AU2019201893A1 - Overhead rolling door packaging - Google Patents

Abstract

C:\Interwoe\NRPortbI\DCC\KMII8476441 L.docx-9/03/2019 Abstract Disclosed is a cradle for a substantially cylindrical object, such as an overhead rolling door curtain. The cradle includes a substantially flat base, two side walls, an arcuate top surface extending between the side walls and a dividing surface extending between the side walls and located between the base and the arcuate surface. The base, side walls and dividing surface together create an open-ended passage through the cradle. The arcuate surface, side walls and dividing surface together also create a second open-ended passage through the cradle. The arcuate surface includes a gap that separates the arcuate surface into two arcuate surface portions. Two or more cradles can be connected by a plank that is fitted into the gap of each cradle and extending between the cradles to make a complete support. [Fig. 1] - 110

Description

OVERHEAD ROLLING DOOR PACKAGING

TECHNICAL FIELD [0001] The present invention generally relates to packaging for an overhead rolling door, suitable for use in storage or transport of such doors prior to installation.

PRIOR APPLICATION [0002] The present application claims priority from Australian Provisional Patent Number 2018900908, the contents of which is hereby included in its entirety.

BACKGROUND [0003] Packaging and transport of overhead rolling doors requires care and planning. Prior to installation, such doors are relatively easy to damage if handled incorrectly, as the door curtain is made from thin sheet material. For example, simply lifting a rolled curtain using a forklift has the potential to dent or scratch the door curtain.

[0004] Further, due to the difficulty of handling the packaged rolling door curtains, when loading a truck it is necessary to carefully plan the order in which the door curtains will be required. The doors are generally customised, with only a single or small number of doors to be delivered to a particular location. However, as the doors are loaded to a truck using a crane, they must be stacked, only permitting the doors at the top to be accessed. Therefore, they must be selected and loaded in the reverse order to which they will be unloaded, thereby requiring careful planning and making changes to such plans inconvenient.

[0005] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

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-2SUMMARY [0006] According to one example aspect of the invention, there is provided a cradle for a substantially cylindrical object, the cradle comprising: a substantially flat base; two side walls extending from the base; an arcuate top surface extending between the side walls; and a dividing surface extending between the side walls and located between the base and the arcuate surface; wherein the base, side walls and dividing surface together create an open-ended passage through the cradle.

[0007] In one form, the arcuate surface, side walls and dividing surface together create a second open-ended passage through the cradle. In another form, the cradle further comprises one or more ribs extending between the arcuate surface and the dividing surface.

[0008] In an example form, the side walls each have a concave outer surface. Such a feature is advantageous not only for the strength that such a configuration provides for supporting the cylindrical object, but also for providing a wide opening to the passage through the cradle that can assist with insertion of a blade of a forklift.

[0009] In other particular, but non-limiting, example forms: the arcuate surface extends beyond an end of the side walls to form a lip; the lip includes a blending rib that blends the lip with the side wall; and the base has one or more strengthening ribs on an outer surface.

[0010] Preferably, the cradle is formed as a single item. Also preferably, the first open-ended passage is sized to receive a blade of a forklift and/or the second open-ended passage is sized to receive a packing strap.

[0011] In one form, the arcuate surface comprises a gap that separates the arcuate surface into two arcuate surface portions. In another form, the side walls each comprise a cutout adjacent to the gap in the arcuate surface, the gap and the cutouts together being shaped to accept a plank.

[0012] According to another example aspect, there is provided a support for a substantially cylindrical object, comprising two or more cradles substantially as defined herein, the cradles being connected by a plank that is fitted into the gap of each cradle and

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-3 extending between the cradles. In one form, the plank extends beyond an outer side of each cradle.

[0013] According to yet another example aspect, there is provided an overhead rolling door curtain packaged for transport, comprising: a rolling door curtain in a rolled configuration; and two or more cradles, each substantially as defined herein; wherein each cradle is attached to the rolling door curtain using a strap that passes around the outside of the rolling door curtain and through the second open-ended passage.

BRIEF DESCRIPTION OF FIGURES [0014] Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but nonlimiting embodiment, described in connection with the accompanying figures, wherein:

[0015] Figure 1 illustrates an isometric view of an overhead rolling door curtain packaged for transport;

[0016] Figure 2 illustrates an enlarged portion of Figure 1 as denoted by Detail A;

[0017] Figure 3 illustrates an end view of the packaged overhead rolling door curtain from Figure 1 in position on the forks of a forklift;

[0018] Figure 4 illustrates an upper angle isometric view of a cradle according to an embodiment of the invention;

[0019] Figure 5 illustrates a plan view of the cradle from Figure 4;

[0020] Figure 6 illustrates a side view of the cradle from Figure 4;

[0021] Figure 7 illustrates a front view of the cradle from Figure 4;

[0022] Figure 8 illustrates a bottom view of the cradle from Figure 4;

[0023] Figure 9 illustrates a low angle isometric view of the cradle from Figure 4;

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-4[0024] Figure 10 illustrates an upper angle isometric view of a cradle according to another embodiment of the invention; and [0025] Figure 11 illustrates a plan view of the cradle from Figure 10.

DETAILED DESCRIPTION [0026] The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

[0027] In the Figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts throughout the Figures.

[0028] Referring to Figure 1, a curtain 10 of an overhead rolling door is shown packaged for transport in accordance with the invention. The rolled curtain 10 is supported on a number of pallets, or cradles 12, and a plank 15 that extends between the cradles 12. The plank 15 is also resting on a number of blocks 16 that are preferably not attached to the plank 15 and do not form an integral part of the packaging. The blocks 16 can be used as shown but are not always required.

[0029] Each cradle 12 is attached to the rolled curtain 10 by a strap 18, which is preferably made from plastic, but in other embodiments may be made from steel or any other suitable material. Padding 19 in the form of corrugated cardboard or another suitable material is placed between the strap 18 and the curtain 10 to prevent any damage to the curtain 10 from movement or rubbing of the strap 18 on the surface of the curtain 10.

[0030] The curtain 10 is also typically covered by a wrapping 20 prior to being placed on the cradles 12, as can be seen in Figure 3. Such a wrapping 20 is typically in the form of a soft plastic, but other suitable materials may be used. The wrapping 20 ensures that the curtain 10 remains rolled while being placed on the cradles 12 and while the straps 18 are attached. The wrapping 20 also helps protect the curtain 10 from damage during transport or from rubbing with the cradles 12 or plank 15.

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-5 [0031] The packaged curtain 10 can be lifted and moved by inserting the blades 22 of a forklift through the cradle 12, as shown in Figures 2 and 3. While this would normally damage the curtain 10 if lifted directly in this way, the cradle 12 allows the curtain 10 to be lifted without damage. Similarly, the cradles 12 allow the rolled curtain to be placed on shelves or rails in a warehouse or on a truck, thereby greatly simplifying storage and transport of the curtains 10.

[0032] Referring to Figures 4 to 9, a preferred embodiment of the cradle 12 is shown separate to the curtain 10. The cradle includes a base 23 that is flat to allow the cradle 12 to be stable when placed on a surface or the ground. Ribs 24 on a lower or outer surface of the base 23 increase the strength of the base 23, however these ribs 24 are optional additions that may be omitted in alternative embodiments or be located on a different surface or in a different configuration. The base 23 also includes holes 25 that reduce the amount of material required to manufacture the cradles 12.

[0033] The base 23 is connected to the bottom of side walls 26. The top of the side walls 26 are connected by a top surface 28. The top surface 28 is an arcuate shape so that it substantially matches and provides even support to the cylindrical shape of the rolled curtain 10.

[0034] The top surface 28 has tapered end portions 29 that extend past the end of the side walls 26 to form a lip. The end portions 29 are blended with the end of the side walls 26.

[0035] A dividing surface 30 extends between the side walls 26 at a position between the base 23 and the top surface 28. The base 23, side walls 26 and dividing surface 30 together creating a passage 32 through the cradle 12. This passage 32 is open ended, thereby providing an opening through which the forklift blades 22 can be inserted. The dividing surface 30 provides a flat and stable surface to abut the blades 22 when the cradle 12 is lifted.

[0036] In a similar manner, the top surface 28, side walls 26 and dividing surface 30 together create a second passage 33 through the cradle 12. This second passage 33 is also

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-6open ended, providing an opening through which the straps 18 can be passed when securing the rolled curtain 10 to the cradle 12. The dividing surface 30 ensures that the forklift blades 22 do not contact the rolled curtain 10 or the straps 18, preventing any damage to either of these components due to lifting by the forklift.

[0037] In the embodiment shown, the top surface 28 includes a gap 34 that separates the top surface 28 into two separate portions. The gap 34 allows for connecting adjacent cradles 12 using the plank 15. In the embodiment shown, the strap 18 passes around the outside of the plank, thereby securing both the plank 15 and the cradle 12 to the curtain 10. In a preferred embodiment, however, the strap 18 actually passes above the plank 15, as the cradle 12 being secured to the rolled curtain 10 is sufficient for the cradle 12 to hold the plank 15 in place.

[0038] Additional support is provided to the top surface 28 by vertical ribs 36 extending between the top surface 28 and the dividing surface 30. These ribs 36 are placed wide enough, however, that the second passage 33 is still wide enough for the straps 18 to be passed through.

[0039] Ribs are typically not used below the dividing surface 30, however, due to the need to keep the passage 32 wide enough to allow the blades 22 of the forklift to be inserted.

[0040] In the embodiment shown, the dividing surface 30 is also broken into two portions, in a similar way to the arcuate top surface 28. It will be appreciated that in alternative embodiments the dividing surface 30 may be a single surface that extends substantially the entire length of the cradle 12, in the same way that the top surface 28 may actually also be a single surface in some alternative embodiments.

[0041] Strengthening ribs 38 are located on the inner surface of the side walls 26, as shown in Figures 4 and 5. There may be a single rib 38, two ribs 38 as shown in the alternative embodiment of Figures 10 and 11, or any other number of ribs 38 on the side walls 26 as may be considered necessary for strengthening purposes. Similarly, other walls

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-Ίον surfaces of the cradle 12 may also include strengthening ribs in various alternative embodiments as may be found to be necessary.

[0042] The side walls 26 of the embodiment shown are curved, so that the cradle 12 is narrower in a central portion than at the ends. That is, an outer surface of each side wall 26 is concave. This curve causes the ends of the passage 32 to be flared, assisting with insertion of the blades 22 of the forklift by guiding them if they are not centred.

[0043] The hourglass shape of the cradle 12 also increases the lateral rigidity when compared to an embodiment that has straight sides. While a cradle 12 with straight sides is still considered to fall within the scope of the invention, such an embodiment would be prone to collapse more easily than the preferred embodiment with curved side walls 26.

[0044] The cradles 12 may optionally be used with or without one or more of the planks 15.

[0045] The cradles 12 are constructed from plastic. The preferred embodiment is moulded as a single item. It will be appreciated, however, that many other suitable materials could be used in alternative embodiments, such as but not limited to wood or composite materials. These alternative forms may be formed as a single item as well, or may be formed from a number of components that are assembled.

[0046] The cradles 12 and/or planks 15 are intended as cheap, single use, throwaway or recyclable items, similar to standard packaging materials such as plastic wrapping and cardboard. Of course, it would also be possible to make some or all items, particularly the cradles 12, as sturdier, reusable items.

[0047] The cradles 12, and particularly the complete support including multiple cradles 12 and plank 15, allow for significantly improved transport of door curtains 10. Where the curtains 10 previously needed to be lifted by a crane, they can now be easily moved by a forklift without the risk of damage to the curtain 10.

[0048] The use of a forklift in conjunction with the support provided by the cradles 12 and/or plank 15 is particularly advantageous because it allows the door curtains 10 to be

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-8placed on racks on a truck, rather than being stacked. This means that there is less need to plan the order in which the curtains 10 will be removed, as any chosen curtain, or at least a larger number, can be accessed at any given time.

[0049] While the preferred embodiment described shows a curtain 10 of an overhead rolling door being packaged using cradles 12, it will be appreciated that the invention could be performed with a wide variety of other substantially cylindrical objects.

[0050] In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as front and rear, inner and outer, above and below and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0051] Whilst the present invention has been described with reference to particular embodiments, it will be understood that many modifications will be apparent to those skilled in the art. All such variations and modifications should be considered to fall within the scope of the invention as broadly described and as claimed below.

[0052] Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises or comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims (15)

1. The claims defining the invention are as follows:

   1. A cradle for a substantially cylindrical object, the cradle comprising:

   a substantially flat base;

   two side walls extending from the base;

   an arcuate top surface extending between the side walls; and a dividing surface extending between the side walls and located between the base and the arcuate surface;

   wherein the base, side walls and dividing surface together create an open-ended passage through the cradle.
2. 2. The cradle according to claim 1, wherein the arcuate surface, side walls and dividing surface together create a second open-ended passage through the cradle.
3. 3. The cradle according to any one of the preceding claims, wherein the cradle further comprises one or more ribs extending between the arcuate surface and the dividing surface.
4. 4. The cradle according to any one of the preceding claims, wherein the side walls each have a concave outer surface.
5. 5. The cradle according to any one of the preceding claims, wherein the arcuate surface extends beyond an end of the side walls to form a lip.
6. 6. The cradle according to claim 5, wherein the lip includes a blending rib that blends the lip with the side wall.
7. 7. The cradle according to any one of the preceding claims, wherein the base has one or more strengthening ribs on an outer surface.
8. 8. The cradle according to any one of the preceding claims, wherein the cradle is formed as a single item.
9. 9. The cradle according to any one of the preceding claims, wherein the first openended passage is sized to receive a blade of a forklift.

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10. 10. The cradle according to any one of the preceding claims, wherein the second openended passage is sized to receive a packing strap.
11. 11. The cradle according to any one of the preceding claims, wherein the arcuate surface comprises a gap that separates the arcuate surface into two arcuate surface portions.
12. 12. The cradle according to claim 11, wherein the side walls each comprise a cutout adjacent to the gap in the arcuate surface, the gap and the cutouts together being shaped to accept a plank.
13. 13. A support for a substantially cylindrical object, comprising two or more cradles as defined by claim 12, the cradles being connected by a plank that is fitted into the gap of each cradle and extending between the cradles.
14. 14. The support according to claim 13, wherein the plank extends beyond an outer side of each cradle.
15. 15. An overhead rolling door curtain packaged for transport, comprising:

    a rolling door curtain in a rolled configuration; and two or more cradles, each defined according to any one of claim 2 or claims 3 to 14 when dependent on claim 2;

    wherein each cradle is attached to the rolling door curtain using a strap that passes around the outside of the rolling door curtain and through the second open-ended passage.