Abstract:
A modular packaging system of corrugated fibreboard construction is provided for relatively large-scale, fragile planiform materials, such as glass doors and architectural glass panels. Panels in a predetermined range of dimensions are individually enclosed within an adaptable, protective case. One or more loaded panel cases, in a substantially vertical orientation, are stacked horizontally and strapped together with a pair of buttressing pillars at each end, on opposite faces thereof. Two shock-absorbing base blocks are provided, upon which said panel case or bound stack rests. Each base block is a laminate, constructed of bonded corrugated fibreboard panels, and is disposed underneath the panel case or stack of cases, proximal to a respective lateral edge thereof, with its ends secured within recesses at the base of the pillars bound at that end.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    I. Field of the Invention 
         [0002]    The present invention relates generally to packaging systems and particularly to a packaging system of corrugated fibreboard construction for the transportation and storage of relatively large-scale fragile planiform materials, such as glass doors and architectural panels. 
         [0003]    II. Brief Description of the Prior Art 
         [0004]    Continual advances, over many centuries, in manufacturing processes of glass resulted in the commercial availability of increasingly large sheets of glass. With the introduction to market of architectural glass, a need arose for packaging systems for the safe transportation and storage of large and heavy glass panels. 
         [0005]    Various designs of crates and racks have emerged to satisfy this need, typically featuring a wooden frame supporting a horizontal stack of glass panels, each panel standing on edge either vertically or somewhat inclined. One example of such a system is U.S. Pat. No. 2,839,198A (F. J. Lefevre, 1958), proposing an A-frame wood structure and a means of clamping inclined stacks of glass panels onto it. Variations on this design are taught in many subsequent patents. 
         [0006]    Wood frame-based packaging systems, albeit traditional, proven technology, inherently suffer from several disadvantages. Wood frame crates are heavy, typically requiring two or more persons or mechanized means to manipulate and move them; the process of constructing wood frame crates is generally lengthy and involved, requiring skilled workers, tools, and fasteners; once assembled, wood frame crates are bulky, occupying precious floor space in any commercial facility which uses them regularly; heavy and bulky, and being moved about of a shipping floor, wood frame crates present a workplace hazard; once delivered and unloaded, they are either wastefully discarded, or shipped back to the sender, as they are, at a non-trivial cost. 
         [0007]    In the late nineteenth century, corrugated fibreboard and prefabricated fibreboard box blanks became commercially available. The rigidity, lightness, and shock absorption properties of this inexpensive material, lent it well to the packaging of fragile objects. In fact, one of its first uses was the packaging of glass bottles and containers. Not surprisingly, corrugated fibreboard packaging systems have continued to evolve in parallel with developments in glass manufacturing. Numerous designs are now found in the prior art teaching the use of fibreboard packaging systems for glass and other fragile panels. 
         [0008]    Corrugated fibreboard cases and envelopes intended to package individual, relatively light panels, such as mirror panes, have been known for decades and typically incorporate structural elements by which the panel to be packaged is suspended internally, at some distance from the container&#39;s outer walls, and is therefore protected from impact damage. U.S. Pat. No. 2,177,241A (H. Burack, 1939), for instance, presents a paperboard box, in whose cavity a receptacle is formed to suspend a fragile article away from the outer walls. Another example is U.S. Pat. No. 2,105,086A (J. Liskin and S. Stimmel, 1938) which teaches the suspension of a fragile planiform article in an internal envelope formed of and integral with the box blank. While suitable for individual, light panels, these systems do not possess the structural rigidity necessary for the packaging of stacks of relatively large and heavy panels. 
         [0009]    Packaging systems have been devised for the containment of individual automobile windshields, strapping the heavy, curved glass panel to an interior position offset from the edges of the encasing fibreboard envelope. U.S. Pat. No. 3,166,188A (M. C. Koester, 1965), for instance, straps the windshield over inwardly folded flaps to a safe interior position within the enclosing envelope. In this application, corrugated fibreboard packaging in the form of an envelope in which a fragile panel is suspended appears to reach its structural limitation. A different system altogether is required for the packaging of heavier, larger panels, such as architectural glass, particularly when several panels are to be packaged as a unit. 
         [0010]    It has been known in the art that although individual sheets of glass or other fragile material readily succumb to deformative stresses, a tightly bound stack of abutting such sheets possesses considerable resistance to damaging deformation. Indeed, binding together multiple sheets or panels to be shipped has been part of the solution to their packaging. 
         [0011]    When a number of fragile panels of relatively large surface area are to be packaged, it is advantageous to bind them together in a substantially vertical orientation as a horizontal stack, since this minimizes the footprint of the package and the probability of damage. Few solutions have been proposed for the containment of such a stack, which depart from the traditional crate of metal and wood construction and avoid the aforementioned shortcomings attendant thereto. 
         [0012]    Broadly, proposed alternatives incorporate modular end units which serve to support and sometimes bind the stack of vertical panels, suspending it somewhat off the floor. Being somewhat elevated protects the stack from floor impact damage, and allows it to be manipulated by a mechanized means, such as a forklift. 
         [0013]    One example of this solution can be seen in U.S. Pat. No. 5,909,808A (D. M. Bartholomew, 1999). This patent teaches an end unit structure constructed of paperboard and nailed wood panels, a wooden baseboard with nailed feet spanning the width of the package and suspending it off the floor, and, optionally, a wooden top cap board. Panels are strapped together with the end units. This design suffers from many of the aforesaid disadvantages of traditional wooden crates, and is limited to packaging a predetermined number of identical panels. 
         [0014]    Another example is U.S. Pat. No. 3,603,455A (David A. Barms, 1971). This patent teaches a two-part bracing member of corrugated cardboard construction that is adaptable in dimensionality to conform to a range of stack geometries. Two such bracing members are employed—one near either end of the stack—binding it and suspending it off the floor. Although flexible in that it can accommodate any number of panels (within limits) in a range of dimensions, this system, too, is limited to packaging panels of the same width and height. Moreover, assembly of the two parts of the bracing members requires drilling holes, fastening bolts, and trimming protruding sections which adds considerably to the time required to assemble the entire package. 
         [0015]    There remains a need, evidently, for an inexpensive, light packaging system for a stack of large panels of frangible materials; a system which requires no particular skill to assemble and very few tools, which is compact when stored unassembled, and which may be readily disassembled for economical return to the sender. The present invention addresses these, among other objects. 
       SUMMARY OF THE INVENTION 
       [0016]    It is the first and main object of this invention to provide an economical packaging system for one or more relatively large panels of fragile material, which may be transported and stored disassembled and may be readily assembled when needed, requiring no specific skill or specialized tools. 
         [0017]    A second object of this invention is to provide a packaging system as described above, which can accommodate panels in a range of thicknesses and surface dimensions. 
         [0018]    A third object of this invention is to provide a packaging system as described above, which occupies minimal volume and which has a minimal footprint. 
         [0019]    A fourth object of this invention is to provide a packaging system as described above, which protects its contents from floor impact damage and which may be manipulated by a forklift. 
         [0020]    These objects are met in embodiments of this invention through a number of features, as outlined below. 
         [0021]    The principle feature of the present invention is its modular design, where each module is constructed primarily of recyclable corrugated fibreboard blanks. The modularity of the design allows it to be readily and economically transported and stored. The corrugated fibreboard construction allows the system to be light yet rigid, and inexpensive. 
         [0022]    A second feature of the invention is an adaptable, multi-part panel case, within which an individual panel in a range of dimensions may be secured. Several such panel cases may be bound in a substantially vertical orientation as a horizontal stack. 
         [0023]    A third feature of the invention is an internally reinforced support pillar, two pairs of which—one at each end of the aforementioned horizontal stack—serve to buttress the stack and stabilize the substantially vertical panel cases. 
         [0024]    A fourth feature of the invention is a shock-absorbing base block. Two such blocks—each disposed underneath the respective end of the aforementioned bound and buttressed stack—suspend the stack off the floor. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0025]    A detailed description of preferred embodiments of the present invention is provided hereafter, in which references are made to the following figures: 
           [0026]    FIG.  1 —A perspective view of an assembled and bound package, according to the present invention, containing three panel cases. 
           [0027]    FIG.  2 —An orthographic front view of the package depicted in  FIG. 1 . 
           [0028]    FIG.  3 —An orthographic side view of the package depicted in  FIG. 1 . 
           [0029]    FIG.  4 —A plan view of the fibreboard blank for the support pillar depicted in  FIG. 5-7 . 
           [0030]    FIG.  5 —A perspective isometric view of a support pillar constructed from the fibreboard blank depicted in  FIG. 4 , with its top and bottom flaps partly open. 
           [0031]    FIG.  6 —A perspective isometric view of the support pillar depicted in  FIG. 5  with its top and bottom flaps closed, tracing its manner of engagement with the laminated base block depicted in  FIG. 9 . 
           [0032]    FIG.  7 —A perspective view of the support pillar depicted in  FIG. 6  from the opposite direction. 
           [0033]    FIG.  8 —A perspective view of the reversed form of a support pillar, according to the present invention. 
           [0034]    FIG.  9 —A perspective view of the laminated base block, according to the present invention. 
           [0035]    FIG.  10 —An orthographic front view of the support pillar depicted in  FIG. 6 . 
           [0036]    FIG.  11 —An orthographic section view of the support pillar depicted in  FIG. 10 , corresponding to line  11 , exposing its internal structure. 
           [0037]    FIG.  12 —A perspective view of a second embodiment of the support pillar, according to the present invention, with its top flap opened. 
           [0038]    FIG.  13 —A plan view of the fibreboard blank from which the second embodiment of the support pillar depicted in  FIG. 12  is constructed. 
           [0039]    FIG.  14 —An orthographic section view of a second embodiment of the support pillar depicted in  FIG. 12 , corresponding to a viewpoint similar to line  11  of  FIG. 10 . 
           [0040]    FIG.  15 —A perspective view of a third embodiment of the support pillar, according to the present invention, with its front wall removed to expose its inner structure. 
           [0041]    FIG.  16 —A plan view of the fibreboard blank from which the third embodiment of the support pillar is constructed. 
           [0042]    FIG.  17 —An orthographic front view of the third embodiment of the support pillar. 
           [0043]    FIG.  18 —An orthographic section view of the third embodiment of the support pillar corresponding to line  18 , exposing its internal structure as seen from above. 
           [0044]    FIG.  19 —An orthographic section view of the third embodiment of the support pillar corresponding to line  19 , exposing its internal structure as seen from below. 
           [0045]    FIG.  20 —A perspective isometric view of a corner pad constructed according to the present invention. 
           [0046]    FIG.  21 —A plan view of a fibreboard blank from which the corner pad depicted in  FIG. 20  is constructed. 
           [0047]    FIG.  22 —An orthographic front view of four pieces of the corner pad depicted in  FIG. 20 , affixed to a panel to be packaged, which, in turn, is affixed to a mounting panel, according to the present invention. 
           [0048]    FIG.  23 —A perspective view of a four-flap envelope, according to the present invention, tracing its manner of engagement with the mounting panel of  FIG. 22 . 
           [0049]    FIG.  24 —A perspective view of the four-flap envelope of  FIG. 23 , engaged with and amid closure over the loaded mounting panel. 
           [0050]    FIG.  25 —A plan view of a fibreboard blank for the four-flap envelope of  FIG. 23 . 
           [0051]    FIG.  26 —A perspective view of a two-flap, outer envelope, according to the present invention, tracing its manner of engagement with the loaded four-flap envelope of  FIG. 25 . 
           [0052]    FIG.  27 —A perspective view of the outer envelope of  FIG. 26  and the four-flap, loaded envelope it encases, forming a complete panel case. 
           [0053]    FIG.  28 —A plan view of a fibreboard blank for the outer envelope of  FIG. 26 . 
           [0054]    FIG.  29 —An orthographic front view of the assembly depicted in  FIG. 27 . 
           [0055]    FIG.  30 —An orthographic section view of the assembly of  FIG. 29 , corresponding to line  30  (for clarity, the corner pads are hidden in this view). 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0056]    A packaging system constructed according to the present invention, in its fully assembled, loaded, and bound state, is depicted in  FIG. 1-3  and is denoted generally by reference numeral  1 . 
         [0057]    Referring to  FIG. 1 , packaging system  1  is comprised of three main elements: a stack  5  of one or more multi-part panel cases  6 , each containing a single fragile panel to be packaged (three such panel cases are stacked in the exemplary embodiment depicted in  FIG. 1 ); two pairs of support and carriage pillars, each pair consisting of pillar  2  and a geometrically mirrored pillar  2   m , the respective pillars of each pair embracing stack  5  on opposite faces at either end thereof; two base blocks  3  upon which stack  5  rests, an end section of each block securely engaged within a corresponding recess at the bottom of each of support pillars  2  and  2   m.    
         [0058]    The use of two-part support structures (viz. pillars  2  and  2   m ) to buttress stack  5  permits the packaging of any number of units of panel case  6 , to a limit imposed by the ability of pillars  2  and  2   m  and blocks  3  to withstand the weight of the stack. 
         [0059]    Although in the preferred embodiments, pillars  2  and  2   m  are bound level with the lateral edges of stack  5  for maximum stability and protection, pillars  2  and  2   m  may also be bound inwardly of these edges by any offset which still provides acceptable stability. 
         [0060]    Stack  5  of panel cases  6 , as discussed above and as seen in  FIG. 1  and  FIG. 3 , is interposed between pillars  2  and  2   m , and the entire assembly is bound together by steel or plastic strapping, seen most clearly in  FIG. 2 . Vertical straps  4   v  bind stack  5  over flanges which extend from each pillar  2  and  2   m  (denoted  2 . 2  in  FIG. 4-7 ), binding pillars  2  and  2   m  to one another and affixing them to stack  5 . Horizontal straps  4   h  bind stack  5  over vertical straps  4   v  (and thus over flanges  2 . 2 ) and through slots in pillars  2  (denoted  2 . 6  in  FIG. 4-7 ) and the corresponding slots in support pillars  2   m , solidifying the attachment of pillars  2  and  2   m  to stack  5 . 
         [0061]    Referring now to  FIG. 4-7 , pillar  2  is formed, in the preferred embodiments, from a corrugated fibreboard blank, denoted generally by the numeral  2 . 0  in  FIG. 4 . Blank  2 . 0  is adapted with pre-pressed fold lines to facilitate its transformation into the solid double-walled structure of pillar  2 . This transformation, in the embodiment depicted in  FIG. 4-7 , is achieved in the following manner: segment  2 . 8  is bent to an acute angle of approximately 20° relative to base segment  2 . 1 ; base segment  2 . 1  is bent at a right angle relative to the segment on its left; the latter segment and, sequentially, each succeeding segment through segment  2 . 2  are bent at a right angle relative to their respective preceding segment; segment  2 . 3  is bent down to cap the structure; segment  2 . 4  is bent up to form an inner bottom cap; segment  2 . 5  is bent up to form an outer bottom cap. 
         [0062]    In the preferred embodiments, one or more sections of an adhesive tape are applied circumferentially to pillar  2  to fix its form; alternatively, the overlapping areas of segment  2 . 2  and the segment it overlies, and—advantageously—overlapping areas of other segments, are bonded or stapled. 
         [0063]    Pillar  2   m , depicted isolated in  FIG. 8 , is formed from a blank of mirrored geometry with respect to that of blank  2 . 0 , following the same procedure. 
         [0064]    Bracing segment  2 . 8  spans diagonally the interior cavity of pillar  2 , when so constructed, thereby increasing the unit&#39;s structural rigidity and resistance to deformation. The diagonal orientation of segment  2 . 8  is revealed in the exposed view of pillar  2  depicted in  FIG. 5  and in the section view of  FIG. 11 , an aspect corresponding to a viewpoint represented by line  11  in  FIG. 10 . 
         [0065]    An identical, though mirrored, arrangement of a diagonal bracing segment is found in pillar  2   m.    
         [0066]    As seen in  FIG. 4 , bracing segment  2 . 8  is truncated at its bottom to allow—in the formed pillar  2 —the insertion of an end section of base block  3 , depicted in  FIG. 9 . In the preferred embodiments, base block  3  is a laminate, constructed of a plurality of bonded fibreboard panels. In an alternative embodiment, the laminate fibreboard block is formed by strapping together the constituent panels. The manner of engagement of support pillar  2  and base block  3  is shown in  FIG. 6 . 
         [0067]    A plurality of slots  2 . 6   t  and  2 . 6   b  are pre-cut in blank  2 . 0 . Slots  2 . 6   t  and  2 . 6   b  are so positioned that when blank  2 . 0  is manipulated according to the aforesaid procedure to form unit  2 , Slots  2 . 6   t  and  2 . 6   b  are disposed in superposed registration with one another near the top and bottom of pillar  2 , respectively, allowing the transverse passage of the aforementioned straps  4   h  therethrough. 
         [0068]    The vertical edge of slots  2 . 6   t  and  2 . 6   b  which is nearer stack  5  in the assembled package is level with the rear face of the innermost wall of unit  2  on its side facing stack  5 . This allows straps  4   h  to lie in abutment with said wall face unhindered. 
         [0069]    An identical arrangement of strapping slots is found in pillar  2   m.    
         [0070]    Two pairs of hand carrying slots  2 . 7 , a representative one is labeled in  FIG. 4 , are pre-cut in blank  2 . 0 . Slots  2 . 7  are positioned on blank  2 . 0 , so that when it is formed into pillar  2  they are disposed in superposed registration with one another on the side of pillar  2  facing away from stack  5  in the assembled package, providing two handhold openings. The vertical positioning of the two handhold openings is set to allow comfortable handgrip by person of normal stature. 
         [0071]    An identical arrangement of handhold openings is found in support pillar  2   m.    
         [0072]    Referring now to  FIG. 12-14 , a second preferred embodiment of pillar  2 , denoted generally by the numeral  2 B in  FIG. 12 , provides an internal bracing of an alternative geometry. Base segment  2 B. 1  is extended, in this embodiment, at a right angle with segment  2 B. 9  which carries the diagonal bracing segment  2 B. 10 . Segment  2 B. 11  extends from segment  2 B. 10  in the opposite direction, as seen in  FIG. 12  and in  FIG. 14  which corresponds to a viewpoint similar to that of line  11  in  FIG. 10 . Segment  2 B. 11  serves to better anchor segment  2 B. 10  in its diagonal position, thus to further reinforce the pillar structure. 
         [0073]    Referring to  FIG. 15-19 , a third preferred embodiment of pillar  2 , denoted generally by the numeral  2 C in  FIG. 15 , provides an internal bracing of a second alternative geometry. In this embodiment, the upper half of base segment  2 C. 1  is extended at a right angle with segment  2 C. 12 , which carries diagonal bracing segment  2 C. 13 . At its lower half, base segment  2 C. 1  is extended directly with diagonal bracing segment  2 C. 14 . Diagonal segment  2 C. 13  is clearly seen in FIG.  18 —a sectional top view, corresponding to line  18  of  FIG. 17 . Diagonal segment  2 C. 14  is clearly seen in FIG.  19 —a sectional bottom view, corresponding to line  19  of  FIG. 17 . The two cross diagonal bracing segments further fortify the pillar structure in this embodiment. 
         [0074]    It will be apparent to those skilled in the art that various other geometries of inner bracing are possible which may provide similar benefits. 
         [0075]    Referring to  FIG. 20-22 , a corner pad—depicted isolated in  FIG. 20  and denoted generally by the numeral  8 —is provided to protectively sheath each of the corners of a fragile panel to be packaged (denoted  7  in  FIG. 22 ) and secure it to a mounting panel (denoted  9  in  FIG. 22 ). Corner pad  8  consists of a main section  8 . 0 , adjacent two of whose sides are extended with inwardly folded, partially overlapping flaps  8 . 1  and  8 . 2 . Corner pad  8  is constructed, in the preferred embodiment, of a corrugated fibreboard blank, depicted in  FIG. 21 , which is adapted with a plurality of pre-pressed fold lines  8 . 3 . The multiplicity of fold lines  8 . 3  permit flaps  8 . 1  and  8 . 2  to be folded squarely over fragile panel  7  according to its thickness, so that it is accommodated snugly therewithin. Flaps  8 . 1  and  8 . 2 , in the preferred embodiments, are taped; alternatively, their overlapping sections may be stapled or bonded together. 
         [0076]    It will be clear to those skilled in the art that various other two-flap envelope geometries will provide corner pads of equally effective functionality. 
         [0077]    Once applied to the respective corners of panel  7 , corner pads  8  are then taped or bonded to mounting panel  9 , as seen in  FIG. 22 , so that panel  7  is secured in a substantially central lateral position with respect to mounting panel  9 , and level with the bottom edge thereof. 
         [0078]    Mounting panel  9  effectively normalizes panel  7  dimensionally, so that an envelope of corresponding predetermined dimensions may be used, as described hereinafter, to securely encase the so mounted panel  7  irrespective of its dimensions. 
         [0079]    Referring to  FIG. 23-24 , a four-flap envelope, denoted  10  in  FIG. 23 , is provided to encase panel  7 , when mounted by corner pads  8  onto mounting panel  9 , as described above. The manner of engagement of mounted panel  7  and envelope  10  is traced in  FIG. 23 , and their relation when coupled is shown in  FIG. 24 . 
         [0080]    In the preferred embodiments, vertical flaps  10 . 1  are folded first, followed by the folding of horizontal flaps  10 . 2 . Once flaps  10 . 1  and  10 . 2  are folded to abut corner pads  8  and one another, they are fixed in this position by an adhesive tape. Alternatively, the overlapping areas of flaps  10 . 1  and  10 . 2  are bonded together or stapled. 
         [0081]    Envelope  10  is constructed, in the preferred embodiments, of a corrugated fibreboard blank, depicted in  FIG. 25 , which is adapted with a plurality of pre-pressed fold lines  10 . 3 . Each of fold lines  10 . 3  corresponds to a particular thickness panel  7  may have, and permits flaps  10 . 1  and  10 . 2  to be folded squarely over panel  7  when of this thickness. 
         [0082]    Referring now to  FIG. 26-30 , a two-flap, outer envelope, denoted  11  in  FIG. 26 , is provided to encase envelope  10  and its contents. As seen in  FIG. 26 , envelope  10 , with panel  7  secured therewithin, is engaged with envelope  11  so that the remaining exposed area of panel  7  is covered by envelope  11 .  FIG. 27  depicts envelopes  10  and  11  engaged, to form the aforementioned panel case  6 . 
         [0083]    In the preferred embodiments, envelope  11  is constructed of a corrugated fibreboard blank, depicted in  FIG. 28 , which is adapted with a plurality of pre-pressed fold lines  11 . 2 . Each of fold lines  11 . 2  corresponds to a particular thickness envelope  10  may assume when loaded, and permits flaps  11 . 2  to be folded squarely over envelope  10  when of this thickness. 
         [0084]    Flaps  11 . 1 , in the preferred embodiments, are taped to envelope  10 ; alternatively, they may be bonded or strapped. 
         [0085]    When the use of outer envelope  11  is deemed superfluous, it may be eliminated, and mounting panel  9  engaged with four-flap envelop  10 , so that panel  7  is emplaced therebetween. Conversely, if greater surface impact protection is desired than that provided by mounting panel  9 , envelope  10 , and envelope  11 , one or more progressively larger envelopes—each formed of a corrugated fibreboard blank adapted with at least two opposite foldable flaps—may be applied to encase the previously applied envelope and its contents. 
         [0086]    Although, advantageously, corrugated fibreboard is the board blank material contemplated for use in the various parts of the preferred embodiments, other materials which allow a board blank to be adapted with foldable segments and flaps may be employed alternatively. 
         [0087]    It is to be understood that the forgoing description of the preferred embodiments of the present invention and the accompanying drawings are intended to better elucidate the invention by way of examples, and not in any way to narrow its purview or the scope of the appended claims to the embodiments exemplified.