US20060113204A1

US20060113204A1 - Reusable packaging system

Info

Publication number: US20060113204A1
Application number: US11/263,803
Authority: US
Inventors: Jurgen Boche; Michael Birkinbine
Original assignee: Individual
Current assignee: HNI Technologies Inc
Priority date: 2002-12-02
Filing date: 2005-11-01
Publication date: 2006-06-01
Also published as: US20040104143A1; US7032747B2

Abstract

A reusable packaging system is disclosed in which a series of thermoformed trays are used to mount six spider type office chair bases. Three bases are mounted in an inverted position on the tray and three bases are mounted upright. A stack of load trays may be constructed with the bottom-most tray fastened to a standard pallet. The stack is plastic wrapped and shipped. After unloading, empty trays may be stacked in a nested arrangement and returned for reuse making for a simple, reliable and inexpensive system.

Description

This application is a continuation of application Ser. No. 10/307,742, filed on Dec. 2, 2002, entitled “Reusable Packaging System”, and applicants claim the benefit of the filing date thereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to a reusable packaging system and more particularly to a reusable packaging system for spider-type chair bases with each base having a hub and five spokes where the system includes support trays having about the same length and width as a standard pallet.
2. Description of the Related Art
Packaging systems have been in existence for many years including packaging systems for handling multiple items bundled together. See for example U.S. Pat. Nos. 758,239; 819,259; 3,910,411; 4,088,225; 4,170,297; and 6,056,121.
Packaging frequently concerns itself with enclosing an item or items to be transported in the smallest volume consistent with item protection. Another consideration is the ability to stack packaged items on a standard pallet so that the packaged items can be easily moved by a forklift truck. By standard pallet, it is meant a pallet having length and width dimensions of about 42 inches by about 48 inches.
Spider-type chair bases are particularly difficult to efficiently package because of their awkward shape.

BRIEF SUMMARY OF THE INVENTION

Difficulties previously encountered have been overcome by the present invention. What is described here is a reusable packaging system for multiple items of similar shape comprising a plurality of trays, each tray having a central panel, a peripheral skirt and a top surface with a plurality of recesses for receiving a first plurality of items in a first position and a plurality of mounds for receiving a second plurality of items in a second position, the second position being opposite to that of the first position. The trays are stacked upon one another in the same orientation with plurality of items being sandwiched between trays so as to alternate with the trays when the reusable packaging system is used to transport the items and the trays are nestable with one another when the trays are not being used to transport items.
There are a number of advantages, features and objects achieved with the present invention which are believed not to be available in earlier related devices. For example, one advantage is that the present invention provides a packaging system that is especially suited for the efficient transport of six spider-type chair bases per support tray within the dimensional perimeters of a standard pallet where as many as seven or eight trays may be bundled together. Another object of the present invention is to provide an efficient packaging system that allows empty trays to be nested and returned for reuse. A further advantage of the present invention is that the packaging system is relatively inexpensive, easy to use and very efficient.
A more complete understanding of the present invention and other objects, advantages and features thereof will be gained from a consideration of the following description of a preferred embodiment read in conjunction with the accompanying drawing provided herein. The preferred embodiment represents an example of the invention which is described here in compliance with Title 35 U.S.C. section 112 (first paragraph), but the invention itself is defined by the attached claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is an elevation view of a spider-type chair base.
FIG. 2 is a top plan view of the chair base illustrated in FIG. 1.
FIG. 3 is an isometric view of a support tray.
FIG. 4 is a top plan view of the tray illustrated in FIG. 3.
FIG. 5 is a partial sectional view taken along line 5-5 of FIG. 4.
FIG. 6 is a partial sectional view taken along line 6-6 of FIG. 4.
FIG. 7 is an upward looking isometric view of the tray illustrated in FIGS. 3-6.
FIG. 8 is a downward looking isometric view of a tray on which is mounted six chair bases.
FIG. 9 is an isometric view of a standard pallet.
FIG. 10 is an elevation view of a stack of seven trays, each with six chair bases.
FIG. 11 is a stack of trays and bases as illustrated in FIG. 10 but with a plastic wrap, a layer of plywood and strapping bands.
FIG. 12 is an elevation view of a stack of nested trays.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

While the present invention is open to various modifications and alternative constructions, the preferred embodiment shown in the various figures of the drawing will be described herein in detail. It is understood, however, that there is no intention to limit the invention to the particular embodiment, form or example disclosed. On the contrary, the intention is to cover all modifications, equivalent structures and methods, and alternative constructions falling within the spirit and scope of the invention as expressed in the appended claims, pursuant to Title 35 U.S.C. section 112 (second paragraph).
As an introduction to what is disclosed here, reference is made to FIGS. 1 and 2 which illustrate a spider-type chair base 10. The chair base includes a central cylindrical hub 12 and five legs or spokes 14, 16, 18, 20, 22. A caster (not shown) is attached at the extended end of each spoke. In turn, the chair base forms the lower portion of an office or work chair, such as that disclosed co-pending application Ser. No. 10/077,409, assigned to the assignee of the present application.
Chair bases may be manufactured or finished at a location distant from an assembly location where a chair base is mated with an upper portion of a chair. Generally the chair bases are cast in a casting shop at a distance from the chair assembly location. The chair bases may then be shipped to a polishing location and from there to the assembly location or to a paint location. From the paint location, the chair bases are shipped to the assembly location for chair completion. During each shipment, it is desirable that the chair bases be handled so as not to mar the surface finish of the bases.
To accomplish transportation of chair bases efficiently and economically, a system has been developed which includes the use of support structures, such as thermoformed trays. One such tray 24 is illustrated in detail in FIGS. 2-7. Each tray includes a central panel 25 with a top surface 26, a bottom surface 27 and a depending peripheral skirt 28. Formed in the top surface 26 are arrays of receiving structures, such as a plurality of recesses and a plurality of mounds. It is apparent that some of the recesses in plan view have the configuration of a chair base, namely, a central recess and five radiating recesses. There are three such arrays, such as five pointed “star” recesses 30, 32, 34, in a generally triangular relationship with each other. Each of the star recesses include a central, cup-like, cylindrical recess 36, 38, 40. Radiating from the central recess 36 of the star recess 30 are five elongated spoke recesses 42, 44, 46, 48, 50. Radiating from the central recess 38 of the star recess 32 are five spoke recesses 52, 54, 56, 58, 60. Extending from the central recess 40 of the star recess 34 are five spoke recesses 62, 64, 66, 68, 70. The triangular relationship may be visualized in FIG. 4 when a line is imagined between the recesses 36 and 38, another line imagined between the recesses 38 and 40, and a third line imagined between the recesses 36 and 40. It should also be noted that as shown in FIG. 4 the star recesses 30 and 32 are generally aligned rotationally, but that the star recess 34 is not aligned. The star recess 34 is disposed rotationally slightly more in a clockwise direction than the star recesses 30 and 32.
The top surface 26 also includes three cup- like recesses 80, 82, 84. Each of the cup-like recesses are related to five generally circular mounds forming an array of receiving structures. For example, the cup-like recess 80 is related to a first group of five circular mounds 90, 92, 94, 96, 98. The cup-like recess 82 is related to a second group of five mounds 100, 102, 104, 106, 108. The third cup-like recess 84 is related to a third set of five mounds 110, 112, 114, 116, 118. Referring again to FIG. 4, another relationship may be visualized by imagining three lines connecting the recesses 80, 82, 84 in triangular fashion as was done with the recesses 34, 36, 38. Furthermore, as with the star recesses 30, 32, 34, the three recesses 80, 82, 84 and their corresponding five mounds arc not rotationally aligned. The array including the recess 82 and corresponding mounds 100, 102, 104, 106, 108 is shown rotated slightly more clockwise than are the arrays of recesses 80, 84, and their corresponding mounds; this relationship may be visualized by drawing imaginary lines between the recess 80 and the mound 90 and between the recess 84 and the mound 110, and comparing those lines with an imaginary line from the recess 82 to the mound 100.
Three reinforcing recesses 120, 122, 124 are also found in the top surface 26 near the periphery to stiffen the tray. The bottom surface 27 of the tray 24, FIG. 7, has the opposite sides of the star recesses 30, 32, 34 (with the cupike recesses 36, 38, 40) and the cup- like recesses 80, 82, 84 and appear as downwardly extending projections 30 a, 32 a, 34 a, 36 a, 38 a 40 a, 80 a, 82 a, 84 a, respectively.
The first group of star recesses 30, 32, 34 are configured to receive three chair bases of the type shown in FIGS. 1 and 2 in which the chair bases are disposed in a first or inverted position. The second group of cup- like recesses 80, 82, 84 and related groups of five mounds 90, 92, 94, 96, 98; 100, 102, 104, 106, 108; and 110, 112, 114, 116, 118 receive three chair bases in a second or upright disposition. The trays are formed of high density polyethylene having a nominal thickness of about 0.100 inches. The starting thickness of the polyethylene sheet, before forming, is about 0.187 inches. A resilient strip 126, FIG. 4, may be used in the spoke recesses, such as the recess 52, if further cushioning is desired for the inverted bases.
An example of a base loaded tray is illustrated in FIG. 8. Six mounted chair bases are shown with three of the chair bases 132, 134, 136 being in an inverted position and three chair bases 138, 140, 142 being disposed upright in a position exactly opposite to the position of the first mentioned group of chair bases. The chair base 132 includes a hub 250 and five legs 252, 256, 256, 258, 260; the chair base 134 includes a hub 262 and five legs 264, 266, 268, 270 272; and the chair base 136 includes a hub 274 and five legs 276, 278, 280, 282, 284. The chair base 138 includes a hub 286 and five chair legs 288, 290, 292, 294, 296; the chair base 140 includes a hub 298 and five legs 300, 302, 304, 306, 308; and the chair base 142 includes a hub 310 and five legs 312, 314, 316, 318, 320. Also, as shown in FIG. 8, the inverted chair bases 132, 134, 136 are supported in the tray 24 by having tops of the hubs and upper portions of the legs disposed in the star recesses 30, 32, 34, respectively. For example, the hub 250 of the chair base 132 is located in the recess 36 and the legs 252, 254, 256, 258, 260 of the chair base 132 arc located in the spoke recesses 42, 44, 46, 48, 50, respectively. The hub 262 of the chair base 134 is located in the recess 38 and the legs 264, 266, 268, 270, 272 are located in the spoke recesses 52, 54, 56, 58, 60, respectively. The hub 274 of the chair base 136 is located in the recess 40 and the legs 276, 278, 280, 282, 824 are located in the spoke recesses 62, 64, 66, 68, 70, respectively. As also shown in FIG. 8, the upright chair bases 138, 140, 142 are supported in the tray 24 by having bottoms of the hubs and extended ends of the legs in the cuplike recesses 80, 82, 84, respectively and their respective circular mounds. For example, the hub 286 of the chair base 138 is located in the cup-like recess 80 and the extended ends of the legs 288, 290, 292, 294, 296 are disposed, respectively, in the mounds 90, 92, 94, 96, 98. The hub 298 of the chair base 140 is located in the cup-like recess 82 and the extended ends of the legs 300, 302, 304, 306, 308 are disposed in the circular mounds 100, 102, 104, 106, 108, respectively. The hub 310 of the chair base 142 is located in the cuplike recess 84 and the extended ends of the legs 312, 314, 316, 318, 320 are disposed in the circular mounds 110, 112, 114, 116, 118, respectively.
Illustrated in FIG. 9 is an example of a standard pallet 150 having a depth dimension represented by the line 152 of about forty-eight inches and a width dimension represented by the line 154 of about forth-two inches. For handling and shipping, the loaded trays are stacked to a height of about sixty-five to seventy-two inches or from between six to nine loaded trays.
The height of the stack is usually a function of ease of loading and unloading and the size of the truck used for transportation.
There is illustrated in FIG. 10 a stack of trays 158 including a bottom tray 160 connected to the pallet 150 and six additional loaded trays 161, 162, 163, 164, 165, 166. As can been seen, the trays are each aligned in the same orientation as are the chair bases. The bottom tray 160 may be attached by screws (not shown) to a length of two by four wood 167 which in turn is bolted (not shown) to the pallet. Each stacked tray (above the lowest tray) is supported by the hubs of the chair bases. For example, the hubs 250, 262, 274, 286, 298, 310, FIG. 8, support the next higher stacked tray. In particular the weight of each loaded tray is transmitted to the hubs of the chair bases of the tray below. When a chair base is inverted, such as the chair bases 132, 134, 136, FIG. 8, the five legs or spokes are cradled by the five recesses of the supporting tray, such as the recesses 62, 64, 66, 68, 70, FIG. 4, and the bottoms of the hubs, such as the hubs 250, 262, 274, are captured by projections of the next higher trays, such as the projections 36 a, 38 a, 40 a, FIGS. 5, 6 and 7. With regard to the upright chair bases, such as the chair bases 138, 140, 142, FIG. 8, the bottom portions of the hubs are captured in the cup-like recesses, such as the recesses 80, 82, 84, FIGS. 3-6 and 8, and the top portions of the hubs, such as the hubs 286, 298, 310, FIG. 8 are captured by projections of the next higher trays, such as projections 80 a, 82 a, 84 a, FIGS. 5 and 7. This supports the next tray and constrains the chair bases.
The arrangement of a tray and six chair bases, three inverted, three upright, is repeated so that a stack of six to nine but more likely seven or eight layers of chair bases are arranged on a pallet as shown in FIG. 10. A plywood sheet 170, FIG. 11, may be placed across the top or uppermost layer of chair bases and then the stack may be shrink wrapped with a plastic film 172. Steel or plastic bands 180, 182, may also be used or may be used instead of a plastic wrap. Another pair of bands, not shown, may be placed perpendicular to the first mentioned bands 180, 182. A preferred arrangement is simply to wrap the stack with plastic only. The plywood and strapping bands may not be needed.
Reference is now made to FIG. 12 where there is illustrated a stack 190 of empty trays. After shipment of chair bases, the trays are returned for reuse. On the return trip the trays are nested one within another on top of the pallet 150 as shown. Because there are no longer layers of chair bases, as many as twenty trays 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214 may be stacked, banded and returned to the chair base casting company, for example, or to the paint and/or polishing company for reuse.
In operation a metal casting or a polisher or a painting company loads six chair bases on a single tray with three of the chair bases being inverted and three of the chair bases being upright as shown in FIG. 8. A tray attached to a pallet acts as a bottom layer of alternating trays and chair bases. After the bottom or lower most tray is loaded with bases, a second tray is positioned over the bottom tray and is loaded with bases. The trays are stacked so that the chair bases are sandwiches between two trays. Each of the trays are in exactly the same orientation or alignment so that the six chair bases are constrained, both by a lower tray to which the chair bases are mounted and by the next upper tray which also engages the same chair bases with its bottom surface. Each tray is positioned on top of six chair bases and loaded with its own six bases. This process continues until seven or eight alternating layers of trays and chair bases are formed. At seven or eight layers of chair bases the stacked trays and chair bases stand approximately between sixty-five to seventy-two inches from the bottom of the pallet to the uppermost tray. Thereafter, a plastic wrap is placed around the stack. A piece of plywood may be placed over the uppermost group of chair bases and metal or plastic strapping bands may also be used to securely fasten the stack together. After the stack is secured, the entire stack is in a stable condition and it may be moved by a fork lift truck to a vehicle for transporting the chair bases to a distant location. It is noted that already loaded trays may be stacked if desired.
The trays are constructed with a slanted peripheral skirt so as to nest one on top of another as shown in FIG. 12 after the chair bases have been unloaded. In this mode approximately twenty trays may be loaded on a pallet and banded for a return trip thereby allowing the trays to be reused for future shipments of chair bases. In this fashion a reliable and efficient packaging system is arranged which is also inexpensive because the trays, bands and pallets may used repeatedly.
The above specification describes in detail a preferred embodiment of the present invention. Other examples, embodiments, modifications and variations will, under both the literal claim language and the doctrine of equivalents, come within the scope of the invention defined by the appended claims. For example, more or less trays may be used in a stack, perhaps as a function of the vertical height of the chair base being transported; a plastic wrap may be used around the stack instead of bands or perhaps in addition thereto and it may be found that the upper plywood sheet can be dispensed with. These are all considered equivalent structures and will also come within the literal language of the claims as will other alternatives and many new technologies. There is no desire or intention here to limit in any way the application of the doctrine of equivalents nor to limit or restrict the scope of the invention.

Claims

1. A reuseable packaging system comprising:

a tray having a first product receiving structure of multiple portions and a second product receiving structure of multiple portions, the multiple portions of said first receiving structure being distributed among the multiple portions of said second receiving structure.

2. The system of claim 1 wherein:

said first product receiving structure being structured and dimensioned to engage a first product at a top surface thereof and said second product receiving structure being structured and dimensioned to engage a second product at a bottom surface thereof.

3. The system of claim 1 wherein:

said first product receiving structure being structured and dimensioned to engage a first product when the first product is in an inverted position and said second product receiving structure being structured and dimensioned to engage a second product when the second product is in an upright position.

4. The system of claim 3 wherein:

said first product receiving structure being structured and dimensioned to engage the second product when the second product is in an inverted position and said second product receiving structure being structured and dimensioned to engage the first product when the first product is in an upright position.

5. A reuseable packaging system for multiple items of similar shape comprising:

a plurality of trays, each tray having a top surface with a first receiving structure to enable the receipt of a first item when the first item is disposed in a first position and a second receiving structure to enable the receipt of a second item when the second item is disposed in a second position, each of said first and said second receiving structures having a plurality of portions, and said plurality of portions of said first receiving structure are distributed among said plurality of portions of said second receiving structure;

said plurality of trays being structured and dimensioned to be stackable after being loaded with the first and the second items and wherein the trays are structured and dimensioned to be supported in a stack by the first and second items when said reusable packaging system is used to transport the items; and

said plurality of trays being structured and dimensioned to be nestable when said trays are transported without items.

6. The system as claimed in claim 5 wherein:

said first receiving structure includes recesses; and

said second receiving structure includes mounds.

7. The system as claimed in claim 6 wherein:

said first receiving structure includes a group of five recesses; and

said second receiving structure includes a group of one recess and four mounds.

8. The system as claimed in claim 7 wherein:

each tray of said plurality of trays is generally the same size; and

a bottom tray of a stack of trays is structured and dimensioned to be fastened to a pallet.

9. The system as claimed in claim 5 wherein:

each tray of said plurality of trays is generally the same size as a supporting pallet.

10. The system as claimed in claim 5 wherein:

said first receiving structure is structured and dimensioned differently from said second receiving structure.

11. The system as claimed in claim 5 including:

a pallet; and wherein

a bottom tray of a stack of said plurality of trays is mounted to said pallet.

12. The system as claimed in claim 11 wherein:

the items to be received are chair bases; and

said plurality of trays is stackable on said pallet; and including

material adapted to wrap said stackable plurality of trays and items receivable by said trays.

13. The system as claimed in claim 12 wherein:

said stackable plurality of trays comprises six to eight trays with mounted chair bases.

14. The system as claimed in claim 11 wherein:

said plurality of trays are stackable in a nested disposition on said pallet when said trays are empty.

15. The system as claimed in claim 14 wherein:

said plurality of nested trays are stackable about twenty trays high.

16. The system as claimed in claim 15 including:

a plywood sheet adapted to be mounted to an uppermost tray of said stackable trays and said plywood is adapted to be wrapped with said stackable trays.

17. The system as claimed in claim 10 including:

a plurality of first receiving structures arranged in a triangular configuration.

18. The system as claimed in claim 17 wherein:

a receiving structure of said plurality of first receiving structures is rotationally misaligned in relation to other receiving structures of said plurality of first receiving structures.

19. The system as claimed in claim 6 including:

cushion strips positioned in selected recesses of said first receiving structure.

20. A reusable packaging system comprising:

a first support structure having a top surface and a bottom surface;

said top surface of said first support structure having a first array of receiving structures to enable receipt of a first group of products to be packaged in an inverted position and a second array of receiving structures to enable receipt of a second group of products to be packaged in an upright position, the first array of receiving structures being distributed among the second array of receiving structures;

said bottom surface of said first support structure being structured and dimensioned to enable engagement with a group of products to be packaged disposed in the inverted position and with a second group of products to be packaged disposed in the upright position; and

a second support structure essentially identical to said first support structure and positioned above said first support structure, said second support structure having top and bottom surfaces;

said top surface of said second support structure having a first array of receiving structures to enable receipt of a third group of products to be packaged in an inverted position and a second array of receiving structures to enable receipt of a fourth group of products to be packaged in an upright position;

said bottom surface of said second support structure being structured and dimensioned to enable engagement with the first group of products to be disposed in the inverted position on said first support structure and with the second group of products to be disposed in the upright position on said first support structure; and

said second support structure being nestable in said first support structure when said first and said second support structures are empty of products to be packaged.

21. The system of claim 20 wherein:

said first support structure is a first tray;

said second support structure is a second tray;

said first array of receiving structures of said top surface of said first tray includes a cup shaped recess and a plurality of radiating recesses; and

said second array of receiving structures of said top surface of said first tray includes a cup shaped recess and a plurality of surrounding mounds.