Abstract:
A protective package for an automobile part; as assembled, packaged and buttressed for shipping; minimizes or eliminates damage to the automobile part being shipped, by providing a carton, side rail supports in the carton to receive the part and padded supports to secure the part in the carton.

Description:
This invention relates to a protective package, especially for an automobile part, and more particularly, to a protective package for an automobile part, especially a hood, which complies with shipping standards and permits efficient shipping of the part. 
     BACKGROUND OF THE INVENTION 
     When a vehicle accident occurs, it is usually necessary to replace various parts of the vehicle. These parts of the vehicle are body parts, frame parts, mechanical parts, or electrical parts. With the body part, one major problem involves appropriate storage of body parts, until the particular use is desired. 
     Because vehicle body parts are generally large and require a substantial amount of storage space, it is usually desirable to warehouse the body parts, and ship the body parts to the desired location. The desired location is usually a body shop that actually makes the vehicle repairs. 
     Since warehouse space can be expensive, it is desired to reduce the number of warehouses and provide a shipping program to efficiently transport the desired part to the desired location. With such transportation, an effective package for the part permits shipping of the part with no damage. Because not all body parts are heavily supported or braced, it is difficult to ship parts. 
     Major keys to efficient use of warehouse space are proper storage and utility of the packaging materials. Not only must the packaging material be easily stored, it must also be easily assembled into the desired package. Such a combination provides value and efficiency to the packaging material. 
     One of the most difficult parts to ship is a vehicle hood or cover for the engine compartment. Some aftermarket suppliers have stopped shipping vehicle hoods because of the difficulty and expense of getting the hoods, to a desired location in an undamaged condition. 
     More particularly, it is known that is very difficult to ship a hood for a Mercedes. In spite of substantial efforts to correct the package and greatly reduce the damage to any part contained in the package, the efforts have met with no success. In fact, more than twenty-five (25%) percent of these shipped hoods are known to arrive in a damaged condition. 
     This damage problem imposes many undesirable limits. One such limit is the distance a hood may be shipped. To solve that problem, more warehouses for parts or better shipping packages are required. Such difficulties also lead a lack of flexibility in type or size of a hood that can be packed and shipped. Furthermore, it is difficult to develop a package acceptable to the commercial delivery services. If the package containing the auto parts or the hood or other body part can meet the standards of a commercial shipping organization, such as Federal Express or United Parcel Service, great advantages can be obtained. Such advantages include, but are not limited to, damage insurance on the part being shipped. 
     SUMMARY OF THE INVENTION 
     Among the many objectives of this invention is the provision of a protective package, which permits an automobile part to be shipped in an efficient fashion. 
     A further objective of this invention is the provision of a protective package, which prevents damage to an automobile part shipped therein. 
     Yet a further objective of this invention is the provision of a protective package, which meets industry standards for shipping. 
     A still further objective of this invention is the provision of a protective package, which is easily installed around an automobile part. 
     Another objective of this invention is the provision of a protective package, which is easily stored. 
     Still, another objective of this invention is the provision of a protective package, which is easily assembled. 
     Also, an objective of this invention is the provision of a protective package, which has repeated uses. 
     A further objective of this invention is the provision of a protective package, which increases the distance an automobile part may be safely shipped. 
     Yet a further objective of this invention is the provision of a protective package, which has flexibility to safely many different products. 
     These and other objectives of the invention (which other objectives become clear by consideration of the specification, claims and drawings as a whole) are met by providing a protective package for an automobile part, which can be assembled, packaged and buttressed for shipping, in order to minimize or eliminate damage to the automobile part being shipped, by providing a carton, side rail supports in the carton to receive the part and padded supports to secure the part in the carton. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a see through perspective view of a package assembly  100  of this invention for a vehicle hood  110 , in a sealed shipping carton  300  shown in phantom. 
         FIG. 2  depicts a perspective view of an inward direction  112  of hood  110 . 
         FIG. 3  depicts a perspective, exploded, related view of all components for package assembly  100 . 
         FIG. 4  depicts a perspective view of a side rail  140  being partially folded to form part of package assembly  100 . 
         FIG. 5  depicts a perspective view of a side rail  140  being completely folded to form part of package assembly  100 . 
         FIG. 6  depicts a perspective view of a side rail  140  using swing brace panels to add strength, form and rigidity to side rail  140 . 
         FIG. 7  depicts a perspective view of the outer side  204  of side rail  140  with a side foam spacer  150  being attached thereto. 
         FIG. 8  depicts a perspective view of thin spacer pad  146  used in package assembly  100 . 
         FIG. 9  depicts a perspective view of medium spacer pad  148  used in package assembly  100 . 
         FIG. 10  depicts a perspective view of thick spacer pad  160  used in package assembly  100 . 
         FIG. 11  depicts a perspective view of corrugated rear insert  164  in a die-cut flat position  166 . 
         FIG. 12  depicts a perspective view of rear foam  168  lying on corrugated die cut flat  166  for rear insert  164 . 
         FIG. 13  depicts a perspective view of rear foam  168  lying on corrugated die cut flat  166  for rear insert  164 . 
         FIG. 14  depicts a perspective view of rear foam  168  set in rear insert  164  partially folded and wrapped. 
         FIG. 15  depicts a perspective view of rear foam  168  set in rear insert  164  completely folded and wrapped. 
         FIG. 16  depicts a perspective view of rear foam  168  set in rear insert  164  completely folded, wrapped and secured. 
         FIG. 17  depicts a perspective view of rear insert  164  as assembled. 
         FIG. 18  depicts a perspective view of corrugated die cut flat  192  of front insert  190 . 
         FIG. 19  depicts a perspective view of front foam  194  on corrugated die cut flat  192  of front insert  190 . 
         FIG. 20  depicts a perspective view of corrugated front insert  190 , in partially folded position  196  with front foam insert  194  positioned thereon. 
         FIG. 21  depicts a front perspective view of corrugated front insert  190 , in completely folded position  200  with front foam insert  194  positioned therein. 
         FIG. 22  depicts a rear perspective view of corrugated front insert  190 , in completely folded position  200  with front foam insert  194  secured therein. 
         FIG. 23  depicts a front perspective view of corrugated front insert  190 , in completely folded position  200  with front foam insert  194  positioned therein, based on a 180 degrees of rotation for  FIG. 22  about a vertical axis. 
         FIG. 24  depicts a perspective view of shipping carton  300 . 
         FIG. 25  depicts a perspective view of rear insert  164  inserted in side rail  140 . 
         FIG. 26  depicts a perspective view of rear foam insert  168  secured in side rail  140 . 
         FIG. 27  depicts dust flaps  302  of shipping carton  300  used to hold a proper shape for shipping carton  300 . 
         FIG. 28  depicts shipping carton  300  with rear bottom flap  304  at least partially secured. 
         FIG. 29  depicts a perspective view of shipping carton  300  having two of side rail  140  inserted therein, one on the left side and one on the right side. 
         FIG. 30  depicts package assembly  100  of this invention receiving vehicle hood  110 . 
         FIG. 31  depicts a person  102  reaching over rear bottom flap  304  into shipping carton  300  to grab hood  110 . 
         FIG. 32  depicts car hood  110  securely held in the corrugated rear insert  164 . 
         FIG. 33  depicts the closing and securing of the rear top flap  310  on the fold over carton  350 . 
         FIG. 34  depicts a perspective view of shipping carton  300  having two of side rail  140  inserted therein. 
         FIG. 35  depicts a perspective view of shipping carton  300  having two of side rail  140  inserted therein with medium spacer pads  148  exploded therefrom, based on  FIG. 34 . 
         FIG. 36  depicts a perspective view of shipping carton  300  having two of side rail  140  inserted therein with corrugated front insert  190  being exploded therefrom. 
         FIG. 37  depicts shipping carton  300  having both of the two side rails  140  inserted therein and with corrugated front insert  190  being secured therein. 
         FIG. 38  depicts closing and securing of the front flap assembly  330  of fold over carton  350 . 
         FIG. 39  depicts securing side rails  140  to the fold over carton  350 . 
     
    
    
     Throughout the figures of the drawings, where the same part appears in more than one figure of the drawings, the same number is applied thereto. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In accordance with the present invention, a protective package for a part to be shipped has a slotted side rail placed on either side of the part. The two side rails containing or supporting the part are inserted into a carton. Some buttressing members are inserted into the slots. Other buttressing members are positioned between each slotted side rail and a side of the carton to further support the part, considering that the part is not perfectly rectangular. 
     This particular package meets the standards set by Federal Express and solves that company&#39;s concern over high damage incidence rates. Furthermore, the protective package meets and exceeds International Safe Transit Association ISTA (hereafter ISTA) standards for testing by being drop tested from 30 inches to a hard surface, which is in excess of the normal 12 inch drop test, and still provides adequate protection. Such a protective package solves the problems of damage to the hood, shipping distance limitations, flexibility in type or size of hood that can be packed. The aftermarket automobile repair industry is interested in this pack due to its flexibility and wide application. 
     Referring now to  FIG. 1  and  FIG. 2 , a package assembly  100  contains a vehicle hood  110 , using a hood packing assembly  120  in a sealed shipping carton  300 . Sealed shipping carton  300  is known in the packaging industry as a regular slotted carton (hereafter RSC). The inward direction  112  places hood  110  in the hood packing assembly  120 . 
     Adding  FIG. 3  to the consideration, all components of hood packing assembly  120  and sealed shipping carton  300  are shown in relationship to each other. Shipping carton  300  receives or has a side rail  140  on either side of hood  110 . In each side rail  140  are mounted a corrugated rear insert  164  and a corrugated front insert  190 . Oppositely disposed from the inserts and between the shipping carton  300  and both of side rails  140  are medium spacer pads  148 , in order to further support hood  110 . 
     With  FIG. 4  and  FIG. 5 , the formation of side rail  140  is depicted as starting with a scored flat corrugated piece of material being folded to form side rail  140 . More particularly, side rail  140  has an outer side  204  and inner side  206 . Outer side  204  is spaced from each end of the flat corrugated piece of material. At one side of outer side  204  is large top panel  210 . Large top panel  210  extends into larger inner panel  212 , which forms part of inner side  206  and is preferably substantially parallel to outer side  204 . Larger inner panel  212  extends into first slot side  214  and then into second base side  216 . 
     Likewise, small bottom panel  220  extends from outer side  204  and is substantially perpendicular thereto. Small bottom panel  220  then forms smaller inner panel  222 . Smaller inner panel  222  extends into second slot side  224  and then, in turn, to the first slot base  226 . Rail channel slot  228  thus formed receives hood  110  in a proper fashion because slot  228 , in this case, is not centered on inner side  206 . 
     Thus, there are two side rails  140  which are folded in mirror fashion, and placed in shipping carton  300  ( FIG. 2 ). These two side rails  140  have rail channel slots  228  on their inner sides  202  facing one another, and an outer side  204  facing the shipping carton  300 . 
     With  FIG. 6  and  FIG. 7 , the reinforcement of side rail  140  is clarified. Adjacent to larger inner panel  212  in outer side  204  is a large top swing brace panel  240  and a smaller top swing brace panel  242  that swing and away from each other. Both top panels  240  and  242  have an upper rest lip  250 , which contacts and rests against inner panel  212 . At the lower portion of outer side  204  are larger bottom swing brace  244  and smaller bottom swing brace panel  246 , both of which swing in, but away from each other. Both of swing brace panels  244  and  246  have a rest lip  252 , which contacts and rests against inner panel  222 . Both sets of swing brace panels offer increased rigidity and strength without increasing the overall weight of the package 
     So from outer side  204  of side rail  140  as the swing brace panels are set, the structure adds strength, form and rigidity to the side rail  140  and hence to the hood packing assembly  120 . For further support, a side foam spacer  150  may be added at or adjacent to one end of the outer side  204 . The side foam spacer  150  is in fact preferred to be so located. 
       FIG. 8 ,  FIG. 9  and  FIG. 10  combine to illustrate some of the variety of spacer pads which are used between the shipping carton  300  and the hood packing assembly  120 . More particularly, thin spacer pad  146  uses one pad block  152  on spacer support  154 , while medium spacer pad  148  has aligned pad blocks  152  on either side of spacer support  154 . Spacer support  154  is preferably a corrugated sheet with a size capable of fitting between shipping carton  300  and outer side  144  ( FIG. 35 ). Thick spacer pad  160  uses three of pad block  152  by wrapping the end of spacer support  154  around one pad block  152  and stacking the two other pad blocks  152  over and under the first with spacer support  154  therebetween. 
     Additionally, hood  110  or other part is supported by corrugated rear insert  164  as shown in  FIG. 11 ,  FIG. 12 ,  FIG. 13 ,  FIG. 14 ,  FIG. 15 ,  FIG. 16  and  FIG. 17 . The rear die-cut flat  166  is folded to form corrugated rear insert  164  and receive larger jaw angle cut spacer  262  therein. Larger jaw angle cut foam spacer  168  has larger hood slot  264  in the end thereof. 
     With both the front insert  190  and corrugated front insert  190 , the folding is preferably done first. Then the desired foam insert is fit therein. Finally, the corrugated rear insert  164  and corrugated front insert  190 . 
     The rear die-cut flat  260  has a foldable tongue  266  in one side thereof, which fits into larger hood slot  264 . The folding process for rear die-cut flat  166  at least partially encases larger jaw angle cut foam spacer  168  therein as shown in  FIG. 15 . Staples  268  can secure the larger jaw angle cut spacer  168  therein. A corrugated rear insert  164  is present in both of rail channel slot  228 . 
     Furthermore, hood  110  or other part is also supported by corrugated front insert  190  as shown in  FIG. 18 ,  FIG. 19 ,  FIG. 20 ,  FIG. 21 ,  FIG. 22  and  FIG. 23 . In  FIG. 18  the corrugated front insert die-cut flat  192  receives front foam support  272  in the form of rectangular solid with front jaw slot  274 . 
     Front insert die-cut flat  192  is formed into a front box  276  to receive front foam support  272  and have inner jaw cover  278  secured thereover. Then outer jaw cover  280  is secured over inner jaw cover  278 . The front foam support  272  is then inserted adjacent to hood  110  in each rail channel slot  228 . Front foam support  272  is preferred because of its shock absorption qualities, but other supports may be used. 
       FIG. 19  shows front foam support  272  laying on corrugated front insert die-cut flat  192 .  FIG. 20  shows front foam support  272  wrapped in front insert die-cut flat  270 . For front jaw slot  274 , the sequence of front insert die-cut flat  192  folding is first the folding of front insert tongue  282  under both inner jaw cover  278  and outer jaw cover  280 .  FIG. 23  secures front insert back flaps  284  with staples  268 . 
     Corrugated front insert  190  ( FIG. 18 ) with front foam insert  194  can be used in place of rear die-cut flat  260  ( FIG. 11 ) with rear insert foam  168 . The opposite is also true. In this manner, all four inserts may be the same. If there is extra space in channel slot  228 , it can be filled in any desirable manner. A foam piece (not shown) may be cut to fit. A corrugated piece may be rolled and cut to fit. 
     By considering  FIG. 24 ,  FIG. 25 ,  FIG. 26 ,  FIG. 27 ,  FIG. 28 ,  FIG. 29  and  FIG. 30 , one may see the relationship of the shipping carton  300  and the hood packing assembly  120  in support of hood  110 . Shipping carton  300  is formed into a hollow, three-dimensional rectangle with a rear closable end  308  oppositely disposed from a front closable end  312 . Two of side rail  140  are inserted in the shipping carton  300  oppositely disposed from each other and substantially perpendicular to both rear closable end  308  and front closable end  312 . Rail channel slot  228  in each of side rail  140  face each other within shipping carton  300 , and space hood  110  or other auto part a desired safe distance away from shipping carton  300 . 
     In  FIG. 26 , corrugated rear insert  164  is secured to side rail  140  with staples  268  through rear insert tongue  290  into second base side  216 . In this fashion, proper positioning is obtained for the corrugated rear insert  164 . 
     Now  FIG. 27  shows the ease of assembly for shipping carton  300 . Rear dust flaps  302  of shipping carton  300  are folded inwardly in order to hold shipping carton  300  in proper shape. Then using  FIG. 28 , rear bottom flap  304  may be secured with staples  268  to rear dust flaps  302 . While rear bottom flap  304  is secured to dust flaps  302 , rear top flap  310  is left free to assist with packing until shipment or storage is desired. 
     After the shipping carton  300  is partially assembled as discussed above,  FIG. 29  shows the insertion two of side rail  140  therein on both the left and right side. Then, as shown in  FIG. 30 , hood  110  is properly directed into shipping carton  300 . 
     With rear top flap  310  left open,  FIG. 31  can illustrate a person  102  reaching into the rear of shipping carton  300  pulling hood  110  back to rest in rear insert jaw  162  of corrugated rear insert  164 . A corrugated rear insert  164  is secured in both of side rails  140 , as shown in  FIG. 32 . Both of corrugated rear insert  164  are adjacent to rear bottom flap  304  and within rail channel slot  228  ( FIG. 31 ). Then as shown in  FIG. 33  rear top flap  310  on fold over carton  350  is secured with staples  268 , thereby causing the securing of fold over carton  350  with rear full flap assembly  360 . 
     Turning now to  FIG. 34  and  FIG. 35 , side rails  140  are pushed in toward each other evenly in order to securely snug and anchor the vehicle hood  110  in place. Then thin spacer pad  146  ( FIG. 8 ), medium spacer pad  148  ( FIG. 9 ), or thick spacer pad  160  ( FIG. 10 ) may be inserted as in  FIG. 35  on both the right and left side of the shipping carton  300 . The appropriate spacer pad is placed between the side rail  140  and the shipping carton  300  on both the right and left side of hood  110 . Each spacer pad is pushed back along side rail  140  to take up the open space there. Any remaining length that may stick out beyond the side rail  140  can be folded over the front of the side rail  140 . 
     Now in  FIG. 36  and  FIG. 37 , a corrugated front insert  190  may be inserted into rail channel slot  228  of  FIG. 34  and around hood  110 . Then the corrugated front insert  190  is, as shown in  FIG. 35 , is secured to side rail  140  by staples  268  from stapler  340  or other fastening device. 
     The final package completion for package assembly  100  as depicted in  FIG. 38  and  FIG. 39  shows fold over carton  350 . Fold over carton  350  is known in the industry as a Full Overlap carton (hereafter FOL). 
     Full rear bottom flap  352 , at least, almost completely, if not fully, covers the rear of fold over carton  350 . Fold over carton  350  is used to ship smaller implements, such as a smaller hood  110 . Full rear top flap  354  folds over full rear bottom flap  352  and closes rear full flap assembly  360 , because the end rear dust flaps  362  over each side rail  140  before either flap  352  or  354  is used. Then, full rear bottom flap  352  is raised and full top rear flap  354  is lowered thereover. Front full flap assembly  370  is closed in same way as rear full flap assembly  360 . 
     Staples  268  secure the full front flap assembly  330  in a closed position. Also, staples  268  secure side rails  140  through the top of seamed shipping carton  300  or fold over carton  350 . Thus, is hood  110 , even in a smaller version, secured appropriately for transport. 
     While it is not desired to be bound by any particular theory, the following postulate is offered for the success of this package assembly  100 . Seamed shipping carton  300  or fold over carton  350  support the side rails  140  with the swing brace panels  142 , and the corrugated rear inserts  164  and the corrugated front inserts  190  work together. Either the seamed shipping carton  300  or the fold over carton  350  renders the part such as hood  110  contained therein at least substantially immovable relative to the packing assembly  120 . Then the blows to package  100  are absorbed thereby without damage to the part contained therein. 
     This application—taken as a whole with the abstract, specification, claims, and drawings being combined—provides sufficient information for a person having ordinary skill in the art to practice the invention as disclosed and claimed herein. Any measures necessary to practice this invention are well within the skill of a person having ordinary skill in this art after that person has made a careful study of this disclosure. 
     Because of this disclosure and solely because of this disclosure, modification of this method and device can become clear to a person having ordinary skill in this particular art. Such modifications are clearly covered by this disclosure.