Abstract:
A package for storing and shipping flat panel products includes a shock- absorbing inner protective material, a telescoping outer packaging material, adjustable to the size of the product being shipped, and an outer binder, such as a plastic banding material. The inner wrapping material is provided around a circumferential edge of the product and is secured in place. The outer protective packaging material is provided around the wrapped product, adjusted to the appropriate size, and is bound in place with a plastic banding material which is wrapped longitudinally and secures the lateral and longitudinal position of the product within the package. The telescoping package includes slots for receiving and retaining the plastic banding material in position.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims priority to earlier filed U.S. Provisional Application Ser. No. 60/510,647, filed Oct.  10 ,  2003 , the contents of which are incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not applicable.  
       BACKGROUND OF THE INVENTION  
       [0003]     The present invention is related to packaging for shipping products, and more particularly to packaging materials for shipping flat panel products.  
         [0004]     Products which are generally narrow in depth and formed-in a sheet, plate or panel construction such as doors, windows, mirrors, and raw sheet materials including glass, plastic, stone, and various composite materials can be difficult to package and ship as they are prone to damage when dropped, particularly when dropped on their corners or edges. These types of products, referred to hereafter generally as “flat panel products” are typically packaged for shipping in an inner protective package enclosed in an outer shipping container. The inner protective package is typically constructed of a corrugated or paperboard material which is die cut to provide a pocket for receiving the package, and flaps which are folded over the product and taped or otherwise adhered over the product to retain the product in position, and away from the edges of the package, during shipping. Prior to being positioned in the pocket, the product is typically wrapped in a poly, plastic or other scratch and/or liquidresistant wrapping material to further protect the product during shipping. The outer packaging material is disposed around the inner package, enclosing the product and providing a location for placing shipping information on the package.  
         [0005]     While methods for packaging flat panel products are therefore known in the art, there are a number of problems associated with these packaging methods. For example, to adequately protect the flat panel product provided within the package, each package must be individually sized to accept the particular product being shipped. Therefore, in production and packaging facilities where a number of different types of products are produced, an equivalent number of different types of shipping cartons must be stocked for packaging. Also, the products must be assembled into the packaging entirely by hand, and the packaging process is therefore labor intensive, relatively expensive, and slow, often taking longer than the actual production. Additionally, the packaging is relatively heavy, thereby contributing to increased labor difficulties and expenses in shipping. Furthermore, damage to the internal products remains a problem when using these types of packages, contributing significantly to the cost of both the product and shipping.  
       SUMMARY OF THE INVENTION  
       [0006]     In one aspect, the present invention provides a package for shipping flat panel products. The package includes an inner protective packaging material disposed peripherally around an outer edge of the flat panel product, a size-adjustable outer packaging material enclosing the inner protective packaging material, and a binder provided around the outer packaging material for securing the outer packaging material to the inner protective packaging material. The binder retains the flat panel product within the package and suspends the inner protective packaging material and the product relative to at least one side wall of the size adjustable outer packaging material. In another aspect of the invention, the inner protective packaging material and flat panel product are spaced in suspension from said at least one sidewall of the size adjustable outer packaging material.  
         [0007]     In yet another aspect of the invention, a package for shipping a flat panel product is provided. The package includes an inner shock-absorbing packaging material disposed around the circumference of the flat panel product. A telescoping outer packaging material comprising a plurality of slots on at least one pair of opposing edges is provided toward the wrapped package and a banding material provided over the outer packaging material. The banding material is received in the slots to bind the outer packaging material to the inner packaging material and the product.  
         [0008]     In still another aspect of the invention, a package for shipping a flat panel product includes a strip of an inner protective packaging material wrapped peripherally around an outer edge of the flat panel product having side edges laterally spaced from opposing faces of the flat panel product to create a protected air space on each side of the flat panel product. An outer packaging material, having a certain lateral size and an adjustable longitudinal size, encloses the inner protective packaging material and product. The package further includes a binder wrapped longitudinally around the outer packaging material, and received in slots in opposed sidewalls of the longitudinal ends of the outer protective packaging material, wherein the binder supportively engages the inner protective packaging material in the slots to laterally support the inner protective packaging material and product within the outer protective packaging material.  
         [0009]     These and other aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is an exploded view of a packaged panel product and outer shipping package;  
         [0011]      FIG. 2  is an exploded view of the packaged panel product of  FIG. 1 ;  
         [0012]      FIG. 3  is a partial view of the panel product received in the inner protective packaging material of  FIG. 2 ;  
         [0013]      FIG. 4  is a cutaway top view of the packed panel product of  FIG. 2 ;  
         [0014]      FIG. 5  is a view of the packaged panel product of  FIG. 4  taken along the line  55 ;  
         [0015]      FIG. 6  is a view of the panel product and inner protective wrapping material of  FIG. 2  disposed on the outer protective packaging material prior to folding;  
         [0016]      FIG. 7  is a view of the panel product and inner protective wrapping material of  FIG. 2  disposed on the outer protective packaging material with the flaps folded; and  
         [0017]      FIG. 8  is a view of the package of  FIG. 7 , with one of the front portions of the outer packaging material folded over to form an enclosure. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0018]     Referring now to the figures and more particularly to  FIG. 1 , a shipping package  11  constructed in accordance with the present invention is shown. The shipping package  11  comprises a protected panel product  10  enclosed inside of an outer shipping packaging  12 . The protected panel product  10  and shipping packaging  12  protect the product from damage during shipping and further provide a location for mounting a shipping label.  
         [0019]     Referring now to  FIG. 2 , the protected panel product  10  is a sheet or flat panel product  14  which is enclosed peripherally about its outer circumferential edge in a length of inner protective packaging material  16 , which is itself enclosed in an outer protective package  21 . The outer protective packaging material  21  is preferably, as shown here, a size-adjustable box constructed of two protective panels  18  and  20  which can be “telescoped” longitudinally to adjust to various lengths of panel products  14 , as described below. The lateral dimension of the panels  18  and  20 , however, is fixed, so the lateral dimension of the product  14  wrapped in inner protective packaging material  16  is less than or equal to the lateral dimension of the panels  18  and  20 . If less, there will be a lateral air space between the wrapped product  14  and at least one sidewall of the outer protective packaging material  21 , with the product  14  wrapped in inner protective packaging material  16  supported by the binder  24 .  
         [0020]     Each of the panels  18  and  20  includes both a back portion  34 , a front portion  38 , a side portion  36 , and flaps  32  extending from opposing ends of each back portion  34 . The back portion  34  is separated from the side portion  36  by a first crease line  40  and the side portion  36  is separated from the front portion  38  by a second crease line  42 . A third crease line  44  separates the flap  32  from the back portion  34 , while a fourth crease line  46  is provided in the flap  32  to allow the flap  32  to be folded, as described below. Each of the panels  18  and  20  further comprises slots  22 , which are die cut or otherwise formed in the panels  18  and  20  in pairs on the side portions  36  of the panels  18  and  20  to receive a binder  24 . The slots extend across the width of each side portion  36  and can extend into portions of each of the back portion  34  and front portion  38 . The slots  22  receive the binder  24  which can be, as shown here, a strap or banding, such as a plastic banding material. The binder  24  is wrapped circumferentially around the protected panel product  10 , extends through the slots  22 , is pulled tight around the outer packaging  21 , and has its ends seared to one another.  
         [0021]     Referring now to  FIG. 3 , the inner protective packaging material  16  is a shockabsorbing resilient material selected to absorb force and protect the panel product  14  in the event it is dropped. The inner protection packaging material  12  is preferably a suspension wrap material such as SUS-RAP®, commercially available from the Sus-Rap Division of the Menasha Corporation in Danville, Va. The suspension wrap material is provided in continuous lengths which can be sized to a particular panel product  14 , and includes Ashaped slots  26  which firmly suspend the panel product  14  to cushion the product from shocks and prevent breakage. The A-shaped slots  26  provide a reinforced wall around the product  14  which provides strong support for stacking and can serve to decrease damage during handling and warehousing. The outer edge of the suspension wrap material can comprise a series of radially externally directed corrugations  30  which are formed in a semicircular shape. These corrugations  30  further cushion the panel product  14  from damage, absorbing shocks and forces applied to the outside edge of the panel  14 . As shown, the A-shaped slots  26  can include a plurality of pairs of slits  27  which are sized and dimensioned to receive an edge of a panel product  14  of a selected size.  
         [0022]     When a panel product  14  is inserted within the A-shaped slot  26 , the portion between the slits  27  is pressed down as shown in  FIGS. 3 through 5 , while the remaining portion of the A-shaped slots  26  extends radially inward toward the center of the product  14 . The side edges of the inner protective packaging material  16  are laterally spaced from opposing faces of the flat panel product  14  so as to create a protected air space on each side of the flat panel product between the face of the product and a plane defined by the adjacent side edges of the packaging material. The air space protects the panel product  14  from a force or pressure applied to the front and/or back of the panel product  14 . The suspension wrap material can further include a scratch-resistant film or coating, particularly when the product  14  comprises wood or other materials prone to scratching. In this application, a suitable product is commercially available under the tradename POLY SUS-RAP®, also available from the Sus-Rap Division of Menasha Corporation in Danville, Va.  
         [0023]     Referring now to  FIG. 4 , a cutaway view of the protected panel product  10  is shown. Here, it can be seen that the panel product  14  is surrounded on all edges by a length of the inner protective material  16  and is received within the slits  27  formed in the A-shaped slots  26  as describe above such that, as shown in  FIG. 3 , the A-shaped portion extends radially inward from either side of the panel product  14  retaining the panel product in place, protecting it from external forces, and cushioning the edges of the panel product  14 . Also as described above, semicircular corrugations  30  extend outwardly radially away from the base sections of the A-shaped slots  26 . The outer protective packaging  21  which can comprise, for example, paperboard or corrugated craft, circumscribes the panel product  14  encased in the inner protective material  16 , adjacent the corrugations  30 . The outer protective packaging  21  further comprises slots  22 , as described above, for receiving the binder  24 . The binder  24  retains the inner protective material  16  and the outer protective material  21  around the circumference of the panel product  14 , and supportively engages the inner protective packaging material  16  in the slots to laterally support the wrapped product  14  in the outer protective packaging material  21 .  
         [0024]     Referring now to  FIG. 5 , a detailed view of the receipt of the panel product  14  within the inner protective material  16  is shown. As described above, the panel product  14  is received within the slits  27  in the A-shaped slot  26 , and semicircular corrugations  30  are directed outward toward the outer protective package material  21 . The binder  24 , here shown as plastic banding, is received in the slot  22  and retains both the inner protective packaging material  16  and the outer protective packaging material  21  against the panel product  14  and further retains the inner protective material  16  against the outer protective packaging material  21 . As described above, the binding  24  further supports the wrapped product  14  laterally.  
         [0025]     Referring again to  FIG. 2 , to assemble the panel product  14  within the protective panel product  10 , the panel product  14  is initially wrapped peripherally about its outer edge with a length of the inner protective packaging material  16 , and is positioned within the inner protective packaging material  16  with the A-shaped slots  26  extending radially inward and the corrugations  30  extending radially outward away from the product  14 .  
         [0026]     As described with reference to  FIG. 3 , the panel product  14  is slid into the inner protective packaging material  16  between the slits of one of a plurality of pairs of precut slits  27  which are sized and dimensioned to receive an edge of a panel product  14  of varying edge widths. Once the inner protective packaging material  16  is provided around the panel product  14 , it is adhered in place, for example, by attaching a piece of tape or other adhesive to the open ends of the inner protective packaging material  16  circumscribing the edge of the panel product  14 .  
         [0027]     The wrapped panel product  14  is then positioned on the panels  20  and  18 , which are arranged with their respective back portions  34  adjacent each other, and with the back  34  of one of the panels  18  and  20  overlapping the back of the other of the panels  18  and  20 .  
         [0028]     Referring now to  FIG. 6 , to adjust the size of the outer protective packaging material  21 , the back of one of the panels  18  and  20  is slid over the back  34  of the opposing panel  18  or  20  until the side portions  36  each abut the inner protective packaging material  16 . When the relative position of the panels  18  and  20  is sized for the panel product  14 , the flaps  32  are folded along the crease line  46  to form, as shown in  FIG. 7 , a triangular wall  48 , the base of the triangle being provided by the back portion  34  of the panels  18  and  20 , and the walls provided by the folded flaps  32 .  
         [0029]     Referring now to  FIG. 8 , after the flaps  32  are folded, the fronts  38  of the panel  18  and  20 , respectively, are folded over the panel product  14  to form an enclosure. Referring again to  FIG. 2  and also to  FIG. 1 , after the front portions  38  of the panels  18  and  20  are folded over the product, the binder  24 , here a plastic banding material, is attached through the slots  22 , pulled tight across the outer packaging material  21 , and adhered in place as, for example, by applying heat or a clip to attach the ends of the bands. The binder  24  is wrapped longitudinally around the outer packaging material  21  and received in the slots  22  to supportively engage the inner protective packaging material in the slots  22  and to laterally support the inner protective packaging material  16  and flat panel product  14  within the outer protective packaging material  21 . The binding  24  suspends the inner protective packaging material  16  and the product  14  relative to at least one side wall of the size adjustable outer packaging material  20  and therefore protects the edges of the product during shipment. Prior to applying the binder  24 , the panel  18  can also be optionally adhered to the panel  20  with a glue, tape, or other adhesive, to simplify the addition of the binder  24 .  
         [0030]     Referring now to  FIG. 1 , after the protected panel product  10  is assembled, it can be enclosed within an outer shipping package  12 . The shipping package  12  is a paper, corrugated, or cardboard construction, and includes foldable flaps which are folded over the protective panel product  10  and adhered in place for shipping. A shipping label can be provided directly on the outer shipping package  12 .  
         [0031]     The packaging shown and described provides improved protection from damage by providing an air cell around the perimeter of the product to protect the product from damage due to drops and vibration during shipment. Because the outer packaging  21  can be telescoped to the appropriate size for the panel  14 , inventory of packaging can be significantly reduced. The weight of the packaging is also reduced as compared to prior art packaging, reducing shipping cost. The packaging as described has been further shown to be effective in meeting shipping standards of the International Safe Transit Association Testing.  
         [0032]     Although a specific embodiment of the present invention has been shown and described above, it will be apparent that a number of variations can be made within the scope of the invention. For example, although a specific suspension wrap material is described above, a number of similar suspension wrap products, also commercially available from the Menasha Corporation, can also be used. Furthermore, various other resilient and/or shockabsorbing protective materials including but not limited to foam, plastic, rubber, corrugated build-ups, corrugated die cuts, and other materials can also be used.  
         [0033]     Furthermore, although the binder  24  is described above as a plastic banding material, various other adhesive devices including glue, tape, cinch-staples, stretch wrap, press seals, and other devices could also be used. Similarly, although the outer protective packaging  21  is described above as corrugated paperboard, corrugated plastic, laminated fiberboard, sheet plastic, shrink wrap, single face corrugated paper, and various other materials could also be used.  
         [0034]     Additionally, a number of different types of flat panel products can be packaged as described including windows, glass, plastic, mirrors, composite materials, granite, entrance doors, shutters, shower doors, medicine cabinets, industrial cabinets, picture frames, glass, circuit board and similar products and devices.  
         [0035]     While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention defined by the appended claims.