Patent Publication Number: US-9889984-B2

Title: Single glass sheet package with suction cups

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation application of U.S. patent application Ser. No. 11/799,028 filed Apr. 30, 2007, the contents of which are incorporated herein by reference. 
    
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     N/A 
     TECHNICAL FIELD 
     The invention generally relates to a container for transporting a sheet of glass or similar material, and more particularly to a corrugated container having a plurality of braces, some of which include suction cups, for securely holding and transporting a sheet of glass such as an automotive windshield. 
     BACKGROUND OF THE INVENTION 
     Containers for transporting glass sheets must provide sufficient structural support and protection against breakage, while still being lightweight and cost effective. Additionally, such containers must meet specifications set forth by any package carrier service (e.g., Federal Express). 
     In addition to meeting all of these requirements, such containers should be easy to handle and assemble. 
     The present invention is provided to solve the problems discussed above and other problems, and to provide advantages and aspects not provided by prior containers of this type. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings. 
     SUMMARY OF THE INVENTION 
     The present invention provides a container that can securely hold and transport a single glass sheet with encapsulated molding or without. The container is preferably formed from a corrugated material, such as cardboard, and includes suction cups connected or mounted to support structure in the container to securely hold the glass sheet. 
     According to one embodiment, a container for transporting a glass sheet, such as an automotive windshield is provided. The container includes a generally rectangular first wall portion. However, other shapes can be used. A first support brace is connected to the first wall portion. The first support brace is positioned on the first wall portion to contact and support a first side of a glass sheet. When placing a glass sheet on the first support brace, the first wall portion is typically laid flat on the floor or other surface and can be referred to as the base or bottom of the container. However, during transport the container is typically placed on edge and the first wall portion, in effect, becomes the back or front wall of the container. 
     A first suction cup is connected to the first support brace. The first suction cup is provided to maintain a secure connection with the glass sheet. The suction cup can be configured to have a cup portion and a base portion having an opening running through it. The brace can include a slot or opening for receiving the base portion of the suction cup. A dowel rod can be inserted through the opening in the base portion of the suction cup (after the suction is positioned on the brace) to lock the suction cup to the brace. All other suctions cups utilized in the container can be secured in a similar manner. 
     A second wall portion is configured to cooperate with the first wall portion to substantially enclose the glass sheet. The second wall portion is also generally rectangular, but again, can be other suitable shapes. The second wall portion can be considered as the top of the container when loading the glass sheet in the orientation discussed above. 
     The container also can include a second support brace connected to the first wall portion. The second support brace is also positioned to support the first side of the glass sheet, and is preferably spaced from the first support brace. A second suction cup can be connected to the second support brace. In one configuration, the first suction cup is connected to the first support brace is positioned proximate a first side of the first wall portion, and the second suction cup connected to the second support brace is positioned proximate a second side of the first wall portion. 
     The first support brace can be a single structure which extends substantially from a first side of the first wall portion to a second side of the first wall portion. Similarly, the second support brace can be a single structure which extends substantially from the first side of the first wall portion to the second side of the first wall portion. The support braces can also be in two or more separate sections. 
     The container also includes a first side wall extending upward from the first side of the first wall portion, and a second side wall extending upward from the second side of the first wall portion opposing the first side, as well as a first end wall extending upward from a first end of the first wall portion, and a second end wall extending upward from a second end of the first wall portion opposing the first end. Collectively, the outer components of the container form a rectangular box. 
     The first support brace is formed to include a first cutaway portion proximate the first side of the first wall portion and a second cutaway portion proximate the second side of the first wall portion. Similarly, the second support brace, when utilized, also includes a first cutaway portion proximate the first side of the first wall portion and a second cutaway portion proximate the second side of the first wall portion. The first and second cutaway portions of the support braces are configured to accommodate curvature in the glass sheet. In this manner, the glass sheet is being supported by a portion of the brace contacting the surface of the glass sheet. If the cutaway portions were not present, the curvature of the glass sheet would cause the brace to first contact and support the glass sheet on the edge of the glass sheet on each side. 
     The container can further include a first opposing side brace for supporting a second side of the glass sheet opposing the first side of the glass sheet. The first opposing side brace can include a third suction cup connected to the brace. Additionally, a second opposing side brace for supporting the second side of the glass sheet having a fourth suction cup can also be utilized. Similar to the support brace(s), the opposing side brace(s) can span from the first side wall to the second side wall of the container. The number of support (and opposing side) braces, and the number and placement of the suction cups, can vary depending on the size of the brace(s) used and the size of the glass sheet being transported. 
     In addition to the braces extending from the first side of the container to the second side of the container, a first cross support brace can also be connected to the first wall portion. The first cross support brace can extend substantially from the first end of the first wall portion to the second end of the first wall portion. The first cross support brace can include a first glass sheet contacting portion proximate a first end of the first cross support brace. The contacting portion can include a plurality of glass sheet contact segments configured to contact glass sheets of varying sizes. Similarly, the first cross support brace can include a second glass sheet contacting portion proximate a second end of the first cross support brace having a plurality of glass sheet contact segments configured to contact glass sheets of varying sizes. The cross support brace is preferably perpendicular to the first support brace (as well as to the second or other braces when utilized). 
     In accordance with another embodiment of the invention, a container for transporting a windshield having a slight curvature is provided. The container includes a corrugated base portion having a first side wall integrally formed with and extending upward from a first side of the base portion, and a second side wall integrally formed with and extending upward from a second side of the base portion opposing the first side, a first end wall integrally formed with and extending upward from a first end of the base portion, and a second end wall integrally formed with and extending upward from a second end of the base portion opposing the first end. The container further includes a corrugated first support brace connected to the base portion configured to support a first side of the windshield, and a corrugated second support brace connected to the base portion configured to support the first side of the windshield. A corrugated top portion is configured to cooperate with the base portion to substantially enclose the windshield. The terms “base” and “top” are used in the context of laying the container on the base for positioning and securing the glass sheet in the container as shown in the Figures and is not meant to limit these features to always being in such positions. For example, during transit, the container is positioned so that the glass sheet is positioned on one of its edges and is not laying flat. In this instance, what was referred to as the base when loading the container is now positioned as a side wall. 
     The container can include a first top brace configured to contact a second side of the windshield and, a second top brace configured to contact the second side of the windshield. The first and second top braces can extend from the first side wall to the second side wall. 
     A first suction cup can be connected to the first support brace. Similarly a second suction cup can be connected to the second support brace. Additionally, a third suction cup can be connected to the first top brace and, a fourth suction cup can be connected to the second top brace. 
     The container can include a cross support brace connected to the base portion and extending from proximate the first end of the base portion to a second end of the base portion. Alternatively, the cross support brace can be a first portion for engaging a first side edge of the windshield positioned proximate the first end of the base portion, and a separate second portion for engaging an opposing second edge of the windshield proximate the second end of the base portion. 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of an embodiment of a container with the top portion only partial shown in accordance with the present invention. 
         FIG. 2  is a cross-sectional view of the container of  FIG. 1  taken along the lines  2 - 2 . 
         FIG. 3  is a perspective view another embodiment of a container in accordance with the present invention. 
         FIG. 4  is a partial perspective view of a portion of the container of  FIG. 3 . 
         FIG. 5  is a cross-sectional view of the container of  FIG. 1  taken along the lines  5 - 5 . 
         FIG. 6A  is a perspective view of a suction cup for use with the container of the present invention. 
         FIG. 6B  is a cross-sectional view of the suction cup of  FIG. 5A  positioned in a brace in the container. 
         FIG. 7  is the partial perspective view of  FIG. 4  showing positioning of dowel rods for holding the suction cups in place. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
     Referring to  FIG. 1 , a container  10  for transporting a single glass sheet  12  is shown. The glass sheet  12  is preferably an automotive windshield having a slight curvature, either with or without full or partial molding. 
     The container includes a base portion  14  that cooperates with a top portion  16  to form a generally rectangular box. Although reference is made to a base and a top (as the configuration is shown in the Figures), the container may actually be positioned on its side or end during transportation (or possibly upside down). Accordingly, these terms are not intended to limit the container to only being in the position shown. 
     The base portion  14  includes a generally planar, rectangular base wall  18 . A first side wall  20  extends perpendicular to the base wall  18  along a first side of the base wall  18 , and a second side wall extends perpendicular to the base wall  18  along a second side of the base wall  18  opposing the first side. A first end wall  24  extends perpendicular to the base wall  18  along a first end of the base wall, and a second end wall  26  extends perpendicular to the base wall along a second end of the base wall  18 . 
     The glass sheet  12  is supported on its lower surface in the base portion  14  by a first support brace  28  and a second support brace  30 , which extend from the first side wall  20  to the second side wall  30  (again, the term “lower” is made in reference to the position of the container  10  as shown in the Figures and not as a limitation as to the orientation of the container  10  at all times). In one alternative embodiment, the support braces  28 , 30  can extend end to end. Moreover, the support braces can be in multiple pieces rather than as a single unit. The number and positioning of the support braces can vary depending on the size of the glass sheet being transported and the amount of support required, and thus can range from one to more than two. Also, cost considerations may dictate or influence the number of support braces. 
     Referring also to  FIG. 2 , each support brace  28 , 30  includes a raised central portion  34  between a first lowered or cutaway portion  36  proximate the first side wall  20 , and a second lowered or cutaway portion  38  positioned proximate the second side wall  22 . The central portion  34  of the brace contacts and supports a central portion of the glass sheet  12 . The top surface of the central portion  34  is die cut using a radius score rule which conforms when folded to the bend or curvature of the surface of the glass sheet  12  being contacted. 
     The lowered or cutaway portions  36 , 38  provide space to accommodate the curvature of the glass sheet  12  at the sides. In this manner, the braces  28 , 30  are able to come into contact with the surface of the glass sheet  12  rather than supporting the glass sheet  12  on its edges. 
     A suction cup  40  is connected to the central portion of the brace in order to more securely hold the glass sheet  12  in place. In the embodiment shown in  FIG. 1 , a suction cup  40  is connected to the central portion  34  proximate the first lowered portion  36  on the first brace  28 , while another suction cup is connected to the central portion  34  proximate the second lowered portion  38  on the second support brace  30 . However, additional suction cups can be connected at various positions on the braces  28 , 30  (see e.g.,  FIG. 4 ). 
     The support braces  28 , 30  are securely kept in position by flaps  42  folded from the base wall  18 . Two flaps  42  are shown on each side of the braces  28 , 30 . The flaps  42  can cooperate with grooves or slots formed in the support braces  28 , 30  to maintain the flaps in the upright positions shown in the Figures. 
     The container also includes a first top brace  44  and a second top brace  46 . The top braces  44 , 46  are aligned with the first support brace  28  and the second support brace  30 , respectively. The top braces  44 , 46  lay over and contact the opposing or top side of the glass sheet  12 . Similar to the support braces  28 , 30 , suction cups  40  can be connected to the top braces  44 , 46  to more securely grip and hold the glass sheet  12  in place. As shown in  FIGS. 1 and 2 , each top brace includes a single suction cup  40 , however, more than one suction cup  40  can be used. 
     Also similar to the support braces  28 , 30 , the top braces  44 , 46  can include a contacting surface that is curved to conform to the shape of the surface of the glass sheet  12  contacted. Alternatively, the top braces  44 , 46  can be formed to be flexible and be sized so that the brace bends in accordance with the curvature of the upper surface of the glass sheet  12 . 
     As with the support braces contacting the lower side of the glass sheet  12 , the number of top braces and their dimensions can vary depending on the characteristics of the glass sheet, the requirements of the carrier, costs, etc. In this regard, in one embodiment only a single top brace is used, preferably over the middle of the glass sheet  12 , while in other embodiments three or more braces may be utilized. 
     The top braces  44 , 46  include fold down flaps  48  at both ends of the brace. The fold down flaps  48  extend over the side walls  20 , 22  and include a further fold  50  that can be inserted in a slot  52  in the side wall. In this manner the top braces  44 , 46  can be securely attached to the base portion  14 . 
     The top  16  is configured to include a top wall  54 , side walls  56 , 58  and end walls. The top  16  is sized to be placed over the base portion  14  to form a box. Straps or other means can be used to ensure the top  16  does not separate from the base portion  14  during transportation of the container  10 . 
     Referring to  FIGS. 3 and 4 , an alternative embodiment of the container  10  is shown. In this embodiment, an additional cross support brace  60  is provided on the base portion  14  of the container  10 . The cross support brace  60  is positioned perpendicular to the first and second support braces  28 , 30  and extends from the first end wall  24  to the second end wall  26 . 
     The cross support brace  60  includes a first end portion  62  and an opposing second end portion  64 . The end portions  62 , 64  are configured to engage and support the ends of the glass sheet  12 . Each end portion  62 , 64  includes an upper surface that is slanted at an angle and/or curved with respect to the generally planar base wall  18  to form an angled or curved portion  66 . The angled or curved portion  66  extends from one of the first or second support braces  28 , 30  to a block portion  68  proximate the end wall  24 , 26 . The angled or curved portion  66  becomes increasing lower (i.e., closer to the base wall  18 ) as it approaches the block portion  68 . The angled or curved portion  66  is also provided to accommodate curvature in the glass sheet  12  which is commonly found in automotive windshields. 
     The angled or curved portion  66  includes a plurality of parallel cuts or slots in the material. The slots form a plurality of adjacent segments  70  spanning across the top of the end portion. The sides  72 , 74  of the end portion  62 , 64  are position closer than the length of the segments  70 . This causes the segments  70  to generally buckle into the interior of the end portion  62 , 64 . However, depending on the size of the glass sheet  12  (i.e., from end to end) a select segment  70  can be positioned to buckle upward from the end portion  62 , 64 . In this manner, the end portions  62 , 64  can be used to contact and support glass sheets  12  of varying sizes. The end portions  62 , 64  are designed to engage an edge of the glass sheet  12 . 
     Similar to the other braces discussed, the cross support brace  60  can be one piece, or a plurality of pieces or segments between the first and second ends of the container  10 . Moreover, more than one cross support brace can be utilized depending on the size of the glass sheet, support required or other factors. 
     Referring back to  FIG. 2 , the glass sheet is contacted on one side of the central portion  34  by the suction cup  40 , but is supported by the top surface of the central portion  34  on the side. However, as shown in the cross-section of  FIG. 5 , if the glass sheet is light enough, or during transit when the container  10  is positioned on one of its sides or ends, the glass sheet  12  is held between the support and top braces by the suction cups  40  and does not necessarily abut any of the braces. 
     The first and second support braces  28 , 30  and the top braces  44 , 46 , along with the suction cups  40 , act like shock absorbers for the glass sheet  12  in the container  10 . This helps protect the glass sheet  12  from impacts or other jarring movement of the container  10  during transportation from one location to the next. 
     In order to avoid any prints or scratches on the surfaces of the glass sheet  12  from the suction cups  40 , a sheet of material can be inserted between the cup  40  and the respective surface of the glass sheet. 
     Referring to  FIGS. 6A and 6B , the suction cups  40  utilized in the container  10  preferably comprise a cup portion  80  and a base portion  82 . The base portion  82  includes an opening  84 . The base portion  82  of the suction cup  40  is inserted through a slot or opening in the brace. 
     As illustrated in  FIG. 7 , a dowel rod  86  is inserted into the opening  84  of the suction cup  40  to lock the suction cup in place on the brace. The dowel rod  86  has a ⅜ inch diameter and is 4½ inches long with tapered ends  88 . The dowel rod is long enough to fit through the base portion  82  and have enough exposed on either side to grab for removal. A dowel rod  86  is used for each suction cup  40  in both the support braces  28 , 30  connected to the base wall  18 , and the top braces  44 , 46 . Wood and other suitable material can be utilized to form the rods  86 . 
     Other than the suction cups  40  and dowel rods  86 , the various components of the container  10  (in all embodiments shown) are formed out of a corrugated material, such as cardboard. The corrugated material can be a plurality of foldable blanks In this manner, the corrugated material can be shipped in a flattened, collapsed state, and the container can be set-up on site by folding the components into the required structures. Additionally, the number of folded layers in a component can be increased or decreased to provide structures of varying strength to accommodate varying sized glass sheets or meet carrier or other criteria. 
     While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.