protect the uppermost yarn on the bobbins of yarn where the bobbins have a constricted cross-sectional dimension from the cross-sectional dimension of the base of the bobbin.

Claims: A pallet-type package system (10) containing a plurality of bobbins of yarn, said system comprising reuseable constructional packaging elements for the transport and the storage of said plurality of bobbins of yarn (18) said system enabling the unload of discrete package units of said plurality of bobbins of yarn (18), said system consisting of (a) a plurality of layers (17) of bobbins of yarn, each bobbin of yarn having a reuseable bobbin (44) which is wound with a plurality of superimposed annular layers of yarn on a core (45) between a base (46) and an annular shoulder portion (29), the base portion (46) having a cavity (21) extending into the core (45), said cavity (21) being dimensioned to accomodate a top portion (19) of an underlying bobbin of yarn (18), said top portion (19) extending beyond said annular shoulder portion (29), (b) a plurality of layers (16) of trays (15) with at least one tray (15) per layer (16), where a tray layer (16) is interspersed between each layer (17) of bobbins of yarn (18) and wherein each tray layer (15) has a plurality of mutually aligned top and bottom planar surfaces (30, 31) having aligned apertures (20) in a grid-like fashion through both top (30) and bottom (31) planar surfaces, the cavity (21) of each bobbin of yarn (18) being aligned with said aperture (20) so that the top portion (19) of each bobbin of yarn (18) from the layer (17) of bobbin of yarn, underneath the tray (15) protrudes through said aperture (21) and into said cavity of the superimposed bobbin of yarn (18), said annular shoulder portion of each bobbin of yarn (18) resting on said bottom planar surface (31) of the superimposed tray (15), said base portion (46) being positively positioned in cavities (32) forming said top planar surfaces (30) of said tray (15), (c) a lid tray layer (23) having a plurality of bobbin top portion receiving means (69) to securely receive the top portions (19) of the topmost layer of bobbins of yarn (18) (d) a bottom pallet layer (11) with at least one positioning means (13), the lowest tray layer (16) of said plurality of tray layers being associated with said bottom pallet layer (11) through that layer's positioning means (13), and (e) a unitizing means (28) to hold said different layers of trays (11, 15, 23) and bobbins of yarn together, thereby forming a unit package (10). The package system of Claim 1, wherein the bottom pallet layer (11) and at least one tray (15) positioned on the bottom pallet layer (11) through the positioning means (13) forms one unitary article, wherein the positioning means (13) on the bottom pallet layer (11) constitutes a nub (13b) to occupy an aperture (20) of each tray (15) positioned on the pallet layer (11). The package system of Claim 1, further comprising a protective wrap (27), wherein said protective wrap (27) is either a separate film wrap around each bobbin (18) or is a separate film wrap around each tray, or is a film wrap around the side and top exterior surfaces of the package system (10) or is a protective wrap (27) around a combination thereof. The package system of Claim 1, wherein two trays (15) are interspersed between each layer (17) of bobbins of yarn (18) constituting a tray layer (16). The package system of Claim 1, wherein the nestable bobbin of yarn (44) has a base that is an open ended bottom with a circular flange (46) of greater circumference than that of the cross-section of the tubular core (45) and has a top (19) that has a circular shoulder (24) and a circular constructed neck (51) above the shoulder (29) and an outwardly extended circular collar (52) with the longitudinal plane parallel to the longitudinal plane of the shoulder (29) where the shoulder (29), neck (51) and collar (52) are sized in lengths to permit nesting of the bobbins by inserting the collar (52) and neck (51) to the shoulder (29) of the top (19) of a bobbin into the cavity (21) of the tubular core (45) of the open ended bottom of the next vertically adjacent bobbin of yarn (44). The package system of Claim 1, wherein the trays (15) are molded from high density polyethylene. The package system of Claim 1, wherein the trays (15) are solid rectangular trays (15) which trays (15) have 15 recesses to accommodate 15 bobbins of yarn (18), wherein the top planar surface (30) has a grid of rectilinear longitudinal and traversing walls (34,35) to define the row recesses (32) having bottom layers (24) that are the top planar surface (30) of the tray and where the grid-like fashion of apertures (20,43) is disposed so that there is one aperture (20) per recess (32), and the reinforcement means are two external longitudinal walls (34), and where traverse reinforcement is provided by the traverse rectilinear walls (35), wherein the reinforcement is from metallic reinforcing bars in a shape selected from the group consisting of two bars, T-shaped members and angles and at least one traversing exterior wall (34,35) is hollow to accommodate metallic reinforcing bars selected from the shapes consisting of bars, T-shaped members and angles, wherein the tray (15) has a plurality of walls (34,35) that are walls around the periphery of the tray (15), and a plurality of traversing walls (37,38) to define a plurality of row recesses (32) where each recess has a plurality of said apertures (20) arranged in a row with each aperture (20) equidistant from the adjacent aperture (20) and where both the internal and peripheral traversing walls (35,38) positively position the bases of the bobbins of yarn (18) by providing contact for two opposed sides of each base. The package system of Claim 7, wherein there are four interior traversing walls (38) which together with the two peripheral traversing walls (35) define five rows of recesses (32), where each recess has three apertures (20) and where both the internal and peripheral traversing walls (35,38) are dimensioned to provide arcuate contact to opposite sides of each bobbin base which is a circular flange (46). The package system of Claim 1, wherein the lid (23) has one recess for each top of bobbin of yarn (18) of the underlying layer (22), and has a plurality of side panels (25) to protect the bobbin of yarn (18) from unitizing means (28) and has a plurality of unitizing support means.

Inventors: DOCKERY, ALLISON ANTHONY, WOLFE, HOMER OLDHAM, JR.
Applicants: PPG INDUSTRIES, INC.
Application year: 1986
Main classification: B65D71
IPC codes: B65D71, D01H9, B65H49, B65D19