CA2034526C - Dunnage - Google Patents

Abstract

Dunnage for automotive trim moldings comprises identical elongated, vacuum-formed strips each having upstanding, spaced apart posts and trim molding supporting bunks intermediate the posts with the bunks shaped to fit within trim moldings and support the Class A surfaces thereof spaced from the strip, and when corresponding ends of the strips are superimposed, the strips nest together in a compact space, and when the strips are reversed end-for-end, the posts support superjacent strips spaced vertically apart whereby the trim moldings are spaced from the superjacent strips.

Description

CPC 0102 P ;

2034S~6 3 Description DUNNAGE

7 Field of Invention 8 This invention relates to vacuum-formed dunnage for 9 storage and shipment of automotive trim and the like.
11 Background of Invention 12 A continuing problem in the manufacture of automobiles 13 has been the damage-free handling of body trim moldings during 14 shipment from the supplier to the assembly line and the storage lS at the line awaiting attachment to the vehicle body. Various 16 types and designs of packaging or dunnage have heretofore been 17 used but what has sufficed in the past is not sufficient to 18 protect the latest forms of trim whose Class A surfaces can be 19 easily scratched or marred-. With the development of trim having O Class A surfaces that can be easily scratched or marred, the 21 problems of protecting such surfaces during shipment have 22 increased.
23 Desirably, the nature of the dunnage to handle such trim 24 should be such as to prevent contact of the Class A surfaces with either other trim pieces or with the dunnage itself to 26 prevent scratching or marring of such surfaces. In addition;
27 the dunnage should be as inexpensive as possible because it is - 1 - 2 - 2034~26 3 used only once, and it should preferrably be capable of storage 4 in a compact space when awaiting use to minimize shipping and storage costs when delivered from the dunnage maker to the 6 automotive trim maker. The dunnage should be dimensionally 7 stable and lightweight, and when in use, should allow the 8 packaging of the maximum number of trim moldings in the most 9 compact space.
11 Summary of the Invention 12 I have found that the foregoing desirable features may 13 be embodied in a vacuum-formed dunnage of high-impact styrene 14 normally from .035~ to .160" in thickness. The dunnage is formed in elongated strips shaped to provide upright, spaced 16 apart posts between which are arranged trim receiving and 17 supporting bunks. The posts and bunks are so designed that when 18 the strips are arranged with corresponding ends superimposed, 19 they may be compactly nested together, while arranged in an _0 opposite end-for-end relation they may be stacked upon each 21 other. In such stacked relation, the posts serve to support 22 superjacent strips with the bunks vertically spaced apart to 23 receive the trim molding thereon.
24 The post design is such that when the strips are arranged in their stacked relation, the posts serve to lock the strips 26 against lateral or longitudinal displacement and the b~nks serve 27 to lock the trim moldings against lateral displacement. The -1 dunnage strips or sections are intended to be placed in cartons 2 or containers within which the trim is shipped. In one 3 embodiment of the invention, the dunnage sections are arranged 4 adjacent opposite ends of the container and the trim molding is placed on the dunnage sections to be supported by the bunks.
6 After a first layer of dunnage and the supported trim moldings 7 have been placed in the carton, a second layer of dunnage 8 sections is stacked on the first sections and a second layer of 9 trim molding is positioned on the second layer of dunnage sections. In like fashion, a carton is filled with layers of 11 dunnage sections and trim moldings and a compact package of 12 trim moldings is thus provided. The moldings are supported in 13 the package in an almost floating relation to the carton with 14 all Class A surfaces out of contact with the dunnage and adjacent trim moldings. As a result of the design, during 16 shipment when the cartons may be jiggled and vibrated during 17 transport, the Class A surfaces are kept from rubbing against 18 the dunnage or other trim moldings and their surface appearance 19 preserved.
Accordingly and more particularly, there is 21 provided a dunnage for the handling of products which 22 comprises, in combination, a plurality of identical plastic 23 sections each having a hollow base and a series of spaced apart 24 upstanding hollow posts between which are product receiving and supporting bunks. The base, posts and bunks are so arranged sg/rn ~

- 3a - 2034526 1 that, when corresponding ends of the sections are superimposed, 2 the posts and bunks of a subjacent section may be telescoped 3 substantially within the corresponding posts and base of the 4 superjacent section. The posts and hollow base have cooperating engaging surfaces which bear against each other 6 when the superjacent section is reversed end-for-end and placed 7 in operative position on the subjacent section with the posts 8 of the subjacent section received within and engaging the 9 hollow base of the superjacent section. These surfaces serve to support the superjacent section spaced vertically from the 11 bunks of the subjacent section, whereby products supported on 12 the bunks of the subjacent section are disposed out of contact 13 with the superjacent section.

Brief Description of the Drawings 16 Fig. 1 is a perspective view of a shipping carton 17 with sidewalls broken away for clarity showing automotive trim 18 moldings packaged in layers therein by my improved dunnage;
19 Fig. 2A is a perspective view of one end of a representative form of my improved dunnage;

~ sg/rn 3 Fig. 2B is similar to Fig. 2A but shows the opposite end 4 of the improved dunnage;
Fig. 3 is a fragmentary cross-sectional view through two 6 stacked dunnage sections taken on the line 3-3 of Fig. l;
7 Fig. 4 is a top view of my improved dunnage taken along 8 the line 4-4 of Fig. 3;
9 Fig. 5 is cross-sectional view taken along the line 5-5 of Fig. 4 and shows the dunnage in stacked relation and 11 automotive trim moldings supported by my improved dunnage;
12 Fig. 6 is a cross-sectional view similar to Fig. 5 but 13 with the trim moldings removed and the middle dunnage section of 14 Fig. 5 reversed end-for-end whereby corresponding ends are superimposed and the sections nested together for storage prior 16 to use;
17 Fig. 7 is a cross-sectional view taken on the line 707 18 of Fig. 5;
19 Fig. 8 is a cross-sectional view taken on the line 8-8 of Fig. 5;
21 Fig. 9 is a perspective view of a modified form of two 22 of my dunnage sections stacked for use with two automotive trim 23 moldings held thereby for storage or transport;
24 Figs. 10 and 11 are opposite ends of one of my dunnage sections of Fig. 9;
26 Figs. 12 and 13 are perspective views of a fragment of 27 my dunnage sections looking in opposite directions;

l ~ 5 ~ 2034526 3 Fig. 14 is a cross-sectional view taken on the line 14-14 4 of Fig. 9;
Fig. 15 is a longitudinal cross-sectional view of the 6 dunnage of Fig. 9 similar to Fig. 6 showing the support of 7 automotive trim moldings; and 8 Fig. 16 is a view similar to Fig. 15 but with the trim 9 moldings removed and showing the upper dunnage section of Fig.
15 reversed end-for-end and nested upon the lower section for 11 storage of the dunnage.

13 Brief Description of Preferred Embodiments 14 Referring to Fig. 1, there is disclosed a shipping carton 20 intended to receive automotive trim moldings for shipment and 16 storage. The carton may comprise a conventional cardboard box 17 of generally rectangular form. Within the box, adjacent opposite 18 ends 22 and 24, are positioned layers of dunnage 26 and 28 19 between which extend the trim moldings TM, only a few of which are shown for purposes of clarity. It will be understood that 21 the layers of dunnage will extend from the bottom to the top of 22 the carton adjacent the ends 22 and 24 thereof and the trim 23 moldings will fill the carton while being supported by the 24 dunnage. A layer of the dunnage (not shown) may be provided intermediate the layers 26 and 28 to support the centers of the 26 trim moldings if there is an unacceptable sagging thereof.

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2034~26 `1 - 6 -3 Conventional lids or the like 30 and~32 will serve to close the 4 top of the shipping carton.
It will be understood that the dunnage 26 and 28 is 6 layered from the bottom to the top of the shipping carton and 7 that the trim moldings extend between the layers of dunnage 8 which in turn provides layers of trim moldings. The dunnage 9 serves to space the trim moldings apart both vertically and horizontally. In addition, the dunnage is so designed as 11 hereinafter disclosed that the exterior decorative surface, 12 conventionally called the Class A surface, indicated at A is 13 spaced from the dunnage and from other trim molding. This 14 spacing of the Class A surface from the dunnage and other trim molding is a critical feature of this disclosure. The design 16 of the dunnage which permits this spacing of the Class A surface 17 from the surrounding dunnage and other trim molding provides 18 what might be considered a floating suspension of the trim 19 molding within the carton 20. Despite bumping, jarring and the 0 like which may occur to the carton during shipment, the Class 21 A surfaces of the trim moldings remain spaced from contact with 22 dunnage and other trim molding which could mar or damage it.
23 The dunnage comprises identical vacuum-molded, elongated 24 plastic strips or sections 34. The sections are made of high-impact styrene which is not only relatively inexpensive but 26 dimensionally quite stable. In thickness it would no~mally be 27 less than .lO0~ and preferrably, for most applications, would ~ 2o34526 3 lie in the range of .035" to .160". Other plastics having good 4 dimensional stability and impact strength combined with low cost may be suitable, but the high-impact styrene has been found to 6 be particularly advantageous.
7 Each strip includes a pair of parallel-base flanges 36 8 and 38 which extend the full length of the strips or sections.
9 These flanges serve to rigidity the strips and provide a flat base for supporting the bottom strip in the shipping carton.
11 Each of the strips include a plurality of upst~n~ing posts 40-52 12 inclusive, as indicated in Fig. 1, which are spaced apart along 13 the length of the dunnage section by a distance slightly greater 14 than the width of the trim molding to be supported thereby as best shown in Fig. 5. The posts are integral with a central 16 raised rib 54 which extends substantially throughout the length 17 of the dunnage sections and bridges between the flanges 36 and 18 38 and together with the flanges forms a hollow base. The 19 channel-like structure shown in cross-section at Figs. 7 and 8 provides a considerable rigidity for the dunnage sections despite 21 their lightweight construction.
22 Intermediate the posts, the central rib 54 is provided 23 with an integral, hollow trim molding receiving and supporting 24 bunk indicated at 56-66 inclusive in the drawings. The height "H" and length "L" of the bunks are such as to be received within 26 the inside of the trim molding and abut the inner-surfaces, 27 herein referred to as the Class B surfaces, identified by the 28 letter B in the drawings, to support the trim molding with all `~' cPC ola2 P
203~526 3 of the Class A surfaces spaced from the dunnage section as best 4 shown in Fig. 5. As the cross-sectional shape or configuration of the trim molding will vary from one style automobile-to 6 another, the bunks are shaped for each specific configuration 7 of trim molding to be accommodated. Thus, the bunks shown in 8 Fig. 5 are generally rectangular while those for other style 9 trim molding such as hereinafter shown will be of a somewhat different shape. In each case, however, the bunk is designed 11 to enter within and contact the Class B surfaces of the trim 12 molding and support the molding with the Class A surfaces spaced 13 from the adjacent portions of the dunnage. It has been found 14 that even a soft, sponge-like material, if allowed to contact the Class A surfaces, can cause marring thereof as a result of 16 vibration and jiggling of the shipping carton during transport 17 of the molding from the molding maker to the vehicle assembly 18 line. Accordingly, I have determined that a floating support 19 of the molding as shown in Fig. 5 with all Class A surfaces 0 spaced from the dunnage is the only wholly satisfactory way to 21 avoid marring the surfaces through accidental contact and 22 rubbing during transport of the trim moldings.
23 The spaced apart posts 40-52 inclusive of the dunnage 24 sections are so shaped and arranged that when corresponding ends of the dunnage sections are superimposed, the sections may be 26 substantially nested together, as shown in Fig. 6, fo~ storage 27 or transport prior to use in supporting trim moldings in a cPC ola2 P ' `r 9 3 shipping carton. On the other hand, when the dunnage sections 4 are reversed end-for-end, the posts are misaligned whereby the strips may be stacked as shown in Fig. 5 and the bunks are 6 vertically spaced apart sufficiently to allow support of the 7 trim moldings thereon without contact with the superjacent 8 strip. The stacking as shown in Fig. 6 is facilitated by the 9 vacuum-forming of the dunnage sections whereby the posts may nest together or inter-fit substantially. On the other hand, 11 when the dunnage sections are reversed end-for-end as shown in 12 Fig. 5, the misalignment of the posts causes the upper ends of 13 the posts of a subjacent strip to bear against bottom surfaces 14 of the central raised rib 54 to support the dunnage sections in the vertically spaced arrangement shown.
16 More specifically, posts 40 and 52 are provided with 17 opposed, cooperating-supporting shoulders best shown in Figs.
18 2A, 2B, 3 and 5. Post 40 has supporting shoulder 68 providing 19 an upwardly-facing surface and shoulders 70 and 72 providing 0 two downwardly-facing surfaces. Shoulder 68 bears against the 21 underside of shoulder 74 while the downwardly-facing surfaces 22 of shoulders 70 and 72 bear at their undersides against the 23 upwardly-facing surfaces of shoulders 76 and 78 formed on post 24 52 with the cooperation of the shoulders best shown in Fig. 5.
As shown in Fig. 4, post 40 also has a pair of shoulders, 80 and 26 82, whose upwardly.facing surfaces bear against the underside ~ CPC 0102 P

--1 lO- 2034526 3 of the central raised rib -54, intermediate post 52 and the 4 adjacent bunk 66. Similarly, the upper ends of the posts 42, 44, 46, 48 and 50 bear against the underside of the central 6 raised rib 54 to support the superjacent dunnage section.
7 Post 40 has a rib-like portion 84 which projects above 8 the shoulders 68, 80 and 82 and is received within the vacuum-9 formed cavity of post 52 to bear against vertical wall 86 to prevent longitudinal displacement of the stacked sections in one 11 direction. Longitudinal shifting in the opposite direction is 12 prevented by a rib-like portion 88 on post 52 which is received 13 within the vacuum-formed cavity of post 40 of the superjacent 14 dunnage section as best shown in Fig. 5. Relative lateral displacement of the stacked dunnage sections is also prevented 16 by the rib-like portions 84 and 88 of the posts 40 and 52 17 respectively being received within the vacuum-formed cavities 18 of the opposite posts of the superjacent dunnage sections.
l9 Thus, when in the operative stacked relation of Fig. 5, the O strips are locked together against lateral or longitudinal 21 displacement, the semi-circular cavities 9O formed by a semi-22 circular wall portion of the central raised rib 54 serve to 23 rigidify the structure and/or provide for the accommodation of 24 projecting portions of the trim molding, Thus, the dunnage sections may be stacked in operative position to accommodate the 26 trim molding thereon and will serve to space the Class ~, cPC ola2 P

3 surfaces of the trim moldings from adjacent surfaces of the 4 dunnage and adjacent trim moldings.
In Figs. 9-16, I have shown a modified form of the 6 dunnage for holding a somewhat differently shaped trim molding 7 and wherein the dunnage sections or strips 34' are longer and 8 are provided intermediate their length with a locating post 90.
9 In these figures of the drawings, parts generally corresponding to parts in Figs. 1-8 utilize primed reference numerals and a 11 specific description is thereby omitted unless otherwise noted.
12 The bunks 92-114 inclusive are in principle the same as the 13 bunks 56-66 inclusive except the configuration is slightly 14 different to accommodate the somewhat differently shaped trim molding TM'. It will be noted particularly from Fig. 15 that 16 when the strips 34' are in stacked relation, the bunks 92-114 17 serve to support the trim moldings similar to the earlier 18 describe embodiment with the Class A surfaces spaced from 19 adjacent surfaces of the dunnage. Because of the length of the _0 dunnage sections of the Fig. 9-16 embodiment, I have provided 21 a locating post 90, intermediate adjacent posts and about midway 22 the length of the strip, having an upwardly projecting locating 23 rib 94 which is received within the vacuum-formed cavity of the 24 oppositely matching post 118. When the dunnage sections are reversed so that the corresponding ends are superimposed, the 26 sections may be nested as shown in Fig. 16 for storage and cPC ol~æ P

2~34526 ~L

4 shipment prior to use. The rib 116 on post 90 cooperates with the superjacent interior of post 118 to augment the locking 6 action of the end posts 40' and 52' when the dunnage sections 7 are in their stacked relationship shown in Fig. 15.

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Claims (7)

1. Dunnage for the handling of products comprising, in combination:
a plurality of identical plastic sections each having a hollow base and a series of spaced apart upstanding hollow posts between which are product receiving and supporting bunks;
said base, posts and bunks being so arranged that, when corresponding ends of the sections are superimposed, the posts and bunks of a subjacent section may be telescoped substantially within the corresponding posts and base of the superjacent section; and said posts and hollow base having cooperating engaging surfaces which bear against each other when the superjacent section is reversed end-for-end and placed in operative position on the subjacent section with the posts of the subjacent section received within and engaging the hollow base of the superjacent section, and such surfaces serve to support the superjacent section spaced vertically from the bunks of the subjacent section, whereby products supported on the bunks of the subjacent section are disposed out of contact with the superjacent section.

2. The invention defined by claim 1 wherein the posts and base have interfitting portions for locking the sections against lateral displacement when the sections are in operative positions.

3. The invention defined by claim 1 wherein the plastic sections are vacuum formed.

4. The invention defined by claim 1 wherein the plastic sections are vacuum formed and have a thickness from .035" to .160".

5. The invention defined by claim 1 in which the plastic sections are vacuum formed of high impact styrene having a thickness from .035" to .160".

6. The invention of claim 1 wherein when the superjacent section is reversed end-for-end into said operative position the posts of the subjacent section are misaligned with the posts of the superjacent section whereby the superjacent section is supported on the posts of the subjacent section with the base of the superjacent section spaced from the bunks of the subjacent section such that products received and supported on the bunks of the subjacent section are disposed out of contact with the superjacent section.

7. The invention defined by Claim 1 wherein said cooperating engaging surfaces comprise upwardly facing shoulders on the posts and downwardly facing shoulders on the hollow base.