Patent Publication Number: US-6668519-B2

Title: Method and apparatus for packaging objects in a shipping container

Description:
RELATED APPLICATION 
     This is a continuation of co-pending application, Ser. No. 09/638,612 filed Aug. 15, 2000, which is expressly incorporated herein by reference. 
     The present application is related to and claims priority based upon provisional application Ser. No. 60/179,702, filed Feb. 1, 2000. 
    
    
     TECHNICAL FIELD 
     The present invention relates in general to packaging, and more particularly to a method and apparatus for packaging and shipping large objects such as household appliances, rolls of paper, carpet, race cars, boats and the like in a transparent container without the use of heat shrink materials. 
     BACKGROUND OF THE INVENTION 
     Recently, industries are requiring that their manufactured objects be visible during shipping. If any damage has occurred to the object, such damage would be immediately visible. Also, it has been determined that when the object is visible in the packaging, more care is given to the object being shipped and less damage, in fact, occurs. 
     Industries are also requiring that the shipping containers have a reduced amount of packaging material in order to comply with other types of loading devices which do not crush under the shrinking plastic. Prior art references include U.S. Pat. Nos. 5,862,911; 5,701,999; 5,307,928; 5,289,969; 5,277,310; 4,919,263; 4,811,840; 4,226,327; 3,891,086; 3,835,986; 3,581,458 and 3,522,688. While the prior art packages allow the object to be seen, any attempt to physically examine the object within the container requires the destruction of the plastic covering. 
     Still another requirement is that if damage has occurred to the object, it is important to be able to gain access to the object without destruction of the entire package. Shrink wrap packages and cardboard packaging material are typically destroyed when entry into the package is attempted. 
     Accordingly, it is desired to have a method for making a shipping container which protects objects during shipping, uses a minimal amount of packaging material, allows the object to be visible, and which further allows access to the object without destruction of the shipping container. 
     It would be also desirable to provide a see-through shipping container which is capable of being temporarily removed from the object and replaced on the object without destruction of the container. 
     It is an object of the present invention to provide an economical method for providing a transparent shipping container that is easily adapted to automatic packaging systems. 
     It is a further object to provide an improved method for packing objects which allows the objects to be readily handled by forklift, trucks and the like. 
     It is a further object to provide a method for packaging objects using a container which is economically constructed from a minimum number of components. 
     It is a further object to provide an improved method for packaging of heavy articles such as kitchen appliances and the like. 
     It is another object to provide an improved method for packaging objects which allows the object in the shipping container to be physically examined after having been packaged in the shipping container without destruction of the shipping container and to be repackaged in the same shipping container. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a method and apparatus for packaging an object in a shipping container. The container has a base for receiving the article and a plurality of corner posts connected to the base. Each post has a first end affixed to a portion of the base and a second, opposed end in a spaced apart relationship to the base. A flexible material is positioned over the base and corner posts. It is preferred that the flexible material is translucent or transparent. The flexible material is capable of being removed from the base and corner posts without being torn or destroyed. The object being shipped is placed on the base and within the flexible material. A removable top is positioned over the flexible material. 
     The present invention also relates to a method for removably storing an object in a shipping container without destruction of the shipping container. The method includes securing a plurality of corner posts to a base. The object to be shipped is positioned on the base/corner posts component. The corner posts are then positioned adjacent the corners of the object. The object/base/corner posts assembly or component is placed in a flexible material having an open end and a closed end. In a preferred method, the object/base/corner posts assembly or component is dropped or slideably placed into the open end of the flexible material. The flexible material is a non-heat shrink plastic transparent or translucent material. Thereafter, a removable top is secured to the flexible material and the base/corner posts assembly by at least one securing means. The securing means is removable to allow the flexible material to be slideably removed from the corner posts to allow access to the object. 
     Other objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description of the preferred embodiments and the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 a  is a plan view of a base and corner posts component of a shipping container in a first or planar position. 
     FIG. 1 b  is a perspective view of the base and corner posts component, as shown in FIG. 1, in a second or raised position. 
     FIG. 2 is a perspective view of an object positioned on the base/corner post component of FIG. 1 b.    
     FIG. 3 a  is a perspective view of an open end of a removable flexible plastic material. 
     FIG. 3 b  is a perspective view of a removable flexible plastic material. 
     FIG. 3 c  is a plan view of a partially closed or sealed end of a removable flexible material. 
     FIG. 4 is a perspective view showing a base/corner posts shipping container component or assembly and an object being placed in the flexible material. 
     FIG. 5 is a perspective view of an object secured within the shipping container component shown in FIG.  4 . 
     FIG. 6 is a perspective view showing the object secured within the shipping container and having a top positioned on the container. 
     FIG. 7 is a schematic view, partially in phantom, showing a first step in producing a transparent and removable shipping container. 
     FIG. 8 is a schematic view, partially in phantom, showing a second step in producing a transparent and removable shipping container. 
     FIG. 9 is a schematic view, partially in phantom, showing a third step and showing an object ready to be positioned within a flexible plastic material. 
     FIG. 10 is a schematic view, partially in phantom, showing the object being positioned in the flexible plastic material of the shipping container. 
     FIG. 11 is a schematic view, partially in phantom, showing the object fully positioned in the shipping container. 
     FIG. 12 is a schematic view, partially in phanton, showing the object being removed from a conveyor to a position above the shipping container. 
     FIG. 13 is a schematic view, partially in phanton, showing the object positioned in the shipping container and mounted on a transfer conveyor. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the Figures, FIG. 1 a  shows a base  10  having a generally rectangular shape. However, it should be understood that other shapes having multiple sides can be used according to the present invention. For ease of illustration, a generally rectangular shape is shown. The base  10  is preferably made of a cardboard type material and has a center  12  for receiving an object such as an appliance. The base  10  has a first flap  14  and an opposing second flap  16  for receiving corner posts  20 . The base further comprises opposing third and fourth flaps  18  and  19 . 
     Each corner post  20  can have a desired predetermined geometry which allows the post to be secured against the object being shipped. One suitable type of corner post is made by Sonoco Products Company of Hartsville, S.C., such as the corner post shown in the Ortlieb U.S. Pat. No. 5,593,039 patent. It should be understood, however, that corner posts having other configurations are also useful with the present invention. 
     Each corner post  20  has a first end  21  and a second end  23 . The first end  21  of a first corner post  20   a  is secured to an outside edge  22  of the first flap  14  using a suitable glue or adhesive material. A second corner post  20   b  is secured to a second edge  24  of the first flap  14 . Similarly, a third corner post  20   c  is secured to a first edge  26  of the second flap  16  while a fourth corner post  20   d  is secured to a second end  28  of the second flap  16 . 
     Referring now to FIG. 1 b , the first and second flaps  14  and  16  are moved in the direction as shown by arrows A and B such that the corner posts  20  are substantially perpendicular to the base center  12 . In various embodiments, the opposing third and fourth flaps  18  and  19  can also be rotated in the direction as shown by arrows C and D to be perpendicular to the base center  12 . However, the present invention can be practiced without rotation of the opposing flap members  18  and  19  into a perpendicular position during this stage of manufacturing of the shipping container. 
     FIG. 2 shows an object  40  positioned on the center  12  of the base  10 . For ease of explanation, the object  40  is shown as an appliance, however, it should be understood that many different types of objects can be packaged using the method and apparatus of the present invention. In the embodiment shown, the object  40  generally has a rectangular shape and defines opposing corners  42 . When the object  40  is placed on the base center  12 , each of the corner posts  20   a - 20   d  is moved into a generally parallel relationship adjacent a corresponding corner  42  of the object  40 . 
     It should be understood, that in preferred embodiments, each corner post  20  has a predetermined geometric cross-sectional configuration which provides support to the shipping container and which protects the object  40  being shipped. For ease of illustration, the corner posts  20  are generally shown as having an L-shape, having an interior corner or angle  44  engages the corner  42  of the object  40 . However, it should be understood that, in certain embodiments, the corner posts  20  can have a more complex cross-sectional configuration and still define an interior corner  44  which engages the corner  42  of the object  40 . 
     FIGS. 3 a-c  show a transparent or translucent flexible plastic material  30 . The flexible plastic material  30  preferably has a bag or sleeve type shape. The sleeve  30  has a first or open end  32  and a second end  34  (see FIG.  4 ). The second end  34  is at least partially closed or sealed in any suitable manner. It is to be further understood that all of the second end  34  of the sleeve  30  need not be totally closed. Rather, the second end  34  can comprise opposing sealed corners  36  and an open center area  38 . In a preferred embodiment, the sleeve  30  can have a general shape similar to the object  40  being shipped. For example, if the object  40  has a generally rectangular shape, then the sleeve  30  can have a generally rectangular shape. it is desired that the sleeve  30  have a cross-sectional area that is at least slightly larger than, or can be stretched to be larger than, the cross-sectional area of the object  40  such that the object  40  can be positioned in the sleeve  30 , as will be further explained in detail below. When the sleeve  30  has definite cross-sectional shape, such as a triangle, rectangle or square, and the like, the sleeve  30  defines a plurality of corners  33 . However, it should be understood that the sleeve can have a generally cylindrical shape and, thus, not have any defined corners. 
     The base  10  and corner posts  20   a - 20   d  component is positioned within the sleeve  30 . In certain embodiments, as explained in detail below, the open end  32  of the sleeve  30  is held open while the base  10 /corner posts  20   a - 20   d  component and the object  40  are slideably positioned in the sleeve  30 . 
     As shown in FIG. 4, the base  10 /corner posts  20   a - 20   d  component and the object  40  are slideably moved into the sleeve  30  until the base  10  comes into contact with the second end  32 . The sealed corners  36  of the second end  32  prevent the base  10 /corner posts  20   a - 20   d  component and the object  40  from falling through the sleeve  30 . 
     FIG. 5 shows the object  40  in position in the sleeve  30  adjacent the base  10 . The corner posts  20   a - 20   d  extend along the corners  42  of the object  40 , protecting the corners  42  of the object  40 . In a preferred embodiment, the open end  32  of the sleeve  30  extends beyond the second ends  23  of the corner posts  20 . 
     FIG. 6 shows a top  50  which is removably secured to the posts  20  and the sleeve  30 . The top  50  generally has a complementary shape to the base  10 . The top  50  has a center  52  and a plurality of flaps  54 . Each flap  54  is folded in a downward direction from the center  52 . The flaps  54  are folded in a generally perpendicular direction away from the center  52  such that the flaps fold over the second end  23  of each corner post  20 . The top  50  can be removably secured to each second end  23  of each post  20  by any suitable securing member  58 , including stapling. Other securing members, such as screws or nails can also be used. 
     If access to the object  40  is desired after the object is secured within the shipping container, the securing members  58  are removed, and the top  50  is removed. The sleeve  30  is slideably moved in a downward direction along the posts  20  so that access can be gained to all parts of the object  40 . After any inspection work or repair is done to the object  40 , the sleeve  30  is slideably moved or repositioned adjacent the posts  20  such that the open end  32  of the sleeve  30  terminates at a point adjacent and in close proximity to the second end  23  of each post  20 . Thereafter, the top  50  is again secured to the posts  20 . 
     Referring now to FIGS. 7-11, a method and apparatus for placing an appliance in the shipping container are generally shown. FIG. 7 is schematic view, partially in phantom, showing the sleeve  30  held in an open position by a sleeve transfer or first means  100 . The sleeve transfer means  100  has at least one, and preferably a plurality of holding members  102  which engage a portion of the open end  32  of the sleeve  30 . The holding members  102  engage the corners  33  of the sleeve  30  and hold the sleeve  30  in an open position. It should be understood that when the sleeve  30  has a generally cylindrical shape, the holding members  102  engage points along the open end  32  of the sleeve  30  such that the object can be readily positioned in the sleeve  30 . 
     Referring again to FIG. 7, the sleeve  20  is brought into coaxial alignment with a sleeve securing or second means  120  along axis A. The sleeve securing means  120  has a plurality of downwardly extending securing members or forks  122  which are generally positioned at opposing corners of a frame  124 . Each fork  122  is operatively connected at a first or proximal end  123  to the frame  124  by a tension member  126  such as a spring or the like. Each tension members  126  holds a corresponding securing form  122  in tension and at an acute angle with respect to the frame  124 . Each fork  122  further defines a distal end  125  which is in a spaced apart relationship to the proximal end  123  of the fork and the frame  124 . 
     The sleeve securing means  120  further comprises a plurality of angled guide members  130  which extend from the frame  124  in a direction opposite to the securing forks  122 . The angled guide members  130  extend at an acute angle with respect to the frame  124 . As will be explained in detail below, the angled guide members  130  aid in aligning the object  40  in a coaxial relationship with the forks  122  and the sleeve  30 . 
     The sleeve securing means  120  is positioned in a coaxial relationship with the sleeve transfer means  100 . The sleeve securing means  120  has a power source  121 , whereby the sleeve securing means  120  is moved from a first position, as shown in FIG. 7, to a second position, as shown in FIG.  8 . When the sleeve securing means  120  is moved to the second position, the securing forks  122  pass through the open end  32  of the sleeve  30  and are extended into the sleeve  30 . When the sleeve  30  has corners  33 , it is desired that the securing forks  122  engage at least the portions of the interior of the corners  33  which are adjacent the open end  32  of the sleeve  30 . As seen in FIG. 8, because the tension members  126  hold the securing forks  122  at an angle with respect to the frame  124 , the distal ends  125  of the forks  122  are in a spaced apart relationship to the bottom corners  36  of the sleeve  30 . However, the sleeve  30  is secured against at least the proximal ends  123  of the forks  122 . 
     The object  40  is positioned on the base  10 /corner posts  10   a - 20   d  component in a suitable manner (not shown) such as by a conveyor system or the like. Referring now generally to FIG. 9, a positioning or third means  150  which has a plurality of clamping arms  152  engages the object  40  and the base  10 /corner posts  20   a - 20   d  component. 
     The positioning means  150  may have any suitable clamping or securing arms  152  which can be pneumatically or hydraulically operated to releasably secure the object  40 . The corner posts  20  are held securely against the corners  42  of the object  40  by the positioning means  150 . The positioning means  150  is positioned to be into coaxial alignment with the sleeve securing means  120  and the sleeve  30 . 
     The positioning means  150  has a power source  151 , whereby the clamping arms  152  are moved from a first position, as shown in FIG. 9, to a second position, as shown in FIG.  10 . In the first position, the positioning means  150  is brought into alignment with the guide members  130  along axis B. The object  40 /base  10 /corner posts  20   a - 20   d  component is positioned to be in alignment with and adjacent the guide members  130 . 
     In operation, the clamping arms  152  are disengaged, thus allowing the object  40 /base  10 /posts  20   a - 20   d  component to be slideably positioned within the sleeve  30 . The corner posts  20   a - 20   d  contact the forks  122 . The weight and momentum of the object  40  being dropped into the sleeve  30  acts on the forks  122  such that the tension members  126  absorb at least a part of the weight of the object  40 . The forks  122  are moved into a substantially parallel alignment with the corner posts  20 . The second end  34  of the sleeve  30  prevents the object  40  from breaking through or dropping beyond the second end  34  of the sleeve  30 . 
     As an additional feature, the clamping arms  152  are moved from the second position, as shown in FIG. 10, to a third position, as shown in FIG. 11 by the power source  151 . The positioning means  150  and the clamping arms  152  are moved in a direction toward the object  40 . The clamping arms  152  are moved into contact with at least two opposing corner posts  20 . The positioning means  150  advances the clamping arms  152  in a direction toward the object  40  such that the object  40  can be further guided into the sleeve  30 , if necessary. It is to be understood that the positioning means  150  and the sleeve securing means  120  can be operated in any suitable manner and can be moved by hydraulics or pneumatic devices. 
     FIGS. 12 and 13 show additional embodiments of the present invention. An object  204  that is to be placed in a sleeve  242  is advanced along a conveyor  208  to a transfer mechanism  212 . The transfer mechanism includes a positioning means  216  that has at least two opposed clamping or securing arms  218  that are used to engage and securely hold the object  204 . The clamping arms  218  are usually operated by a fluid pressure to cause the clamping arms to releasably engage the object  204 . The clamping arms  218  and positioning means  216  are substantially the same as the previously described positioning means  150  and clamping arms  152  and function in substantially the same way when engaging the object  204  by the corner posts  206  that are positioned along the corners of the object  204 . 
     Each clamping arm  218  is pivotally secured to one end of a transfer arm  222 . The transfer arm is pivotally secured to each clamping arm  218  at substantially the midpoint of the clamping arm. The second end of the transfer arm  222  is secured to a pulley or sprocket  226 . The pulley or sprocket  226  is operatively connected to a drive pulley or drive sprocket  228 . The drive pulley or sprocket is operatively connected to a motor  230 . A chain or belt  232  is used to operatively connect the drive pulley  228  to the pulley  226  on the second end of the transfer arm  222 . 
     In operation, the motor  230  is activated to cause the drive pulley  228  to rotate wherein the belt  232  is caused to advance which in turn causes the pulley  226  to rotate. The rotation of the pulley  226  causes the transfer arm  222  to rotate with the pulley  226  whereby the transfer arm  222  and clamping arms  218  are caused to move in a clockwise direction. The object  204  held in the clamping arms  218  is lifted from the conveyor  208  and transferred to a packaging station  234 . In the packaging station  234 , the object  204  is held by the clamping arms  218  immediately above a sleeve securing means  240  which is substantially similar to the sleeve securing means  120  previously described. When the object  204  is properly positioned over the sleeve securing means  240 , the clamping arms  218  are moved to release the object  204  and the object  204  falls through the force of gravity into the sleeve securing means  240  and into the plastic sleeve  242  positioned on the sleeve securing means  240  in the manner previously described above. When the object  204  is completely positioned in the plastic sleeve  242 , the object  204  will be resting upon a transfer conveyor  246 . 
     A pusher device  250  is usually positioned above the object  204  in the packaging station  234 . The pusher device  250  can be advanced toward the object  204  so that it engages the surface of the object  204  that is spaced apart from the sleeve securing means  240 . The pusher device  250  can be biased in a manner that it acts upon the object  204  to move the object  204  in a direction toward the plastic sleeve  242 . The pusher device  250  moves vertically to assist the object  204  in advancing into the plastic sleeve  242  so that the object  204  is completely inserted into the plastic sleeve  242 . 
     In FIG. 13, the sleeve securing means  240  is advanced vertically in a direction away from the transfer conveyor  246  to remove the forks  244  from the plastic sleeve  242  to complete the packaging of the object  204  in the plastic sleeve  242 . The sleeve securing means  240  has a positioning motor  254  that engages a rack or cable (not shown) positioned adjacent the packaging station  234  to remove the forks  244  from the plastic sleeve  242 . Once the forks  244  are removed from the plastic sleeve  242 , the object  204  packaged in the plastic sleeve  242  can be advanced along transfer conveyor  246  for moving to another location. 
     The present invention provides a method and apparatus for providing an economical and easy to use shipping container. The method of placing the object within the shipping container is readily automated to permit high speed and economical packing and shipping of large objects. 
     The invention has been shown and described with respect to the particular embodiments thereof for the purpose of illustration rather than limitation. Other variations and modifications of the specific embodiment herein shown and described will be apparent to those skilled in the art within the intended spirit and scope of the invention. 
     The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims.