Abstract:
A system and method are provided for palletless shipment of gas cylinder arrays. A three-dimensional array of gas cylinders is formed from a plurality of vertically-stacked two-dimensional subarrays. First elongated voids extend through the array in a width direction at a first handle elevation. Second elongated voids extend through the array in a depth direction at a second handle elevation. The first and second elongated voids are bilaterally bounded by handle portions of adjacent gas cylinders, and vertically bounded by upper and lower surfaces of surrounding cylinders. Pairs of tunnel elements are disposed within respective elongated voids and are each configured to releasably receive a corresponding forklift tong. Vertically-disposed pillars may be provided to increase the rigidity and load distribution of the system. Flaps may radiate from the pillars to minimize impact and abrasion between adjacent cylinders during shipment. Key system components may be inexpensively formed from recyclable, lightweight materials.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/057,185 filed Sep. 29, 2014, the content of which is incorporated by this reference in its entirety for all purposes as if fully set forth herein. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to the field of product packaging and shipment. More particularly, the invention involves systems and methods for packaging an array of gas cylinders for space-efficient and secure storage and shipment. 
       BACKGROUND 
       [0003]    Conventional systems and methods for packaging and shipping a three-dimensional array of gas cylinders, such as propane tanks, generally require a pallet to be placed under the array to facilitate lifting by a forklift. Such pallets add height to the overall shipment package, thereby restricting the number of gas cylinders which can fit vertically within a typical shipping truck or shipment container. By way of example, a typical conventional propane tank shipment configuration contains 60 propane tanks in an array of four wide, three deep and five high. Only one such configuration can fit vertically in a typical shipping truck. Moreover, once the outer securement means is removed during unpackaging, an array having five propane tanks high typically requires a worker to use a ladder to access and remove the upper level of tanks from the array. This presents an undesirable safety risk during unpackaging and shelving operations. Further, conventional propane tank shipment systems and methods frequently rely on expansive amounts plastic wrapping to secure the array of propane tanks together during shipment. 
         [0004]    What is needed is a system and method which allows a three-dimensional array of gas cylinders to be moved by forklift and shipped in a manner which simultaneously optimizes space efficiency, protects the product from damage, improves safety, reduces packaging costs and waste materials, and uses recyclable components. 
       SUMMARY 
       [0005]    In an example embodiment of a system for palletless shipment of gas cylinder arrays, a three-dimensional array of gas cylinders may be formed from a plurality of vertically-stacked two-dimensional subarrays. Each subarray is defined by a subset of gas cylinders which are laterally tightly disposed with respect to one another. Each gas cylinder typically includes an upper surface, a lower surface and a handle portion extending from its upper surface. Each subarray has at least two columns extending in a depth direction and at least three rows extending in a width direction. As a byproduct of the compact arrangement of gas cylinders in the array, a pair of first elongated voids extend through the array in the width direction at a first handle elevation. Each first elongated void is bilaterally bounded by respective handle portions of the subarray below. It is also vertically bounded by the upper surface of the gas cylinders immediately below the void and the lower surfaces of the gas cylinders immediately above the void. Each of a pair of first tunnel elements is disposed within a respective one of the first elongated voids and is configured to releasably receive a corresponding forklift tong. 
         [0006]    Where each gas cylinder includes a foot portion extending from its lower surface, and, the vertical stacking preferably involves at least partial nested engagement of the handle portions of each lower subarray with the foot portions of the respective subarray immediately thereabove. 
         [0007]    Additional tunnel elements may be provided to allow a forklift to engage the system at various elevations in the array, and at various lateral angles with respect to the array. Moreover, the key components of the system may be inexpensively formed from cardboard or similar recyclable, lightweight materials. Improved rigidity and weight distribution may be imparted to the system by way of vertically-oriented pillar elements configured to engage the tunnel elements. The pillar elements may also provide additional protection to the gas cylinders during shipment, by including flaps capable of shielding closely adjacent gas cylinders from rubbing against one another. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Further advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings in which: 
           [0009]      FIG. 1  is a diagrammatic perspective view of a package system in accordance with one non-limiting embodiment of the present invention; 
           [0010]      FIG. 2  is a diagrammatic side view of the embodiment depicted in  FIG. 1 ; 
           [0011]      FIG. 3  is a diagrammatic side view of the embodiment depicted in  FIG. 1 ; 
           [0012]      FIG. 4  is a diagrammatic cross-sectional view take along lines  4 - 4  in  FIG. 2 ; 
           [0013]      FIG. 5  is a diagrammatic cross-sectional view take along lines  5 - 5  in  FIG. 3 ; 
           [0014]      FIG. 6  is a diagrammatic magnified view of detail  6  in  FIG. 4 , illustrating the partial receipt of the handle ring of a lower gas cylinder within the foot ring of the gas cylinder of the respective upper gas cylinder, as well as a second tunnel element disposed in the space lateral of the handle ring; 
           [0015]      FIG. 7  is a diagrammatic is a magnified view of detail  7  in  FIG. 4 , illustrating a flap member protectively disposed between weld lines of adjacent gas cylinders; 
           [0016]      FIG. 8  is a diagrammatic is a magnified view of detail  8  in  FIG. 5 , illustrating multiple flap members of a pillar element protectively disposed between weld lines of adjacent gas cylinders; 
           [0017]      FIG. 9  is a diagrammatic plan view of a bottom tray element box blank in accordance with the system embodiment shown throughout the several FIGS.; 
           [0018]      FIG. 10  is a diagrammatic plan view of a cap element box blank in accordance with the system embodiment shown throughout the several FIGS.; 
           [0019]      FIG. 11  is a diagrammatic plan view of a pillar element box blank in accordance with the system embodiment shown throughout the several FIGS.; 
           [0020]      FIG. 12  is a diagrammatic plan view of a first tunnel element box blank in accordance with the system embodiment shown throughout the several FIGS.; 
           [0021]      FIG. 13  is a diagrammatic plan view of a second tunnel element box blank in accordance with the system embodiment shown throughout the several FIGS.; 
           [0022]      FIG. 14  is a diagrammatic perspective view of one embodiment of a pillar element; 
           [0023]      FIG. 15  is a diagrammatic side view of the pillar element of  FIG. 14 ; 
           [0024]      FIG. 16  is a further diagrammatic side view of the pillar element of  FIG. 14 , but orthogonal to the side view of  FIG. 15 ; 
           [0025]      FIG. 17  is a diagrammatic end view of the pillar element of  FIG. 14 ; 
           [0026]      FIG. 18  is a diagrammatic perspective partially exploded view illustrating a multiplicity of pillar elements being inserted between a first subarray of gas cylinders placed in a bottom tray element; 
           [0027]      FIG. 19  is a diagrammatic perspective partially exploded view illustrating a pair of first tunnel elements being inserted into first tunnel receiving apertures of respective pillar elements; 
           [0028]      FIG. 20  is a diagrammatic perspective partially exploded view illustrating a pair of second tunnel elements being inserted into second tunnel receiving apertures of respective pillar elements, with a second subarray of gas cylinders having been placed on the first subarray; 
           [0029]      FIG. 21  is a diagrammatic perspective partially exploded view illustrating a cap element being placed atop the upper ends of the pillar elements and the third subarray of gas cylinders, such that the handle rings of the top cylinders about the lateral perimeter of the assembly are snuggly received by the upper portion of the cap element; 
           [0030]      FIG. 22  is a diagrammatic perspective view of the fully-assembled system of  FIG. 1 , but shown without the securement straps; 
           [0031]      FIG. 23  is a diagrammatic perspective view two systems in accordance with the present invention in vertically stacked configuration; and 
           [0032]      FIG. 24  is a diagrammatic flow chart representing steps comprised in one or more non-limiting examples of a method of packaging an array of gas cylinders for shipment. 
       
    
    
       [0033]    While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0034]    The following description of preferred embodiments generally relates to systems and methods for palletlessly shipping arrays of gas cylinders, such as propane tanks and the like. 
         [0035]    With particular reference to the figures, one or more non-limiting embodiments of a system are illustrated generally at  100 . Embodiments of a system  100  may comprise an array of gas cylinders  102 , a base tray element  104 , a cap element  106 , and at least a pair of first tunnel elements  110 . The base tray element  104  may have corner portions  108  which are chamfered (as shown in  FIGS. 1 and 8  for example), filleted or the like. Certain embodiments, such as the one illustrated for example in  FIG. 1 , may comprise a pair of second tunnel elements  112  in place of or in addition to the pair of first tunnel elements  110 . In such embodiments, the first tunnel elements  110  and second tunnel elements  112  may preferably be disposed orthogonally to one another, and may reside at different heights in the system  100 . The first and second tunnel elements are each adapted to receive a respective tong of a forklift. 
         [0036]    With reference to  FIGS. 14-17 , embodiments of a system  100  may preferably comprise pillar elements  126 . Referring to  FIG. 8  for illustration, such pillar elements  126  may preferably be configured for lateral disposition between four respective gas cylinders  102 . Moreover, the pillar elements  126  may include a plurality of flap members  130 , each being positionable between respective laterally-adjacent gas cylinders  102  to shield those cylinders (e.g., their weld lines  128 ) from destructively contacting one another during, for example, movement or transportation of the system  100 . In preferred embodiments, the pillar elements  126  may also include a first tunnel receiving aperture  132  and a second tunnel-receiving aperture  134 . The first tunnel receiving aperture  132  may be configured to receive a first tunnel element  110  therethrough, and the second tunnel aperture  134  may be configured to receive a second tunnel element  112  therethrough. 
         [0037]    Referring to  FIG. 1 , when the system  100  is in its assembled form, it may be secured by way of packing straps  114  or the like. Referring to  FIGS. 2 and 3 , the assembled system typically has height  116 , depth  118  and width  120 . Referring to  FIG. 6  for illustration, the handle portion (or “handle ring”)  122  of each lower gas cylinders  102  may be preferably partially received by or “nested within” the foot ring  124  of the gas cylinder  102  directly thereabove. This results in vertical space savings in the system  100 . Referring to  FIGS. 1-3 , tunnel elements  110  and  112  may extend throughout the assembly  100 . Further, as illustrated in  FIGS. 4 and 6  for example, the tunnel elements  110  and  112  may preferably non-obtrusively reside within the gaps defined between the handle rings  122  of laterally-adjacent gas cylinders  102  and between the vessel walls of vertically adjacent gas cylinders  102 . 
         [0038]    Particular embodiments of a system  100  may be configured with only two levels of gas cylinders. In such embodiments, either the first tunnel elements  110  or the second tunnel elements  112  may not be included, and the shortened pillar elements  126  may correspondingly lack either the first tunnel apertures  132  or second tunnel apertures  134 . 
         [0039]    Referring to  FIGS. 9-13 , what are illustrated are example box blanks which correspond to respective embodiments of a bottom tray element  104 , cap element  106 , pillar element  126 , first tunnel element  110  and second tunnel element  112 . Some or all of these components may be formed of corrugated cardboard, such as double-walled, B-flute 275# bursting test with a Kraft finish, or an alternative material with similar performance characteristics. Such blanks can be folded about their fold lines or creases (shown in dashed lines in  FIGS. 9-13 ), and the formed component may be secured in its operative configuration using tape, adhesive or the like. 
         [0040]    A system for palletless shipment of gas cylinder arrays preferably comprises a three-dimensional array of gas cylinders  102  and a pair of first tunnel elements  110 . Referring to  FIG. 1 , the array is formed from a plurality of vertically-stacked two-dimensional subarrays (see, for example, subarrays  136   a,    136   b  and  136   c . Each such subarray is defined by a subset of gas cylinders  102  laterally disposed with respect to one another. Each gas cylinder  102  may include an upper surface  138 , a lower surface  140  and a handle portion  122  extending from the upper surface  138 . With reference to  FIG. 5  for illustration, each subarray may have at least two columns  142  extending in a depth direction  146  and at least three rows  144  extending in a width direction  148 . Referring to  FIGS. 1 and 2 , a pair of first elongated voids  150  typically extend through the array, for example in the width direction  148 , at a first handle elevation  156 . 
         [0041]    Each of the first tunnel elements  110  may be disposed within a respective one of the first elongated voids and configured to releasably receive a corresponding forklift tong  154 . With reference to  FIGS. 4 and 6  for illustration, each elongated void discussed herein may preferably be bilaterally bounded by at least respective handle portions  122 , and vertically bounded by at least respective upper surfaces  138  and lower surfaces  140  of immediately surrounding gas cylinders  102 . 
         [0042]    Referring again to  FIGS. 4 and 6  for illustration, in preferred embodiments, each gas cylinder  102  may include a foot portion  124  extending, for example, from its lower surface  140 . In such embodiments, the vertical stacking previously discussed may preferably involve at least partial nested engagement of the handle portions  122  of a lower subarray (e.g.,  136   a ) with the foot portions  124  of the respective subarray immediately thereabove (e.g.,  136   b ). 
         [0043]    As illustrated for example in  FIGS. 1-4 , in certain preferred embodiments of a system, the array may comprise at least three subarrays. Similarly, each subarray may have at least three columns extending in the depth direction. In such embodiments, a pair of second elongated voids  152  (see, for example,  FIGS. 4 and 6 ) may extend through the array in the depth direction  146  at a second handle elevation  158  (see  FIG. 2 ). In particular preferred embodiments, the first and second handle elevations (e.g.,  156  and  158 ) are distinct from one another. Thus, the system  100  may further comprise a pair of second tunnel elements  112 , each of which may be disposed within a respective one of the second elongated voids and configured to releasably receive a corresponding forklift tong  154 . 
         [0044]    Certain preferred embodiments of a system  100  may further comprise a multiplicity of third elongated voids  160  extending vertically through the array. Therefore, a plurality of pillar elements  126  may each be disposed within a respective third elongated void  160 . With reference to  FIG. 14 , each pillar element  126  may preferably include a pair of tunnel receiving apertures (for example,  132  and  134 ) extending orthogonally to one another. As illustrated in  FIGS. 19 and 20 , each tunnel receiving aperture is preferably configured to receive a respective first tunnel element  110  or second tunnel element  112  therethrough. With reference to  FIG. 8 , each third elongated void is typically substantially defined by four respective adjacent gas cylinders  102  in each subarray. Moreover, with reference to  FIGS. 14-17 , each pillar element  126  may include flap members  130  extendable radially thereof. With reference to  FIGS. 5 ,  7 ,  8 , each such flap member  130  may be protectively disposed between weld lines  128  of a respective pair of adjacent gas cylinders  102 . 
         [0045]    Preferred embodiments of a system  100  may further comprise one or more of a base tray element  104 , a cap element  106  and an array securement means. As illustrated, for example, in  FIGS. 1 and 4 , the base tray element  104  may be in at least partial receipt of a bottommost subarray (for example,  136   a ). Similarly, a cap element  106  may be in a least partial receipt of a topmost subarray (for example,  136   c ). An array securement means (for example, packing straps  114  or the like) may be provided for substantially rigidly securing the array between the base tray element and cap element. 
         [0046]    In particular preferred embodiments a system  100 , one or more of the first tunnel elements, second tunnel elements, pillar elements, base tray element and cap element are comprised substantially of corrugated cardboard. In such embodiments, the first tunnel elements, second tunnel elements, pillar elements, base tray element and cap element are preferably each formed from respective corrugated cardboard blanks 
         [0047]      FIGS. 18-22  sequentially illustrate certain key steps of one or more embodiments of a method for assembling a system  100  (packaging an array of gas cylinders) in accordance with the present invention. 
         [0048]    A method of packaging an array of gas cylinders for palletless shipment may be comprised of, for example, one or more of the steps illustrated in  FIG. 24 . The method is not necessarily restricted to the particular order or steps shown in  FIG. 24 . At block  162 , a base tray element  104  may be provided. The base tray element may be formed from a respective base tray blank  104 ′. At block  164 , a first subarray  136   a  of gas cylinders  102  may be placed on the base tray element  104 . With reference to  FIG. 5 , the first subarray  136   a  may have at least three columns  142  extending in a depth direction  146  and at least three rows  144  extending in a width direction  148 . Each gas cylinder  102  may include a handle portion  122  and an opposing foot portion  124 . 
         [0049]    At block  170  of  FIG. 24 , a pair of first tunnel elements  110  may be provided. The first tunnel elements  110  may be formed, for example, from respective first tunnel blanks  110 ′. Each first tunnel element  110  is configured to releasably receive a corresponding forklift tong  154 . At block  172 , the first tunnel elements  110  may be positioned between pairs of handle portions  122  of the first subarray  136   a  such that the first tunnel elements  110  extend in the width direction  148 . At block  174 , a second subarray  136   b  of gas cylinders  102  may be placed on top of the first subarray  136   a  such that the foot portions  124  of the second subarray  136   b  are in nesting engagement with the handle portions  122  of the first subarray  136   a.  Such a relationship is illustrated, for example, in  FIGS. 4 and 6 . 
         [0050]    At block  176 , a pair of second tunnel elements  112  may be provided. The second tunnel elements  112  may be formed, for example, from respective second tunnel blanks  112 ′. Each second tunnel element  112  may be configured to releasably receive a corresponding forklift tong  154 . At block  178 , the second tunnel elements  112  may be positioned between pairs of handle portions  122  of the second subarray  136   b  such that the second tunnel elements  112  extend in, for example, the depth direction  146 . At block  180 , a third subarray  136   c  of gas cylinders  102  may be placed on top of the second subarray  136   b  such that the foot portions  124  of the third subarray are in nesting engagement with the handle portions  122  of the second subarray  136   b.  Such a relationship is illustrated, for example, in  FIGS. 4 and 6 . 
         [0051]    At block  166 , a plurality of pillar elements  126  may be provided. The pillar elements  126  may be formed, for example, from respective pillar blanks  126 ′. Referring to  FIG. 14 , each pillar element  126  may include a first tunnel receiving aperture  132  and a second tunnel receiving aperture  134 . At block  168 , each pillar element  126  may be vertically positioned within a respective void defined by four adjacent gas cylinders  102  in the first subarray  136   a.  Such construction is illustrated, for example, in  FIGS. 8 and 18 . Returning to block  172  of  FIG. 24 , during the positioning of the first tunnel elements  110 , the first tunnel elements  110  may be inserted through at least one respective first tunnel receiving aperture  132 . Such a process is illustrated, for example, in  FIG. 19 . Similarly, returning to block  178 , during the positioning of the second tunnel elements  112 , each second tunnel element  112  may be inserted through at least one respective second tunnel receiving aperture  134 . Such a process is illustrated, for example, in  FIG. 20 . In certain preferred embodiments of the method, in each pillar element  126 , the first tunnel receiving aperture  132  is orthogonal to the second tunnel receiving aperture  134 . 
         [0052]    Referring to  FIGS. 14-17 , in particular embodiments of a method, each pillar element  126  may include flap members  130  extendable radially thereof. In such embodiments, each flap member  130  may be placed in protective disposition between weld lines  128  of a respective pair of adjacent gas cylinders  102 . See, for example,  FIGS. 5 and 8 . 
         [0053]    At block  182  of  FIG. 24 , a cap element  106  may be provided. The cap element  106  may, for example, be formed from a respective cap blank  106 ′. The cap element  106  may be placed in at least partial receiving engagement with the uppermost subarray (e.g., third subarray  136   a ). At block  184 , the subarrays, base tray element and cap element may be substantially rigidly secured together. Such securement may be provided by way of packing straps  114  or the like. The aforementioned blanks may be comprised of corrugated cardboard, such as double-walled, B-flute 275# bursting test with a Kraft finish, or an alternative material with similar performance characteristics. 
         [0054]    Embodiments in accordance with the present invention eliminate the need for a pallet to support the load of gas cylinders during forklift operations, while ensuring the lifting load is adequately distributed about the shipping system  100 . By way of example, preferred three-level configurations of the present invention, such as the one shown in  FIG. 1 , allow two systems  100  to be stacked on top of one another while fitting in a typical large shipping truck. See, for example,  FIG. 23 . There is no need for a pallet to support the arrays of gas cylinders, as is generally relied on in the conventional art. Thus, 72 gas cylinders can be shipped in a truck using roughly the same shipping volume and footprint as the conventional 60-unit (5-level high) cylinder shipment configuration requires. 
         [0055]    While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.