Abstract:
A Clearview packaging assembly for containing an irregular shaped appliance such as a washer or dryer is provided. The assembly comprises a clamshell-like framework placed around the appliance and wrapped tightly in transparent film. The framework includes a hinged top cap, front corner posts glued to the front portion of the top cap, rear corner posts glued to the rear portion of the top cap, front and rear bottom pieces glued to the lower ends of the corner posts, and a basiloid piece glued to the two rear corner posts. The top cap and the basiloid piece cooperate to form a three-layer thick basiloid handling flange to facilitate basiloid lifting of the packaging assembly with the appliance contained therein. The top cap has triangular shaped side walls that, along with the front corner posts, maintain the structural integrity of the package and prevent trapezoiding during basiloid handling.

Description:
BACKGROUND 
     1. Field of the Invention 
     This patent relates to packaging for large appliances. More particularly, this patent relates to a Clearview packaging assembly for basiloid handling of appliances with irregular top surfaces. 
     2. Description of the Related Art 
     Large household appliances with irregular shapes, such as washers and dryers, traditionally have been packaged in large six-sided corrugated boxes. Such boxes protect the appliance from damage during shipping and handling and may be moved with the use of a standard forklift truck. The boxed appliances may be stacked if sufficient structural support is provided. This may be accomplished by inserting vertical support posts inside the corrugated box between the box interior walls and the appliance. Support posts may be positioned around the corners of the appliance and/or along the sides of the appliance. When packaged in a corrugated box of this type, the appliance is not visible. 
     See-through containers for large appliances have been proposed in U.S. Pat. Nos. 3,891,086, 4,811,840 and 5,307,928. These proposed see-through containers generally comprise top and bottom caps, corner support posts extending between the top and bottom caps, and heavy plastic see-through wrapping. The top and bottom caps may be secured to the support posts with horizontal retaining bands, as in U.S. Pat. No. 3,891,086, or vertical retaining bands, as in U.S. Pat. No. 5,307,928. When packaged in this way the appliances can be moved with standard fork lift trucks or with basiloid lift trucks. 
     A basiloid lift truck lifts an appliance container by the top cap instead of by the bottom of the container. Basiloid lift trucks have a vertically oriented lift blade extending from an upper frame that is secured to an elevator mechanism mounted on the front end of the lift truck. To lift an appliance having a top cap, the vertical blade is placed in flat contact with the side of the packaged appliance. As the elevator mechanism raises the lift blade, the top edge of the blade extends into the crease between the side of the package and the downwardly extending lip of the top cap. The lift blade is raised until a horizontal lifting bar mounted on the blade abuts the bottom edge of the top cap lip. The appliance can then be lifted off the floor by the elevator mechanism and moved. The lift blade must be slightly shorter than the top cap lip so that the blade does not pierce the top cap. 
     If the package is built properly, the force of the blade lifting at the top of the unit is transferred to the bottom of the unit. No significant force is applied to the front edge of the top cap opposite the basiloid blade. However, when a second packaged appliance is placed on top of the first unit, the weight of the top unit, since it is not all on top of the basiloid flap, tends to shift forward. As the weight of the top unit shifts forward, the front edge of the bottom unit top cap deflects downwardly, a phenomenon referred to as trapezoiding. As the front edge of the bottom unit deflects downwardly, the top unit tips forward and can fall off. The front edge of the top cap can deflect up to six inches or more, depending on the vertical space between the front edge of the top cap and the top surface of the irregular shaped appliance. 
     One method for preventing trapezoiding of packages containing irregular shaped appliances is to use a standoff made of a resilient material such as expanded polystyrene to take up the space between the top cap and the appliance top surface, thereby transferring the force from the top appliance directly to the top surface of the bottom appliance. However, standoffs waste material and put extra undue force on the bottom of the bottom package. 
     Thus it is an object of the present invention to provide a see-through packaging assembly that maintains its structural integrity during basiloid lifting and handling. 
     A further object of the present invention is to provide a packaging assembly for irregular shaped appliances that resists trapezoiding during basiloid lifting with a second unit on top. 
     A still further object of the present invention is to provide a packaging assembly having an integral basiloid flap formed by the cooperation of the top cap and a separate basiloid piece. 
     Another object of the present invention is to provide a clamshell-type packaging assembly that can be easily installed over an appliance mounted on a base pad. 
     Further and additional objects will appear from the description, accompanying drawings, and appended claims. 
     SUMMARY OF THE INVENTION 
     The present invention is a packaging assembly for an irregular top appliance, that is, an appliance having a relatively flat top surface and a raised portion extending above the top surface, typically in the rear. The packaging assembly comprises a clamshell-like framework that is glued together prior to installing it over the appliance, and a transparent polymer film wrapped tightly around the framework after it has been installed over the appliance. 
     The clamshell-like framework is made from a corrugated top cap, front and rear corner posts, two bottom pieces and a basiloid piece. The top cap has a large flat top panel, substantially triangular shaped side panels extending downward from opposite sides of the top panel, and a rear flap separated from the top panel by a fold line that functions as the clamshell hinge. The two front corner posts are glued to the triangular shaped side panels. The lower ends of the two front corner posts may be glued to one of the bottom pieces to form one half of the clamshell. 
     The basiloid piece has a rear panel and a basiloid flap separated by a fold line. The top cap rear flap and the basiloid flap are glued together to form a basiloid handling flange which facilitates lifting and moving of the packaging assembly with the appliance contained therein by a basiloid fork lift truck. The two rear corner posts are glued along their upper ends to the basiloid piece rear panel and along their lower ends to the second bottom piece to form the other half of the clamshell. 
     The clamshell framework can be easily installed over an appliance mounted on a base pad. The framework and appliance, except for the basiloid flap, is wrapped in a transparent polymer wrapping material, leaving much of the appliance visible. The basiloid flap is retained by a horizontal retaining band to from the completed structure. 
     With conventional see-through packages, the downward force caused by a second unit stacked on top during basiloid lifting can cause the front edge of the bottom unit top cap to deflect downward, a phenomenon referred to as trapezoiding. This deflection can continue until the front edge of the top cap meets the top surface of the bottom appliance, causing the top appliance to tip forward. 
     The present invention prevents such trapezoiding by providing substantially triangular-shaped side panels glued to the front corner posts. The front corner posts abut the front vertical corners of the appliance. During basiloid lifting of two stacked appliances, the downward force from the top unit to the front edge of the top cap is transferred to the front corner posts and then to the front vertical corners of the appliance. The front vertical corners prevent the corner posts and top cap from rotating about the clamshell hinge, thereby preventing the trapezoiding associated with conventional see-through appliance packages. 
     The front corner posts serve as an extension of the triangle defined by the top cap sidewalls, and serve to spread the force created by the top unit during basiloid lifting to an area along the entire front vertical edges of the bottom appliance. If the front corner posts are not glued to the top cap, the top cap could slide downward along the front corner posts, resulting in trapezoiding. 
    
    
     THE DRAWINGS 
     FIG. 1 is a perspective view of the packaging assembly framework of the present invention shown before installation over an appliance. 
     FIG. 2 is a top view of a blank from which the top cap of the present invention is formed. 
     FIG. 3 is a top view of a blank from which the basiloid piece of the present invention is formed. 
     FIG. 4 is a top view of a blank from which the bottom pieces of the present invention are formed. 
     FIG. 5 is a side view of the packaging assembly framework of FIG. 1 shown partly installed over an appliance. 
     FIG. 6 is a side view of the packaging assembly framework of FIG. 1 shown containing an appliance and wrapped in transparent wrapping to form the complete packaging assembly. 
     FIG. 7 is an enlarged view of a portion of the packaging assembly of FIG.  6 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is a packaging assembly comprising a framework and transparent wrapping. Turning to the drawings, there is shown in FIG. 1 one embodiment of a framework made according to the present invention. The framework  10  is designed for basiloid handling of irregular top appliances, and comprises four structural support members  12 ,  13 ,  14  and  15 , two bottom pieces  30 , a top cap  40  and a basiloid flange piece  50 . The assembly framework  10  has a two-piece hinged design that installs easily over an appliance  20 . 
     In one common anticipated application shown in FIG. 5, the appliance is mounted to a base pad  60  that supports the appliance  20  during assembly and handling. The base pad  60  may be formed of wood, paper and paperboard, expanded foam, or any other suitable material or combination of materials. The base pad may be made from a combination of low and high density materials, such as the type manufactured by Sonoco Products Company under the trademark Sonobase™M, which is the subject of a pending United States patent application. 
     After installation over an appliance, the packaging assembly framework  10 , with the exception of the basiloid handling flange  70  to be described later, is wrapped in transparent plastic film  80  (“Clearview”) that allows much of the appliance  20  to be seen (FIG.  6 ). A retaining band  28  is tightly wrapped around the top end of the top cap  40  and the basiloid handling flange  70  to maintain the flange  70  in the proper position during basiloid lifting and handling. The final packaging assembly, including the framework  10  and transparent wrapping  80 , may be referred to as a Clearview basiloid pack. 
     For the purpose of the following description, the modifiers “left”, “right”, “front” and “rear” shall refer to the left, right, front and rear sides of the appliance to be packaged. 
     FIG. 2 shows a cardboard blank used to form the top cap  40 . The blank has a top panel  41  defined by fold lines  42   a ,  43   a ,  46   a  and  47   a , the width and depth of the top panel being determined by the dimensions of the appliance to be packaged. In the assembled framework  10 , left and right side panels  42 ,  43  extend downward from the top panel  41  and are glued to the two front corner posts  12 ,  13 . Preferably the side panels  42 ,  43  are cut at an angle so that they are substantially triangular in shape, with their front edges extending farther down than their rear edges. Preferably, the front edges of the side panels  42 ,  43  extend near or below the plane defined by the top surface  21  of the appliance  20  (see FIGS.  5  and  6 ). 
     Referring again to FIG. 2, the left side panel  42  is folded along fold line  44   a  to create a left front flap  44  that is folded at a right angle to the top panel  41  and glued to the left front corner post  12 . Likewise, the right side panel  43  is folded at a right angle along fold line  45   a  to create a right front flap  45  that is then glued to the right front corner post  13 . A front panel  46  extends downward from the front edge  46   a  of the top panel  41  and is glued to the upper portions of the left and right front flaps  44 ,  45 . 
     Referring now to FIGS. 2 and 7, a fold line or hinge  47   a  separates the top panel  41  from a short rear flap  47 . This hinge  47   a  allows for the framework&#39;s clamshell operation. After installing the framework  10  over an appliance  20 , the short rear flap  47  extends downward from the top panel  41  and terminates at upturned edge  49 . An inner flap  48 , which is a continuation of the top panel  40 , extends upward from the edge  49  parallel to rear flap  47 , defining a space therebetween to accommodate a separate basiloid flap  55  as will now be described. 
     FIG. 3 is a top view of a blank used to form the basiloid piece  50 . The blank has a rear panel  51  defined by fold lines  53   a ,  54   a , a lower edge  54  and a down turned edge  55   a . As shown in FIG. 6, the basiloid piece  50  preferably extends below the plane defined by the top surface  21  of the appliance  20 . The basiloid piece  50  forms a three-sided shell around the rear elevated portion  23  of the irregular shaped appliance  20 . In the assembled framework  10 , left and right side flaps  52 ,  53  extend from the rear panel  51  and are glued to the upper portions of the rear left and right corner posts  14 ,  15  respectively. 
     As best shown in FIG. 7, a basiloid flap  55  extends downward between the rear flap  47  and the upturned inner flap  48  of the top cap  40  and is secured therebetween by glue or other adhesive means to form a basiloid handling flange  70 . After the framework  10  is installed over an appliance  20  and wrapped in transparent film  80 , a retainer band  28  is wrapped tightly around the upper portion of the assembly to retain the basiloid handling flange  70 . The basiloid flange  70  is three layers thick and has a lower edge  49  that bears the lifting force of a basiloid blade. 
     The basiloid handling flange  70  preferably extends about six to fourteen inches downward from the top panel  41  and is held in place by the retaining band  28 . The purpose of the flap  70  is to accommodate the basiloid lifting blade of a basiloid fork lift truck. The basiloid blade (not shown) is inserted into the slot  71  between the basiloid flange  70  and the rear panel  51  of the basiloid piece  50 . The basiloid blade has a rounded top edge so that the forklift operator doesn&#39;t inadvertently hook the blade into the plastic film cover  70  and rear panel  51  of the basiloid piece  50 . The basiloid blade is slightly shorter than the length of the basiloid flange  70  so that, when fully inserted into slot  71 , the top edge of the blade does not pierce upper edge  55   a  of the basiloid flap  55 . 
     When fully installed, a horizontal bar mounted on the basiloid blade abuts the lower edge  49  of the basiloid flap  55  to lift the package and appliance. The retaining band  28  keeps the basiloid flap  55  in position during lifting. 
     FIG. 4 shows a cardboard blank used to form each of the bottom pieces  30 . The blank has a bottom panel  31  defined by fold lines  32   a ,  33   a ,  36   a  and edge  37 . As shown in FIG. 1, and with respect to the front bottom piece  30 , side panels  32 ,  33  extend upward from the bottom panel  31  and are glued to the sides of lower portions of the front left and front right corner posts  12 ,  13  respectively. The left and right side flaps  32 ,  33  are folded at about a ninety degree angle to form front flaps  34 ,  35  which are glued to the lower front surfaces of the front corner posts  12 ,  13 . A front flap  36  extends upward from the bottom panel  31  and is glued to the lower outer surfaces of the front flaps  34 ,  35 . A similar blank is used to make the rear bottom piece  30  which is glued to the rear corner posts  14 ,  15 . 
     To assemble the packaging framework  10 , the four corner posts  12 ,  13 ,  14  and  15 , two bottom pieces  30 , top cap  40 , and basiloid flange piece  50  are glued together as shown in FIG. 1 to form the packaging framework  10 . The packaging framework  10  is then slipped onto an appliance  20  resting on a base pad  60  in clamshell fashion as shown in FIG.  5 . With the basiloid handling flange  70  extending generally horizontally, a tight clear poly covering  80  is wrapped around the appliance  20  and package framework  10 . When the wrapping process is complete, the basiloid handling flange  70  is folded down to the position shown in FIGS. 6 and 7 and the metal or plastic retaining band  28  is wrapped tightly around the top of the Clearview basiloid pack. 
     When installed around an appliance  20 , the packaging assembly is resistant to the trapezoiding phenomenon that can occur when irregular shaped appliances are packaged inside conventional appliance packages, stacked one on top of the other, and lifted with a basiloid blade. This resistance to trapezoiding is due to the unique structure and geometry of the Clearview basiloid package. 
     An important feature of the package assembly is the substantially triangular-shaped sidewalls  42 ,  43  that extend downward to an area near or below that top surface of the appliance  20 . The top cap and sidewalls are glued to the front corner posts  12 ,  13  which abut the front vertical corners of the appliance  20 , thereby resisting rotation of the top cap side walls  42 ,  43  about the hinge  47   a . Preferably, the triangular shaped side panels  42 ,  43  extend below the top surface of the appliance  20 , but the system is also operable if the side panels  42 ,  43  extend downward to an area slightly above the top surface. 
     The front corner posts  12 ,  13  serve as an extension of a side of the triangle defined by the top cap side panels  42 ,  43 . Gluing the top cap  40  to the front corner posts  12 ,  13  prevents the top cap from sliding down the corner posts  12 ,  13 , which would result in trapezoiding. During basiloid lifting, the corner posts  12 ,  13  spread the downward force caused by the top appliance unit to those areas along the front vertical edges of the bottom appliance  20  that contact the corner posts  12 ,  13 . 
     During basiloid lifting of two stacked appliances, the downward force from the top unit along the front edge of the top cap  40  is transferred to the front corner posts  12 ,  13  and then to the front vertical corners of the appliance  20 . The front vertical corners prevent rotation of the corner posts  12 ,  13  and the top cap  40  glued thereto. Thus the trapezoiding associated with conventional see-through appliance packages is avoided. 
     Preferably, the bottom pieces  30 , top cap  40  and basiloid piece  50  are made from corrugated board, although other suitable materials may be used. In the preferred embodiment the corner posts  12 ,  13 ,  14  and  15  are formed of multiple sheets of paper laminated together in a sufficient number of layers to provide adequate structural strength. Other corner post materials are contemplated, such as convolutely wound paperboard, recycled paper, treated paper, mixtures of paper and paperboard, and corrugated board. The corner posts must be able to be glued to the top cap. The corner posts  12 ,  13 ,  14  and  15  may be of the type manufactured by Sonoco Products Company of Hartsville, S.C. under the trademark Sonopost. 
     Thus there has been described a Clearview packaging assembly for basiloid handling of irregular top appliances that prevents trapezoiding of the package when picked up by a basiloid fork lift truck with another packaged appliance on top. The packaging assembly prevents trapezoiding without using the top of the appliance for support. 
     Other modifications and alternative embodiments of the invention are contemplated which do not depart from the spirit and scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications that fall within their scope.