Patent Abstract:
A void board is configured for placement between adjacent horizontal layers of bricks to maintain an opening in a lower of the layers. The void board includes a relatively thin base element having first and second opposing sides and a plurality of ribs extending along a length of the base element. The ribs extend from the first and second sides, generally transverse to the base element. The ribs are positioned such that the ribs that extend from the first side of the base element are offset from the ribs extending from the second side of the base element. The base element has a longitudinally extending central region, between a closest pair of ribs, that is devoid of ribs. A bundled load of objects have the void board positioned therein and a method of bundling a load of objects are also disclosed.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION DATA 
     This application claims the benefit of priority of Provisional U.S. patent application Ser. No. 61/488,018, filed May 19, 2011, the entire disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     Bricks and other masonry materials are typically bundled as a plurality of stacked individual units (i.e., individual bricks) formed into a 3-dimensional bundle. The bundle includes one or More package straps, corner protectors, and a void board that is placed between two horizontal layers of bricks. Generally, the void board is placed above a layer of bricks that has bricks omitted, e.g., forming openings in the bundle. Additional layers of bricks are placed on top of the board. The openings, which are typically centrally disposed, are configured to allow the tines of a forklift or similar device to pass into the bundle. In moving the package of bricks, the forklift exerts a force on the underside of the board to lift the entire package. Typically, the openings are formed extending through the entire depth of the bundle. 
     One known void board is formed as a veneer. These veneer void boards are often of poor quality and have a tendency to warp and degrade after prolonged exposure to the elements. Warping results in uneven surfaces upon which layers of bricks are stacked, which in turn can result in package instability and/or the inability to insert the forklift tines. 
     Other void boards use solid or ribbed plastic sheets. Such void boards are disclosed in Duke et al., U.S. Pat. No. 6,989,184, Varma, et al., U.S. Pat. No. 7,838,095, and Kruelle et al., Published U.S. Patent applications publication Nos. 2008/0311334 and 2008/0311335, all of which are commonly assigned with the present application and incorporated herein by reference. While the polymeric void boards have been found to function well at a given thickness, they require a higher material weight (and thus, cost) than desired for such a consumable item. When a thinner sheet is used (and thus, less material), it has been found that the boards may not have the desired stiffness. To increase stiffness, a board having a wide, ski-like element formed on one or both sides of the board has been used. While this functions well for some applications, it also adds material weight and cost to the board. 
     Moreover, there has been an industry shift to the use of textured bricks. These bricks, unlike conventional bricks, may not have flat sides or faces. Rather, the faces of the bricks may be irregularly shaped or non-planar. As such, when a ski-containing sheet-like board is used, the bricks may tend to lean or skew to one side, because the ski creates a fulcrum on which the bricks rest. This results in the brick bundle not being properly strapped and can cause package (bundle) instability and/or failure. 
     Other polymeric or plastic sheets have been used that include embossings or shapes formed in the sheets, transverse to the plane of the sheet. It has been observed that the embossings can collapse under the weigh of the bricks, especially when the bundle is subject to vibration, as during transport, and consequently bundle failure can occur. 
     Accordingly, there is a need for a void board that is of consistent quality, reliability, and strength to allow stable stacking of bricks for bundle forming, without crushing the board. Desirably, such a void board does not collapse after exposure to the elements and/or vibration, and provides a planar, consistent support, even when used with irregularly surfaced bricks. 
     More desirably, such a void board is used as a component in a brick package or bundle in which corner edge protectors and straps are used to complete the package to, for example, facilitate storage, handling, shipping and the like. 
     SUMMARY 
     A polymeric void board is configured for placement between adjacent horizontal layers of bricks to maintain an opening in a lower of the brick layers. The board includes a relatively thin base element having first and second opposing sides. A plurality of ribs extends along a length of the base element. The ribs extend from both the first and second sides, generally transverse to the base element. 
     In an embodiment, the ribs are positioned such that the ribs extending from the first side of the base are offset from the ribs extending from the second side of the base element. The base element has a longitudinally extending central region, between a closest pair of ribs, that is devoid of ribs. 
     In this embodiment, the ribs extend from the base element at a base portion. The base portion has a width that is less than a width of an end of the ribs. In such a configuration, the ribs have a truncated pyramidical profile that defines a truncated portion that is contiguous with the base element. The ribs can be formed in mirror image relation to one another relative to a longitudinal centerline of the base element. A recess can be formed in the base element, on the side opposite of each rib. 
     The void board is preferably formed from a thermoplastic or thermoplastic-blend material. The material can be a filled polymer. 
     In another embodiment void board is formed as a relatively thin base element having first and second opposing sides and a plurality of ribs extending along a length of the base element. The ribs extend from the first and second sides, generally transverse to the base element, and are positioned such that the ribs extending from the first side of the base element are aligned with the ribs extending from the second side of the base element. Each rib, when viewed in cross-section, has a semi-circular profile. 
     A bundled load of objects is formed with the void board. In such a bundle, an array of objects are arranged in multiple horizontal layers. Each horizontal layer is formed of multiple objects. At least one opening is defined in at least one horizontal layer by an absence of at least one object. 
     The array defines four sides, a top and a bottom. The four sides, top and bottom define four vertical edges, four top horizontal edge and four bottom horizontal edges. 
     The polymeric void board is positioned between the horizontal layer of objects having the opening therein and an adjacent upper horizontal layer of objects. At least one corner edge protector is positioned on one of the top or bottom horizontal edges and strap is positioned around the array and the corner edge protector to secure the corner edge protector against the edge. 
     Corner edge protectors can be positioned at opposing top horizontal edges and multiple straps can be positioned around the array to form the bundle of objects. 
     A method of bundling a load of objects includes the steps of providing an array of objects arranged in multiple horizontal layers with each horizontal layer formed of multiple objects. The bundle includes at least one opening in at least one horizontal layer that is defined by an absence of at least one object. The array defines four sides, a top and a bottom. The four sides, top and bottom define four vertical edges, four top horizontal edges and four bottom horizontal edges, 
     A void board is positioned between horizontal layers of objects, above the layer having the opening therein. An edge protector is positioned on at least one top horizontal edge and a strap is positioned around the load of objects and the edge protector to secure the edge protector to the load and to bundle the load. 
     These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a bundle of bricks having a void board disposed between horizontal layers of bricks, the bundle being shown with edge/corner protectors and strapping material around the bundle to secure the bundle; 
         FIG. 2  is a perspective view of one vertical layer of bricks separated from the bundle of  FIG. 1 ; 
         FIG. 3  is a top view of an embodiment of the void board; 
         FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 3 ; 
         FIG. 5  is an enlarged view of one side of the void board  FIG. 3 ; 
         FIG. 6  is an enlarged view of the circled area of  FIG. 5 ; 
         FIG. 7  is a top view on another embodiment of the void board; and 
         FIG. 8  is a cross-sectional view taken along line  8 - 8  of  FIG. 7   
     
    
    
     DETAILED DESCRIPTION 
     While the present device is susceptible of embodiments in various forms, there is shown in the drawings and will hereinafter be described exemplary and non-limiting embodiments, with the understanding that the present disclosure is to be considered an exemplification of the device and is not intended to be limited to the specific embodiments illustrated. 
     With reference now to the figures and in particular to  FIG. 1 , a bundle  10  of bricks  14  is shown with a void board  12 . The bundle  10  is a 3-dimensional stack of individual bricks  14  that form a matrix with a plurality of horizontal layers, e.g.,  16   a - j . The bundle  10  thus defines a length l 10 , a height h 10  and a width w 10 , which are represented by the x, y and z directional axes as shown. 
     The bundle  10  is maintained in the 3-dimensional configuration by straps  18  that are positioned about the bundle  10 . In a typical bundle  10 , vertical straps (in the y-direction) are positioned around the bundle  10  extending in both the x and z-directions. Horizontal straps (not shown) can be used. Corner edge protectors  20  are disposed along the corners of the bundle  10  between the bricks  14  and strap  18  to protect the bricks  14  from damage due to rubbing and accidental bumping. The corner protectors  20  also preclude strap  18  failure due to, for example, abrasion. 
     In order to readily transport the bundle  10 , openings  22  are formed in the bundle  10  by removing or eliminating bricks  14  in a predetermined area of the matrix. The openings  22  are configured to, for example, permit the insertion of the t of a forklift. In this manner, the tines can be inserted into the openings  22  and the bundle  10  raised and transported as desired. 
     To maintain the layer  16   d  of  14  bricks above the opening  22 , the void board  12  is placed between the horizontal layers  16   c  and  16   d  of bricks  14 , that is, above the layer  16   c  in which the openings  22  are formed. 
     An embodiment of the void board  12  is illustrated in  FIGS. 3-6 . The board  12  is fabricated as an extruded member and includes a planar base  28  element. A plurality of stand-offs or ribs  30  extend longitudinally along the length l 12  of the element  28  from first and second sides  32 ,  38  respectively. In an embodiment, the ribs  30  are parallel and are generally equal in height h 30 . In the illustrated embodiment, the ribs  30  have a truncated triangular cross-section with the truncated or upper portion  34  of the triangle formed integral (e.g., contiguous) with the base element  28 . A recess  36  can be formed in the base element  28 , opposite each rib  30 . It has been found that the recess, if used, may add strength to the board  12 . It will be appreciated that although truncated triangular shaped ribs  30  are shown, these are exemplary and that the ribs  30  can take many other shapes, such as cruciform, semi-circular and like profiles. 
     In an embodiment of the board  12 , the ribs  30  are formed extending from both sides  32 ,  38  of the base element. The ribs  30  can be formed in a staggered configuration so that the ribs  30   a  extending from one side  32  of the base element  28  do not oppose the ribs  30   b  extending from the other side  38  of the base element  38 . That is, the ribs  30   a  extending from one side  32  of the base element  28  are between ribs  30   b  extending from the opposite side  38  of the base element  28 . It has been found that this staggered arrangement of the ribs  30  prevents high and/or low spots as the bricks  14  lie on the board  12 , that could otherwise tend to allow the bundle  10  to skew. The staggered arrangement can also permit the board to dissipate heat and thus cool faster during manufacture. 
     In the embodiment illustrated in  FIG. 3-6 , the ribs  30  are formed on each side  32 ,  38  of the base element  28 , equally spaced from a centerline or longitudinal axis A 12  of the base element  28 . That is, on side  32 , the ribs  30   a  on each side of the center line (for example ribs  30   a ′) are equally spaced from the centerline A 12  and on the other side  38  of the base element  28 , (for example, the ribs  30   b ′) are also equally spaced from the centerline A 12 . 
     As seen in  FIG. 3 , the center region  40  of the board  12 , generally about the centerline A 12 , is relatively flat. It will be appreciated that this flat region  40  provides an area for automated equipment to pick and move the board  12 . Typically, picking is carried out using vacuum-type devices and, as such, a flat center region  40  permits the application of vacuum with a high degree of confidence. 
     A present board  12  can be manufactured in a variety of lengths, particularly, if the board is manufactured using extrusion methods. An exemplary board  12  has a width w 12  of about 5.0 to 5.5 inches and a thickness t 12  of about 0.05 inches. The board  12  can include ten ribs, five on each side of the centerline A 12 . In this arrangement, four ribs  30   a  are formed on one side  32  of the board  12  and six ribs  30   b  on the opposite side  38  of the board  12 . The ribs  30  can be formed with the inboard most ribs  30   b ′ formed about 2.25 inches spaced from one another (or about 1.125 inches from the centerline), and with the second set of ribs  30   a ′ (on the opposite side  32  of the board  12 ) spaced about 3.0 inches apart (or about 1.5 inches from the centerline). The remaining ribs  30   a ,  30   b  can be equally spaced outboard of the first and second ribs  30   b ′ and  30   a ′ such that the spacing between ribs  30  is about equal to the edges  42  of the board  12 . The last or outboard most ribs are formed at or near the outer edges  42  of the board  12 . 
     The ribs  30  can extend transverse from the base element  28 , relative to a center C 12  of the board  12  to a height h 30  of about 0.0935 inches (such that a rib end  44  to rib end  44  dimension or height h 44  is about 0.187 inches) and can extend from the surface  32  or  38  of the element  28  about 0.069 inches. The ribs  30 , at the ends  44  can have a width w 44  of about 0.115 inches. A juncture (as indicated at  46 ) of the ribs  30  and the base element  28  can be rounded to better distribute stresses transferred from the ribs  30  to the base element  28 . 
     An alternate embodiment of the board  112  is illustrated in  FIGS. 7 and 8 . In this embodiment, the ribs  130  extend from the base element  128  aligned with one another (see  FIG. 8 ). The illustrated ribs  130  are formed having a semi-circular profile. The central region  140  of the base element  128  is without ribs to permit automatic (vacuum-assisted) transport of the boards  112 . The ribs  130  can be equally spaced from one another, with the outer-most ribs  130 ′ at or near the edge  142  of the board  112 . 
     The materials from which the board  12 ,  112  is formed can vary. Exemplary materials include high density polyethylene (HDPE), polyvinylchloride (PVC), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polystyrene (PS), combinations of these and other polymers, and the like. Other suitable materials will be recognized by those skilled in the art. The materials can include, as desired, fillers, stabilizers, colorants and the like to achieve certain desired physical, chemical and processing (e.g., manufacturing) characteristics. 
     It is anticipated that the board  12 ,  112  will be formed by an extrusion process, however, other methods for manufacture of the board  12 ,  112  are contemplated. 
     In an exemplary bundling operation, full courses of bricks  14  are laid (e.g., layer  16   a ) until the course  16   c  that includes the forklift openings  22 . Edge protectors  20  can be positioned at about the lower edges  70  of the first course  16   a  of bricks  14 . The edge protectors  20  can be positioned at all four edges  70   a - d , or at two, opposing edges  70   a ,  70   c  as desired. It is anticipated that edge protectors  20  will be used wherever strap  18  is positioned around the bundle  10  to prevent damage to the bricks  14 , to prevent strap  18  failure, for example due to abrasion, and to better stabilize the bundle  10 . 
     A partial course  16   c  of bricks  14  is then positioned outboard and between the positions that the forklift openings  22  will occupy. One or more void boards  12  are then positioned over the partial course  16   c  of bricks  14  that define the openings  22 , and a full course  16   d  of bricks  14  is then positioned over the partial course  16   c  of bricks  14  and the void board  12  until a desired height (e.g., to  16   j ) of the bundle  10  is achieved. Edge  20  protectors can then be positioned along the top edges, for example at edges  72   a  and  72   c  to correspond to the location and position of the edge protectors  70   a  and  70   c  on the first course  16   a  of bricks  14 , and strap material  18  is used to secure the bundle  10 . A top sheet (not shown) may be provided on the bundle  10 , between the bricks  14  and the strap  18  material, to provide additional protection for the bricks  14 . 
     In the disclosure, the use of the disjunctive is intended to include the conjunctive. The use of the definite article or indefinite article is not intended to indicate cardinality. In particular, a reference to “the” object or “a” or “an” object is intended to denote also one of a possible plurality of such objects. 
     All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
     From the foregoing it will be observed that numerous modification and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.

Technology Classification (CPC): 1