Abstract:
A packaging system for soft-walled plastic containers of tapered or other non-cylindrical shapes has a supporting base to which the containers are secured, with a superposed positioning means engaging the upper portions of the containers; and load transfer spacer sheets extending upwardly in substantially coplanar relation with the tops of the containers, to support a superposed similar package, for palletizing. The package may be strapped, horizontally or vertically and used in plasti-wrapped multi-tier pallet loads. The supporting base may be a tray, which can be of the nesting variety. Formed or die-cut top sheets can be used in combination with the load-transfer spacer sheets

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     CIP of applications Nos.: Ser. No. 11/082,984 filed Mar. 18, 2005 and Ser. No. 11/594,187 filed Nov. 8, 2006. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       REFERENCE TO MICROFICHE APPENDIX  
       [0003]     Not Applicable  
       BACKGROUND OF THE INVENTION  
       [0004]     1. This invention is directed to a packaging system for multi-pack stackable structured packaging for shaped containers.  
         [0005]     2. There exists a large family of taper-shaped containers, differing both in shapes and sizes, used for pourable or pumpable fluids, most of which containers are soft, thin-walled plastic bottles. Owing to the thin-ness of their soft, flexible walls these containers are subject, when loaded externally, to deformation with consequent stress cracking, so that they presently are transported in a substantially loose-packed condition within substantially rigid, fully enclosed cardboard cartons.  
         [0006]     Cardboard packaging is used extensively in the Western world for an extremely wide range of goods. This “board”, primarily of the three-layer type having a corrugated core, is frequently used in a ‘once-off’ manner, and then either scrapped, or recycled. The adverse ecological burden that this represents is little recognised. The production, use and re-cycling of the vast quantities of material involved requires the ongoing destruction of forests and requires vast quantities of fuel (for transportation), water and power for initial production, and for recycling, when that is practiced.  
         [0007]     In the present matter of global warming, vast quantities of green-house gas are generated in the manufacture and subsequent disposal or re-utilization of cardboard (board) packaging. Any effective diminution in the quantity of board required for packaging, or increase in its utilization by way of re-use represents a significant reduction in the generation of green-house gases, and can provide a highly desirable reduction in the rates of world-wide de-forestation.  
         [0008]     A brief review of the background concerning the usage of corrugated cardboard (CC) establishes the following facts:  
         [0009]     In the United States CC-fibre is re-cycled twice on average: in Europe it is recycled four times. [source—Barbara Crowell—Pack3 conference Brussels May 3-4, 1993] 
         [0010]     In Asia CC is recycled so many times as to be significantly weaker and less water-resistant than US recycled fibre, so as to be unacceptable for further recycling.  
         [0000]     The reduction by one Tonne of Corrugated Board can lead to representative cost savings:  
         [0000]    
       
         
           
              Municipal Solid waste Management—$176; Municipal Wastewater management—$7;  
              Value of reduced Greenhouse Gas emissions—$19. Totalling Direct Savings $183.  
              A further indirect saving of $19 may also accrue. 
 
 The present invention, in common with the above-referred to Applications, aims at providing integrated structural packaging that particularly lends itself to being multi-tier stacked on a pallet for purposes of handling, shipping, storage and display, while minimizing the quantity of packaging material required to achieve the desired structural characteristics. 
 
           
         
       
     
         [0014]     In the above-referred patent applications the goods containers are primarily of substantially rigid, cylindrical form (including rectangular cylindrical sections), with the packaging having D-cut and other separators positioned between the respective containers, to provide mutual separation, combined with integration of the containers with the package, under the compressive effects of tensioned wrapping strap or straps.  
         [0015]     In the subject family of thin-walled plastic containers, most such containers are non-cylindrical, being shaped generally with an upwardly modified cross section, both for aesthetic and for hand-held purposes, and also to facilitate their withdrawal from their moulds. This tapered formation, allied with the thin-walled flexible structure of the containers militates against their satisfactory immobilization within, and integration with the containing package, under the compressive influence of external strapping, as taught in the forementioned Applications.  
       BRIEF SUMMARY OF THE INVENTION  
       [0016]     The present invention provides a packaging system for the bulk packaging of flexible walled containers of non-uniform section, wherein a plurality of the containers are mounted upon a tray, in secured relation thereto to form a package, having at least one integrating collar engaging at least some of the containers in secured, mutually spaced relation; and upwardly extending load transfer means to promote the load carrying capability of the package in the support of a superimposed like package or packages in stable, stacked relation therewith, usually for transportation by way of wooden pallets, which loads may be plasti-wrapped for transportation.  
         [0017]     The subject containers may have upwardly tapering walls to provide a portion of the container with an upwardly diminishing cross section.  
         [0018]     The subject containers may have screw cap closures; the subject integrating collar having a plurality of apertures in mutually spaced relation to receive a corresponding plurality of the cap closures extending in penetrating relation through the collar.  
         [0019]     The subject collar apertures may have flexible edge portions to enter undercut portions of the container located below the caps, to thereby engage the caps and secure the integrating collar to the containers. The collar may be of corrugated board or paperboard. The load transfer means may be in the form of board separators extending between the containers and having upwardly extending portions projecting substantially coplanar with the tops of the containers, to provide co-planar load-receiving means as support for a superimposed package. The board separators are preferably of vertically oriented corrugated board.  
         [0020]     The subject containers may be glued to the tray.  
         [0021]     The subject containers may be positioned on the tray by way of upturned board portions of the tray engaging edge portions of the lower extremity of respective ones of the containers.  
         [0022]     Selected adjoining ones of the subject containers may be joined by way of a low-tension adhesive.  
         [0023]     The subject load transfer means may comprise upwardly extending partition means having the lower end portion thereof secured to the tray, and extending upwardly between adjacent ones of the subject containers, with an upper edge portion of the partition means located substantially coplanar (flush) with the tops of the container caps, in load sharing relation therewith.  
         [0024]     The subject partition means may be convoluted when seen in plan view, with adjoining portions respectively extending laterally and longitudinally of the subject tray, in mutual stiffening relation.  
         [0025]     The subject partition means may have first and second portions in mutually inclined, normal relation, each portion extending in interdigitated stiffening relation with an adjoining, normally extending portion.  
         [0026]     The subject package may include low tension (frangible) glue as an attachment agent between package components and containers, and between adjoining containers, at their mutual contact areas.  
         [0027]     One embodiment may have a planar die-cut top sheet, having a series of die-cut apertures having radiating cut-lines, for penetration and capture of the caps of the respective containers. A further series, of laterally and of longitudinally extending cut lines or slots receive upwardly projecting tab portions of the convoluted (“Z”) dividers. The shoulder portions of the separators adjoining the tabs support the undersurface of the top sheet, and the tabs project through the cut slots and extend above the top sheet, to be substantially coplanar with the top surfaces of the projecting caps of the containers.  
         [0028]     A further embodiment provides a tray having slightly tapered walls, such that the trays may be nested. The top sheet may be dimensioned to fit into the base of the tray, enabling a number of trays and their associated top sheets to be packaged into a “solid” block for return shipping to the goods Supplier, for re-use. The tray wall height may be selected to match a predetermined number of top sheets, such as the five of a pallet stack.  
         [0000]     The Z-spacers may pack flat with the trays and top sheets. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0029]     Certain embodiments of the invention are described by way of illustration, without limitation thereto other than as set forth in the accompanying claims, reference being made to the accompanying drawings, wherein:  
         [0030]      FIG. 1  shows a first group of five containers A through E, of non-uniform section;  
         [0031]      FIG. 2  shows a second group of containers A through D of non-uniform section;  
         [0032]      FIG. 3  shows a third group of containers A through C of less usual shape;  
         [0033]      FIG. 4  is a plan view of a first embodiment package of containers, packaged in accordance with the present invention, and incorporating a load-bearing spacer;  
         [0034]      FIG. 5  is a side elevation of the  FIG. 4  package embodiment;  
         [0035]      FIG. 6  is a perspective view of the spacer of  FIGS. 4 and 5 ;  
         [0036]      FIG. 7  is a plan view of a second embodiment package of containers incorporating a top locator/load transfer cover;  
         [0037]      FIG. 8  is a perspective view of a further embodiment of a top locator/load transfer cover in an inverted position;  
         [0038]      FIG. 9  is a plan view of a loaded tray, before application of the transfer cover of  FIG. 8 , with four partition members shown in their assembled condition;  
         [0039]      FIG. 10  is a partial top perspective view of portions of a package having a planar die-cut top sheet, showing projecting container caps and upstanding spacer tabs;  
         [0040]      FIG. 11  is a plan view of the  FIG. 10  arrangement;  
         [0041]      FIG. 12  is a perspective view of a nestable tray;  
         [0042]      FIG. 13  is a perspective view of a top sheet matched to the  FIG. 12  tray; and,  
         [0043]      FIG. 14  is a perspective view of a portion of a store&#39;s trolley for use with nestable package components 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0044]     It will be understood by those skilled in the art that the above disclosure is directed primarily to specific embodiments of the present invention, and that the subject invention is susceptible of reduction to practice in other embodiments that fall within the scope of the appended claims.  
         [0045]     Referring to the drawings,  FIGS. 1, 2  and  3  illustrate a very small portion of an almost limitless assortment of plastic container ‘bottles’, many of which are “soft-walled”, and are suited for packaging in the presently disclosed high efficiency packaging, characterized by its integration of packaging components with the structure of the container, to form structural packages that are well adapted for multi-layer palletizing. It will be understood that ‘hard-walled’ containers, including other than plastic may also be susceptible of use within the present invention.  
         [0046]      FIG. 4  shows a package  10  including six shaped containers  12  mounted in a tray base  14  and having a spacer  16  of corrugated board secured by way of insert tabs  18  to the bottom  20  and wall  21  of the tray base  14  (see also  FIG. 6 ). The containers  12  are each secured by way of low-tension adhesive (not shown) to the package bottom  20 . The abutting side surfaces of containers  12  may also be mutually adhered by way of small patches of ‘low-tensile’ (strength) adhesive (not shown).  
         [0047]     A strap  17  may be used, which is positioned by corner slots  19  to engage and retain the ‘corner’ containers  12 .  
         [0048]     The top edge of the spacer  16  is substantially coplanar with the tops of the caps  24  of the containers  12  (see  FIG. 5 ), to supplement the load-bearing capacity of the containers  12 .  
         [0049]     Referring to  FIG. 7 , in this package embodiment  25 , a spacer such as  16  may be supplemented or replaced by a spacer/platform  26  shown in overlaid (but non-applied) relation with the base  14  and the containers  12 . The spacer/platform  26  has a die-cut sheet portion  28  with score-cut holes  30  that are sized to receive and engage beneath the lower edges of the caps  24 , so as to locate the top portions of the containers  12 , when the spacer/platform  26  is pushed down over the underlying caps  24 .  
         [0050]     The spacer platform  26  has an upstanding peripheral rim  32  that projects upwardly to be flush with the tops of the container caps  24 , so as to provide a supporting base for a superposed like package  10  or  25 , which would overly the rim  32 .  
         [0051]     It will be understood that for the package embodiment  25  the spacer  16  would be made shorter, so as to be flush with the bottom surface of the sheet portion  28  when sheet  28  has been pushed down to engage beneath the caps  24 .  
         [0052]     The load strength of corrugated boards in a range of board weights has been tested, using specimens reinforced against buckling failure by having two adjoining areas being bent mutually at an angle of about 90 degrees to form a so-called Z-spacer, it being understood that the corrugations are edge-on to the direction of applied load, to provide optimum columnar strength.  
         [0053]     Turning to  FIGS. 8 and 9 , a top locator/load transfer cover  40 , shown inverted, and illustrated as being of moulded paper board, has eight score-cut holes  30  to receive and engage beneath the lower edges of container caps, such as the caps  24  of  FIG. 5 .  
         [0054]     A central upstanding rib  42  of inverted U-section (when viewed in its inverted orientation of use) extends the length of the cover  40 . The rib  42  is dimensioned to be substantially coplanar with the tops of the container cans (such as  24 ). Laterally extending ribs  44  of similar cross-section intersect with rib  42  at upstanding caps  46 , the tops of ribs  44  being co-planar with the top of rib  42  and the caps  46 , and also with the container caps  24 , when assembled.  
         [0055]     The illustrated undersurface of the cover  40  forms passages  45  into which dividers  48  are slotted. The dividers  48  extend to the floor of the tray or base upon which the package contents would stand, to provide a contiguous, reinforced support structure. The dividers  48  and the interior width of the ribs  42 ,  44  may be dimensioned to provide a tight slide-in fit, or the dividers may be spot-glued in place, or located by ‘toe tabs’ fitted into tray recesses.  
         [0056]     It will be understood that different arrangements and smaller numbers of dividers may be used, in accordance with the need for separation of containers, and the desired load bearing capacity of the combined contents and package to meet pallet load requirements. Referring to  FIGS. 10 and 11 , the embodiment  101  has a bottom tray  102  with eight containers  104 , only one of which is fully represented. A top sheet  106  has eight container caps  108  projecting above, and engaged by respective die-cut cap apertures of the sheet  106 .  
         [0000]     Aperture tabs  110  are engaged beneath the lower edges of the caps  108 , to secure the top sheet  106 .  
         [0057]     Ten upstanding tab portions  112  project from die-cut tab apertures of the top sheet  106 . The upper edges of the tab portions  112  are coplanar with the tops of the container caps  108 , to provide support to the tray  102  of an overlying like package.  
         [0058]     The dividers  114  from which the tab portions  112  extend are supported by the tray  102  of the package, such that when packages  110  are stacked five-high as part of a pallet load, the dividers  114  and their associated projecting tab portions  112  provide substantially continuous columnar support from the bottom tray to the top of the stack of packages, as reinforcement to the load bearing capacity of the containers  104  and their respective caps  108 , which also form contiguous columnar supports from the bottom tray to the top of the package stack  
         [0059]     Turning to  FIGS. 12, 13  and  14 : a stackable tray  120 , has symmetrical sloped sides and ends that provide a shallow ‘draw’ angle, to enable it to be nested with like trays  120 , having the associated top sheets sized to the size of the bottom tray, so as to fit within the nested trays, and to fill the top tray to its upper edge, to provide a strong return package. The tray  120  is illustrated as having a slot-indented bottom, to engage the bottom of the Z-spacers, which may be provided with shallow, bottom-edge tabs to fit the slot indents. The trays  120  and top sheets  122  each have an oriented peg-slot  121 ,  123  that enables their ready separation by store shelf stockers, using a cart  124  having correspondingly oriented pegs  125 ,  127 . These pegs  125 ,  127  may be bayonet-mounted to the cart, such that a quarter twist will free the respective peg from the cart, enabling the ready downward and unobstructed removal of the trays  120  and top sheets  122  from off the pegs  125 ,  127 . The dividers  114  may be flattened and packaged separately for return, or packaged to the nested trays when the sizes are compatible.