CA2235508A1 - Stretch-wrapped modular masterpackage and method of making same - Google Patents
Stretch-wrapped modular masterpackage and method of making same Download PDFInfo
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Abstract
A horizontally stretch-wrapped masterpackage includes four individual horizontally tension film-wrapped modular units in a horizontal two-by-two relationship. Each unit includes a rectangular pallet which is capable of being lifted from any of the four sides by a forklift truck. Each unit contains fifty bundles of builders shims. Each bundle contains, for example, forty-eight builders shims. Each bundle may itself be horizontally shrink-wrapped around its vertical outer periphery to facilitate drying of the shims during shipment. A method of loading the masterpackages in a truck trailer is also disclosed.
Description
CA 0223~08 l998-04-22 ~W:rdr 5185-4775a.pa ~ 1 - EXPRESS MAIL NO. EM171447735US
STRETCH-WRAPPED MODULAR MASTERPACKAGE
AND METHOD OF MAKING SAME
FIELD OF THE INVENTION
This invention relates to a stretch-wrapped modular masterpackage and, more particularly, to such a masterpackage compr:ising palletized modular units each of which comprises a plurality of articles such as bundles of builder's shims.
BACKGROUND OF THE INVENTION
Builder's shims are a standard product used by builders to shim door and window assemblies and the like. Typically, they are shipped to builders supply stores on pallets, where they are purchased by building contractors and professional window installers, as well as by homeowners themselves. The builders supply store likes to display the shims on the pallets on which they are shipped.
Builders shims are typically made from green wood; that is, wood that is not completely dry. It is very advantageous to group the shims in bundles and wrap each bundle around its vertical outer periphery to permit the moisture to escape. The wrapping is essential, because otherwise the bundle would fall apart as the individual shims dry out.
It is also commercially advantageous to ship a group of pallets banded together to form what is known as a masterpackage. The builders supply store can then separate the individual pallets from the masterpackage and distribute such individual pallets as desired throughout the store.
Builders supply stores also desire to eliminate handling of the product by store personnel. This is advantageous in that it minimizes the risk of injury to the product, but it also minimizes any disruption in the relationship between the ultimate consumer and the manufacturer, thereby to leave unaffected the CA 0223~08 l998-04-22 ~W:rdr SlaS-47758.pa - 2 - EXPRESS MAIL NO. EM171447735US
manufacturer's ultimate liability and responsibility for its product.
Stretch-wrapping of palletized articles is a common way to prepare such articles for shipment to an ultimate destination. An example of this technique is disclosed in Dreher U.S. Patent No. 3, 986,611. Examples of stretch-wrapping of multiple stacked non-palletized articles are disclosed in Gombos et al., U.S. Patent No. 5,090,177, Lancaster et al., U.S. Patent 10No. 5,195,297 and Lashyro U.S. Patent No. 5,450,708.
The ' 297 patent discloses machinery suitable for the purpose. The machinery is made and sold by Lantech, Inc., Louisville, Kentucky, assignee of the Lashyro patent.
15Accordingly, it is a principal object of the present invention to provide a tension film-wrapped modular masterpackage of palletized modular units which can be safely and eI-ficiently transported to an ultimate destination, whence the individual modular palletized units can be distributed as desired by the recipient.
It is a furt:her object of the present invention to provide a method of unitizing for shipment a plurality of such modular palletized units to reduce handling to a minimum at the ultimate retail distribution site.
It is a still further object of the present invention to provide a method of shipping a plurality of unitized modular masterpackages to provide the most cost effective system for delivering a product from the manufacturer to the ultimate consumer.
It is a still further object of the present invention to provide a masterpackage as above set forth wherein bundles of builders shims, shipped in a "green"
condition, are themselves shrink wrapped to insure bundle integrity right to the point of ultimate purchase by the consumer.
CA 0223~i~i08 l998-04-22 ALW:rdr 5185-47759.pa - 3 - EXPRESS MAIL NO. EM171447735US
SU~MARY OF THE INVENTION
The invention provides a tension film-wrapped masterpackage for shipment to a destination. The masterpackage comprises a plurality of pallets each of which supports a pll~rality of articles in a predetermined array. The articles form a column having a superimposed outer tension wrap of a flexible cling film which envelops the vertical outer periphery of the column. The column and the pallet form a modular unit.
The pallets comprise means such that they can be handled in any of the four sides by the tines of a forklift truck.
The palletized modular units are disposed in a horizontal side-by-side relationship to form the masterpackage. The masterpackage also has a superimposed outer t:ension wrap of a flexible cling film which envelops the outer periphery of the group of individually wrappecl palletized modular units. Thus, removal of the outer tension wrap from the masterpackage 2C following shipment t:o the destination permits the individually outer wrapped palletized modular units to be distributed as desired by the consignee.
Preferably, the articles in the column comprise individual bundles of builder's shims. Each bundle of shims may optionally have a superimposed tension wrap of a flexible cling film enveloping its own vertical outer periphery, and this wrap may desirably comprise a shrink wrapped film.
The pallets utilized in the invention have been 3 0 configured in such a way that permits a truck trailer to be loaded to its maximum capacity, thereby to achieve maximum efficiency in shipment.
The invention also provides a method of unitizing a masterpackage for shipment to a destination.
The method comprises loading a plurality of articles in a predetermined array on a pallet to form a column of articles. The pallet is capable of being lifted from any direction using the tines of a forklift truck. The method then comprises wrapping a flexible cling film CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa - 4 - EXPRESS MAIL NO, EM171447735US
under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit.
The method further comprises placing a plurality of the palletized film-wrapped modular units in a horizontal side-by-side relationship. A flexible cling -film under tension is then wrapped around the vertical outer periphery of the plurality of palletized film-wrapped modular units to form a masterpackage. Removal of the film from around the vertical periphery of the masterpackage after arrival at the destination permits the plurality of in,~ividually wrapped modular units to be distributed as desired at the destination.
Preferably, the articles forming the column comprise individual bundles of builder's shims.
Optionally, the method comprises wrapping the bundles of builder's shims comprising the articles of the column each with a flexible cling film around the vertical outer periphery thereof. Wrapping of each bundle may comprise shrink wrapping the bundle.
The invention also provides a method of shipping unitized masterpackaLges in a cost effective manner to a selected destination in a truck trailer having a defined interior width.
The method comprises loading a plurality of articles in a predet:ermined array on a rectangular pallet to form a column of articles having sides having dimensions substantially in the ratio of x:y, wherein x is less than y, and x and y are integers. The side corresponding to the integer x is the short side of the column, and the side corresponding to the integer y is the long side of the~column. The pallet is capable of being lifted from any of the four sides using the tines of a forklift truck.
The method further comprises wrapping a flexible cling film under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit.
CA 0223~08 1998-04-22 ~W:rdr 5185-47758.pa ~ 5 - EXPRESS MAIL NO. EM171447735US
Four of the palletized tension film-wrapped modular units are then placed in a horizontal two-by-two relationship. A flexible cling film under tension is then wrapped around the vertical outer periphery of the palletized tension film-wrapped modular units in the horizontal two-by-two relationship to form a unitized -masterpackage having sides substantially in the ratio of x:y. The side corresponding to x is the short side of the masterpackage, and the side corresponding to y is the long side of the masterpackage.
The unitized masterpackages are then loaded in the truck trailer in a pattern such that x of the masterpackages (x being an integer) are placed in a first line with their short sides adjacent each other, and y of the masterpackages (again, y is an integer) are placed in a second :Line adjacent the first line with their long sides adjacent each other. The masterpackages thus form a group of x + y masterpackages having a rectangular exterior boundary which substantially extends across the full width of the interior of the truck trailer.
Preferably, the column has dimensions at least equal to the dimensions of the pallet. For a standard sized truck trailer, x:y = 3:4.
Preferably, the articles comprising the columns comprise bundles of builder's shims. Optionally, the method comprises shrink wrapping the bundle of builders shims comprising each of the articles with a flexible cling film around the vertical outer periphery thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a tension film wrapped modular masterpackage according to the invention, after the masterpackage has been shipped to a destination, and wherein the superimposed outer tension film wrap around the masterpackage has been cut to permit the individually outer wrapped palletized modular units to be distributed as desired by the store owner.
CA 0223~08 l998-04-22 ~:rdr sl8s-477sa.pa ~ 6 ~ EXPRESS MAIL NO. EM171447735US
Fig. 2 is a perspective view of one of the palletized modular units, particularly illustrating the pallet, wherein the column of articles is wrapped with a superimposed outer tension wrap of a flexible cling film.
Fig. 3 is a perspective view of a bundle of -builders shims itself shrink wrapped with a superimposed tension wrap of a flexible cling film.
Fig. 4 is a top plan view of the pallet of Fig. 2.
Fig. 5 is a view of one (the short) side of the pallet.
Fig. 6 iS a view of the other (the iong) side of the pallet.
Fig. 7 is a plan view of the interior of a truck trailer loaded with one layer of unitized masterpackages according to the method of the invention.
Description of a Preferred Embodiment Referring to the drawings, builders shims 10 are typically sold in bundles 12 comprising 48 shims. Such a bundle 12 is designed to satisfy the needs of both homeowners and contractors. Shims may also be bundled in bundles comprising 24 shims for an end user having a single job (such a bundle not being shown), or in bundles comprising 80 pieces for the professional installer of windows and doors (such a bundle also not being shown).
Each indiviclual bundle 12 can be wrapped with a superimposed tension wrap 14 of a flexible cling film 16 around its side edges 18, deemed the vertical outer periphery of the bundle 12. The side edges 18 are the only surfaces wrapped, because the shims 10 are typically prepared in the wet or pre-dried condition.
Leaving the tops anc! bottoms of the bundles open, permits the shims to dry out prior to actual use. See Fig. 3.
Wrapping each bundle 12 is preferably accomplished by what is known as "overbanding"; that is, CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa - 7 - EXPRESS MAIL NO. EM171447735US
shrink banding the bundle 12, to let the moisture out, with a non-tacky polyvinyl chloride (pvc) film using a Seal-A-TronTM shrink tunnel, Model TST-2410-LR15VSA. The film 16 preferably extends slightly below the bundle and slightly above the upper surface thereof (see Fig. 3), thereby to secure the individual shims 10 together.
- The bundles 12 of shims 10 are typically shipped to builders supply .,tores on pallets loaded with fifty bundles 12. The stores prefer to receive them on pallets, because a pallet loaded with fifty bundles 12 can be placed wherever the store manager desires.
Shipping individual pallets loaded with shims, however, is an inefficient and impractical way to transport them.
Thus, fifty of the bundles 12 are loaded in a predetermined array, for example, stacked on a pallet 20 such that the bundles 12 all have their shims 10 disposed in the same direction. The fifty bundles 12 form what is called a column 21. See Fig. 2.
The pallet 20 is preferably constructed as a rectangular frame 22, having a short side 24 (the side parallel to the longitudinal direction of the shims 10) twenty inches long, and a long side 26 (its other horizontal dimension) twenty-seven inches long. A
rectangular pallet is preferable because of the inherent rectangular nature of the bundles 12 themselves. The rectangular nature of the pallets also greatly facilitates the ultimate loading of a truck trailer as will be more fully explained hereinafter.
The stacked or loaded bundles 12 preferably extend slightly outwardly of the sides 24, 26 of the pallet 20, such that the column 21 has sides 28, 30 slightly larger than the sides 24, 26 of the pallet.
The sides 28, 30 of the column 21 typically may have dimensions of about 20-1/2 inches by 27-1/2 inches. It will be noted that the ratio of the length of the side 28 to the length of the side 30; i.e., 20-1/2:27-1/2, iS about 3:4, and the significance of this ratio will be hereinafter more fully explained.
CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa - 8 - EXPRESS MAIL NO. EM171447735US
The pallet frame 22 iS preferably constructed of two "two-by-four" pieces 32 forming its long sides 26 joined by two "two-by-three" pieces 34 extending interiorly of the pieces 32 and flush with their upper 5 surfaces 36 and two more "two-by-three'~ pieces 38 extending exteriorly of the pieces 32, positioned below the lower surfaces 40 thereof and extending to the outer side surfaces 42 of the pieces 32, as shown in Fig. 2.
By this means the tines of a forklift truck (not shown) facing either long side 26 of the pallet 20 can be inserted in the space 44 formed below the long side pieces 32 (between the pieces 38) to handle the pallet 20 and associated column 21 from the direction of the long side 26. Similarly the tines of a forklift truck facing either short side 24 of the pallet 20 can be inserted in the space 46 formed between the cross pieces 34 and 38 to handle the pallet 20 and associated column 21 from the direction of the short side 24.
Thus, the pallets 20 are capable of being lifted from any of the four sides using the tines of a forklift truck, and this greatly facilitates the loading of a truck trailer as wi:ll be hereinafter further described.
Each of the columns 21 is then vertically banded using a single vertically oriented steel or plastic strap 47. The strap 47 passes through the space 46 between the cross pieces 34 and 38, around the bundles 12 comprising the column 21, thereby tying the bundles 12 to the pallet 20. See Figs. 1 and 2.
The column 21 and pallet 20 are then wrapped by another tension wrap 48, using a flexible cling (tacky) film 50, to form a vertically wrapped palletized modular unit 52. This is ac:complished using a LantechT~ machine, sold by Lantech, Inc:., Louisville, Kentucky, preferably a LantechTU Model STE'SD, using LLDPE stretch film. The film 50 preferably extends slightly above the upper surface of the column 21, slightly over the bundles 12 as shown in Fig. l; also slightly below the upper surfaces 36 of the "two-by-four" side pieces 32, and CA 0223~08 l998-04-22 AlW:rdr sl~s-477sa~pa - 9 - EXPRESS MAIL NO. EM171447735US
slightly below the upper surfaces of the two "two-by-three" cross pieces 34. The wrapping, together with the banding provided by the strap 47, insures that the pallet 20 is secureLy incorporated within the modular 5 unit 52 and that it remains with the column 21 when the unit 52 is moved.
- After each modular unit 52 is wrapped, it is taken off the Lantec;hTM machine and put aside until a desired number of such units 52 have been wrapped, typically groups of four such units. Four wrapped modular units 52 are then placed in a horizontal side-by-side, two-by-two relationship on the LantechT~
machine, where they are again wrapped to form the masterpackage 54 shown in Fig. 1. As in the case of the 15 modular units 52, wrapping of the masterpackage 54 is preferably accomplished on a LantechTM Model STPSD
machine using LLDPE stretch film.
Because the ratio of the lengths of the sides 28, 30 of the columns 21 is approximately 3 :4, the 20 ratio of the length of the short side 56 of the masterpackage 54 to the length of the long side 58 thereof is also approximately 3: 4.
The masterpackage of four outer wrapped palletized modular units 52 is wrapped with a tension 25 wrap 60 of a flexible cling film 62. The four wrapped units 52 stay together very well, without the necessity of using another strap, because the tension wrap 60 forces them into a close relationship. This takes advantage of the inherent tackiness of the film 50 30 surrounding each modular unit 52 and the tendency of the edges of the shims 10 to protrude through the film.
Thus, it has been found that no pallet is needed below the masterpackage 54 itself for support. The finished masterpackage 54 has side dimensions of about 41 inches 35 by 54 inches, i.e., twice that of the modular units 52 themselves, and also approximately in the ratio of 3 :4.
Upon arrivin~ at the ultimate destination, typically the builders supply store, the wrap 60 around the masterpackage 54 can be cut, as shown in Fig. 1, CA 0223~i~i08 l998-04-22 ALW:rdr SlaS-47758.pa - 10 - EXPRESS MAIL NO. EM171447735US
such that the individually wrapped modular units 52, which include the pa:llets 20, can be placed in the store as desired.
The assembly as above described permits efficient usage of e~isting truck trailers to ship the product. As shown in Fig. 7, the interior of a truck ~railer 64 is loaded in the following manner. Three masterpackages 54 are placed in a first line 66 with their short sides 56 adjacent each other and their long sides 58 adjacent the interior sidewall of the trailer.
Loading in this manner is facilitated because the tines of a forklift truck can engage each masterpackage 54 using the spaces 46 :in the two side-by-side pallets 20.
Four masterpackages 54 are then placed in a second line 68 adjacent the first line 66, the four masterpackages 54 being placed with their long sides 58 adjacent each other and their short sides 56 adjacent the opposite interior sidewall of the truck trailer 64.
In loading these four masterpackages 54, the forks of the forklift truck engage the-two pallets 20 using the spaces 44 formed in the long sides 26 thereof.
Because the outer dimensions of the masterpackages 54 are substantially in the ratio of 3:4, seven masterpackages 54 loaded as aforesaid, form a group 70 which has a rectangular boundary. The 54 inch long side 58 of the masterpackages 54 in the second line 68, placed adjac~ent the 41 inch short side 56 of the masterpackages 54 in the first line 66, provide the group 70 with a tota] width of 95 inches, thereby efficiently filling t:he 98-inch standard interior width of the trailer 64.
An additiona] two groups 70 plus two more individual masterpackages 54 are usually loaded into the truck trailer 64 as shown in Fig. 7, preferably alternating short sicles and long sides of the masterpackages 54, as shown, thereby substantially fully loading the interior with twenty-three masterpackages 54, each consisting of four modular units 52, each unit ',2 containing fifty bundles 12, each CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa , - 11 - EXPRESS MAIL NO. EM171447735US
bundle 12 containing forty-eight shims 10. Typically, the truck trailer 64 is loaded with two layers of groups 70, thus to accommodate a total of forty-six such masterpackages 54. There is enough interior height in a typical truck trailer 64 to add a third layer, providing existing weight lim:itations are not exceeded.
- A trailer could be loaded with more groups 70 in each layer if the truck trailer is long enough to accommodate them, which would also depend on the particular dimensions of the masterpackage 54 concerned.
Also if a particular truck trailer is slightly longer than, for example, t:he trailer described herein that accommodates the forty-six masterpackages 54 shown, additional masterpac:kages 54, not necessarily the seven that form a complete group 70, can be loaded at the end of the trailer and maintained in position during transit with airbags (not shown).
Although an example has been selected wherein the dimensions of the masterpackage optimizes truck trailer loading using a group of seven masterpackages, in two lines of three and four masterpackages, respectively, the loading method would be analogous for any assembly of modular units and masterpackages having short sides and long sides in the ratio of x:y. The truck trailer would merely be loaded in a pattern wherein x of the masterpackages are placed in the first line and y of the masterpackages are placed in the second adjacent line, thereby to form a group of x + y masterpackages having a rectangular exterior boundary.
The present invention may be embodied in other specific forms without departing from the spirit and essential characteristics thereof. The present embodiments are presented merely as illustrative and not restrictive, with the scope of the invention being indicated only by the attached claims. All changes coming within the meaning and equivalency of the claims are, therefore, intended to be embraced thereby.
STRETCH-WRAPPED MODULAR MASTERPACKAGE
AND METHOD OF MAKING SAME
FIELD OF THE INVENTION
This invention relates to a stretch-wrapped modular masterpackage and, more particularly, to such a masterpackage compr:ising palletized modular units each of which comprises a plurality of articles such as bundles of builder's shims.
BACKGROUND OF THE INVENTION
Builder's shims are a standard product used by builders to shim door and window assemblies and the like. Typically, they are shipped to builders supply stores on pallets, where they are purchased by building contractors and professional window installers, as well as by homeowners themselves. The builders supply store likes to display the shims on the pallets on which they are shipped.
Builders shims are typically made from green wood; that is, wood that is not completely dry. It is very advantageous to group the shims in bundles and wrap each bundle around its vertical outer periphery to permit the moisture to escape. The wrapping is essential, because otherwise the bundle would fall apart as the individual shims dry out.
It is also commercially advantageous to ship a group of pallets banded together to form what is known as a masterpackage. The builders supply store can then separate the individual pallets from the masterpackage and distribute such individual pallets as desired throughout the store.
Builders supply stores also desire to eliminate handling of the product by store personnel. This is advantageous in that it minimizes the risk of injury to the product, but it also minimizes any disruption in the relationship between the ultimate consumer and the manufacturer, thereby to leave unaffected the CA 0223~08 l998-04-22 ~W:rdr SlaS-47758.pa - 2 - EXPRESS MAIL NO. EM171447735US
manufacturer's ultimate liability and responsibility for its product.
Stretch-wrapping of palletized articles is a common way to prepare such articles for shipment to an ultimate destination. An example of this technique is disclosed in Dreher U.S. Patent No. 3, 986,611. Examples of stretch-wrapping of multiple stacked non-palletized articles are disclosed in Gombos et al., U.S. Patent No. 5,090,177, Lancaster et al., U.S. Patent 10No. 5,195,297 and Lashyro U.S. Patent No. 5,450,708.
The ' 297 patent discloses machinery suitable for the purpose. The machinery is made and sold by Lantech, Inc., Louisville, Kentucky, assignee of the Lashyro patent.
15Accordingly, it is a principal object of the present invention to provide a tension film-wrapped modular masterpackage of palletized modular units which can be safely and eI-ficiently transported to an ultimate destination, whence the individual modular palletized units can be distributed as desired by the recipient.
It is a furt:her object of the present invention to provide a method of unitizing for shipment a plurality of such modular palletized units to reduce handling to a minimum at the ultimate retail distribution site.
It is a still further object of the present invention to provide a method of shipping a plurality of unitized modular masterpackages to provide the most cost effective system for delivering a product from the manufacturer to the ultimate consumer.
It is a still further object of the present invention to provide a masterpackage as above set forth wherein bundles of builders shims, shipped in a "green"
condition, are themselves shrink wrapped to insure bundle integrity right to the point of ultimate purchase by the consumer.
CA 0223~i~i08 l998-04-22 ALW:rdr 5185-47759.pa - 3 - EXPRESS MAIL NO. EM171447735US
SU~MARY OF THE INVENTION
The invention provides a tension film-wrapped masterpackage for shipment to a destination. The masterpackage comprises a plurality of pallets each of which supports a pll~rality of articles in a predetermined array. The articles form a column having a superimposed outer tension wrap of a flexible cling film which envelops the vertical outer periphery of the column. The column and the pallet form a modular unit.
The pallets comprise means such that they can be handled in any of the four sides by the tines of a forklift truck.
The palletized modular units are disposed in a horizontal side-by-side relationship to form the masterpackage. The masterpackage also has a superimposed outer t:ension wrap of a flexible cling film which envelops the outer periphery of the group of individually wrappecl palletized modular units. Thus, removal of the outer tension wrap from the masterpackage 2C following shipment t:o the destination permits the individually outer wrapped palletized modular units to be distributed as desired by the consignee.
Preferably, the articles in the column comprise individual bundles of builder's shims. Each bundle of shims may optionally have a superimposed tension wrap of a flexible cling film enveloping its own vertical outer periphery, and this wrap may desirably comprise a shrink wrapped film.
The pallets utilized in the invention have been 3 0 configured in such a way that permits a truck trailer to be loaded to its maximum capacity, thereby to achieve maximum efficiency in shipment.
The invention also provides a method of unitizing a masterpackage for shipment to a destination.
The method comprises loading a plurality of articles in a predetermined array on a pallet to form a column of articles. The pallet is capable of being lifted from any direction using the tines of a forklift truck. The method then comprises wrapping a flexible cling film CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa - 4 - EXPRESS MAIL NO, EM171447735US
under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit.
The method further comprises placing a plurality of the palletized film-wrapped modular units in a horizontal side-by-side relationship. A flexible cling -film under tension is then wrapped around the vertical outer periphery of the plurality of palletized film-wrapped modular units to form a masterpackage. Removal of the film from around the vertical periphery of the masterpackage after arrival at the destination permits the plurality of in,~ividually wrapped modular units to be distributed as desired at the destination.
Preferably, the articles forming the column comprise individual bundles of builder's shims.
Optionally, the method comprises wrapping the bundles of builder's shims comprising the articles of the column each with a flexible cling film around the vertical outer periphery thereof. Wrapping of each bundle may comprise shrink wrapping the bundle.
The invention also provides a method of shipping unitized masterpackaLges in a cost effective manner to a selected destination in a truck trailer having a defined interior width.
The method comprises loading a plurality of articles in a predet:ermined array on a rectangular pallet to form a column of articles having sides having dimensions substantially in the ratio of x:y, wherein x is less than y, and x and y are integers. The side corresponding to the integer x is the short side of the column, and the side corresponding to the integer y is the long side of the~column. The pallet is capable of being lifted from any of the four sides using the tines of a forklift truck.
The method further comprises wrapping a flexible cling film under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit.
CA 0223~08 1998-04-22 ~W:rdr 5185-47758.pa ~ 5 - EXPRESS MAIL NO. EM171447735US
Four of the palletized tension film-wrapped modular units are then placed in a horizontal two-by-two relationship. A flexible cling film under tension is then wrapped around the vertical outer periphery of the palletized tension film-wrapped modular units in the horizontal two-by-two relationship to form a unitized -masterpackage having sides substantially in the ratio of x:y. The side corresponding to x is the short side of the masterpackage, and the side corresponding to y is the long side of the masterpackage.
The unitized masterpackages are then loaded in the truck trailer in a pattern such that x of the masterpackages (x being an integer) are placed in a first line with their short sides adjacent each other, and y of the masterpackages (again, y is an integer) are placed in a second :Line adjacent the first line with their long sides adjacent each other. The masterpackages thus form a group of x + y masterpackages having a rectangular exterior boundary which substantially extends across the full width of the interior of the truck trailer.
Preferably, the column has dimensions at least equal to the dimensions of the pallet. For a standard sized truck trailer, x:y = 3:4.
Preferably, the articles comprising the columns comprise bundles of builder's shims. Optionally, the method comprises shrink wrapping the bundle of builders shims comprising each of the articles with a flexible cling film around the vertical outer periphery thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a tension film wrapped modular masterpackage according to the invention, after the masterpackage has been shipped to a destination, and wherein the superimposed outer tension film wrap around the masterpackage has been cut to permit the individually outer wrapped palletized modular units to be distributed as desired by the store owner.
CA 0223~08 l998-04-22 ~:rdr sl8s-477sa.pa ~ 6 ~ EXPRESS MAIL NO. EM171447735US
Fig. 2 is a perspective view of one of the palletized modular units, particularly illustrating the pallet, wherein the column of articles is wrapped with a superimposed outer tension wrap of a flexible cling film.
Fig. 3 is a perspective view of a bundle of -builders shims itself shrink wrapped with a superimposed tension wrap of a flexible cling film.
Fig. 4 is a top plan view of the pallet of Fig. 2.
Fig. 5 is a view of one (the short) side of the pallet.
Fig. 6 iS a view of the other (the iong) side of the pallet.
Fig. 7 is a plan view of the interior of a truck trailer loaded with one layer of unitized masterpackages according to the method of the invention.
Description of a Preferred Embodiment Referring to the drawings, builders shims 10 are typically sold in bundles 12 comprising 48 shims. Such a bundle 12 is designed to satisfy the needs of both homeowners and contractors. Shims may also be bundled in bundles comprising 24 shims for an end user having a single job (such a bundle not being shown), or in bundles comprising 80 pieces for the professional installer of windows and doors (such a bundle also not being shown).
Each indiviclual bundle 12 can be wrapped with a superimposed tension wrap 14 of a flexible cling film 16 around its side edges 18, deemed the vertical outer periphery of the bundle 12. The side edges 18 are the only surfaces wrapped, because the shims 10 are typically prepared in the wet or pre-dried condition.
Leaving the tops anc! bottoms of the bundles open, permits the shims to dry out prior to actual use. See Fig. 3.
Wrapping each bundle 12 is preferably accomplished by what is known as "overbanding"; that is, CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa - 7 - EXPRESS MAIL NO. EM171447735US
shrink banding the bundle 12, to let the moisture out, with a non-tacky polyvinyl chloride (pvc) film using a Seal-A-TronTM shrink tunnel, Model TST-2410-LR15VSA. The film 16 preferably extends slightly below the bundle and slightly above the upper surface thereof (see Fig. 3), thereby to secure the individual shims 10 together.
- The bundles 12 of shims 10 are typically shipped to builders supply .,tores on pallets loaded with fifty bundles 12. The stores prefer to receive them on pallets, because a pallet loaded with fifty bundles 12 can be placed wherever the store manager desires.
Shipping individual pallets loaded with shims, however, is an inefficient and impractical way to transport them.
Thus, fifty of the bundles 12 are loaded in a predetermined array, for example, stacked on a pallet 20 such that the bundles 12 all have their shims 10 disposed in the same direction. The fifty bundles 12 form what is called a column 21. See Fig. 2.
The pallet 20 is preferably constructed as a rectangular frame 22, having a short side 24 (the side parallel to the longitudinal direction of the shims 10) twenty inches long, and a long side 26 (its other horizontal dimension) twenty-seven inches long. A
rectangular pallet is preferable because of the inherent rectangular nature of the bundles 12 themselves. The rectangular nature of the pallets also greatly facilitates the ultimate loading of a truck trailer as will be more fully explained hereinafter.
The stacked or loaded bundles 12 preferably extend slightly outwardly of the sides 24, 26 of the pallet 20, such that the column 21 has sides 28, 30 slightly larger than the sides 24, 26 of the pallet.
The sides 28, 30 of the column 21 typically may have dimensions of about 20-1/2 inches by 27-1/2 inches. It will be noted that the ratio of the length of the side 28 to the length of the side 30; i.e., 20-1/2:27-1/2, iS about 3:4, and the significance of this ratio will be hereinafter more fully explained.
CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa - 8 - EXPRESS MAIL NO. EM171447735US
The pallet frame 22 iS preferably constructed of two "two-by-four" pieces 32 forming its long sides 26 joined by two "two-by-three" pieces 34 extending interiorly of the pieces 32 and flush with their upper 5 surfaces 36 and two more "two-by-three'~ pieces 38 extending exteriorly of the pieces 32, positioned below the lower surfaces 40 thereof and extending to the outer side surfaces 42 of the pieces 32, as shown in Fig. 2.
By this means the tines of a forklift truck (not shown) facing either long side 26 of the pallet 20 can be inserted in the space 44 formed below the long side pieces 32 (between the pieces 38) to handle the pallet 20 and associated column 21 from the direction of the long side 26. Similarly the tines of a forklift truck facing either short side 24 of the pallet 20 can be inserted in the space 46 formed between the cross pieces 34 and 38 to handle the pallet 20 and associated column 21 from the direction of the short side 24.
Thus, the pallets 20 are capable of being lifted from any of the four sides using the tines of a forklift truck, and this greatly facilitates the loading of a truck trailer as wi:ll be hereinafter further described.
Each of the columns 21 is then vertically banded using a single vertically oriented steel or plastic strap 47. The strap 47 passes through the space 46 between the cross pieces 34 and 38, around the bundles 12 comprising the column 21, thereby tying the bundles 12 to the pallet 20. See Figs. 1 and 2.
The column 21 and pallet 20 are then wrapped by another tension wrap 48, using a flexible cling (tacky) film 50, to form a vertically wrapped palletized modular unit 52. This is ac:complished using a LantechT~ machine, sold by Lantech, Inc:., Louisville, Kentucky, preferably a LantechTU Model STE'SD, using LLDPE stretch film. The film 50 preferably extends slightly above the upper surface of the column 21, slightly over the bundles 12 as shown in Fig. l; also slightly below the upper surfaces 36 of the "two-by-four" side pieces 32, and CA 0223~08 l998-04-22 AlW:rdr sl~s-477sa~pa - 9 - EXPRESS MAIL NO. EM171447735US
slightly below the upper surfaces of the two "two-by-three" cross pieces 34. The wrapping, together with the banding provided by the strap 47, insures that the pallet 20 is secureLy incorporated within the modular 5 unit 52 and that it remains with the column 21 when the unit 52 is moved.
- After each modular unit 52 is wrapped, it is taken off the Lantec;hTM machine and put aside until a desired number of such units 52 have been wrapped, typically groups of four such units. Four wrapped modular units 52 are then placed in a horizontal side-by-side, two-by-two relationship on the LantechT~
machine, where they are again wrapped to form the masterpackage 54 shown in Fig. 1. As in the case of the 15 modular units 52, wrapping of the masterpackage 54 is preferably accomplished on a LantechTM Model STPSD
machine using LLDPE stretch film.
Because the ratio of the lengths of the sides 28, 30 of the columns 21 is approximately 3 :4, the 20 ratio of the length of the short side 56 of the masterpackage 54 to the length of the long side 58 thereof is also approximately 3: 4.
The masterpackage of four outer wrapped palletized modular units 52 is wrapped with a tension 25 wrap 60 of a flexible cling film 62. The four wrapped units 52 stay together very well, without the necessity of using another strap, because the tension wrap 60 forces them into a close relationship. This takes advantage of the inherent tackiness of the film 50 30 surrounding each modular unit 52 and the tendency of the edges of the shims 10 to protrude through the film.
Thus, it has been found that no pallet is needed below the masterpackage 54 itself for support. The finished masterpackage 54 has side dimensions of about 41 inches 35 by 54 inches, i.e., twice that of the modular units 52 themselves, and also approximately in the ratio of 3 :4.
Upon arrivin~ at the ultimate destination, typically the builders supply store, the wrap 60 around the masterpackage 54 can be cut, as shown in Fig. 1, CA 0223~i~i08 l998-04-22 ALW:rdr SlaS-47758.pa - 10 - EXPRESS MAIL NO. EM171447735US
such that the individually wrapped modular units 52, which include the pa:llets 20, can be placed in the store as desired.
The assembly as above described permits efficient usage of e~isting truck trailers to ship the product. As shown in Fig. 7, the interior of a truck ~railer 64 is loaded in the following manner. Three masterpackages 54 are placed in a first line 66 with their short sides 56 adjacent each other and their long sides 58 adjacent the interior sidewall of the trailer.
Loading in this manner is facilitated because the tines of a forklift truck can engage each masterpackage 54 using the spaces 46 :in the two side-by-side pallets 20.
Four masterpackages 54 are then placed in a second line 68 adjacent the first line 66, the four masterpackages 54 being placed with their long sides 58 adjacent each other and their short sides 56 adjacent the opposite interior sidewall of the truck trailer 64.
In loading these four masterpackages 54, the forks of the forklift truck engage the-two pallets 20 using the spaces 44 formed in the long sides 26 thereof.
Because the outer dimensions of the masterpackages 54 are substantially in the ratio of 3:4, seven masterpackages 54 loaded as aforesaid, form a group 70 which has a rectangular boundary. The 54 inch long side 58 of the masterpackages 54 in the second line 68, placed adjac~ent the 41 inch short side 56 of the masterpackages 54 in the first line 66, provide the group 70 with a tota] width of 95 inches, thereby efficiently filling t:he 98-inch standard interior width of the trailer 64.
An additiona] two groups 70 plus two more individual masterpackages 54 are usually loaded into the truck trailer 64 as shown in Fig. 7, preferably alternating short sicles and long sides of the masterpackages 54, as shown, thereby substantially fully loading the interior with twenty-three masterpackages 54, each consisting of four modular units 52, each unit ',2 containing fifty bundles 12, each CA 0223~08 l998-04-22 ~W:rdr 5185-47758.pa , - 11 - EXPRESS MAIL NO. EM171447735US
bundle 12 containing forty-eight shims 10. Typically, the truck trailer 64 is loaded with two layers of groups 70, thus to accommodate a total of forty-six such masterpackages 54. There is enough interior height in a typical truck trailer 64 to add a third layer, providing existing weight lim:itations are not exceeded.
- A trailer could be loaded with more groups 70 in each layer if the truck trailer is long enough to accommodate them, which would also depend on the particular dimensions of the masterpackage 54 concerned.
Also if a particular truck trailer is slightly longer than, for example, t:he trailer described herein that accommodates the forty-six masterpackages 54 shown, additional masterpac:kages 54, not necessarily the seven that form a complete group 70, can be loaded at the end of the trailer and maintained in position during transit with airbags (not shown).
Although an example has been selected wherein the dimensions of the masterpackage optimizes truck trailer loading using a group of seven masterpackages, in two lines of three and four masterpackages, respectively, the loading method would be analogous for any assembly of modular units and masterpackages having short sides and long sides in the ratio of x:y. The truck trailer would merely be loaded in a pattern wherein x of the masterpackages are placed in the first line and y of the masterpackages are placed in the second adjacent line, thereby to form a group of x + y masterpackages having a rectangular exterior boundary.
The present invention may be embodied in other specific forms without departing from the spirit and essential characteristics thereof. The present embodiments are presented merely as illustrative and not restrictive, with the scope of the invention being indicated only by the attached claims. All changes coming within the meaning and equivalency of the claims are, therefore, intended to be embraced thereby.
Claims (14)
1. A stretch-wrapped modular masterpackage for shipment to a destination, comprising:
a plurality of pallets each supporting a plurality of articles in a predetermined array, the articles forming a column, the column being wrapped -around its vertical outer periphery with film under tension, the column and the pallet forming a vertically wrapped palletized modular unit, the pallet being capable of being lifted from any of the four sides using the tines of a forklift truck, the palletized modular units being disposed in horizontal side-by-side relationship to form a masterpackage of individually wrapped palletized modular units, the masterpackage being wrapped around its vertical outer periphery with film under tension, whereby removal of the film from around the masterpackage following shipment to the destination permits the plurality of individually outer wrapped palletized modular units to be distributed as desired at the destination.
a plurality of pallets each supporting a plurality of articles in a predetermined array, the articles forming a column, the column being wrapped -around its vertical outer periphery with film under tension, the column and the pallet forming a vertically wrapped palletized modular unit, the pallet being capable of being lifted from any of the four sides using the tines of a forklift truck, the palletized modular units being disposed in horizontal side-by-side relationship to form a masterpackage of individually wrapped palletized modular units, the masterpackage being wrapped around its vertical outer periphery with film under tension, whereby removal of the film from around the masterpackage following shipment to the destination permits the plurality of individually outer wrapped palletized modular units to be distributed as desired at the destination.
2. The masterpackage of claim 1, wherein each of the articles comprises a bundle of builder's shims.
3. The masterpackage of claim 2, wherein the bundle of builder's shims comprising each of the articles is wrapped around its vertical outer periphery with film under tension.
4. The masterpackage of claim 1, wherein each of the pallets comprises a rectangular frame having two pairs of sides, and wherein one of the pairs of sides is longer than the other of the pairs of sides.
5. The masterpackage of claim 4, further comprising means to lift each of the pallets, said lifting means being associated with each of the pairs of sides.
6. The masterpackage of claim 4, wherein the column has sides whose dimensions are substantially in the ratio of 3:4.
7. A method of unitizing a masterpackage for shipment to a destination, the masterpackage comprising a plurality of modular units each comprising a plurality of articles in a predetermined array, each of the modular units being supported by a pallet capable of being lifted from any of the four sides using the tines of a forklift truck, the method comprising:
loading a plurality of articles in a predetermined array on a pallet to form a column of articles, the pallet being capable of being lifted from any of the four sides using the tines of a forklift truck;
wrapping a flexible cling film under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit;
placing a plurality of the palletized film-wrapped modular units in a horizontal side-by-side relationship; and wrapping a flexible cling film under tension around the vertical outer periphery of the plurality of palletized film-wrapped modular units to form a masterpackge, whereby removal of the film from around the vertical periphery of the masterpackage after arrival at the destination permits the plurality of individually wrapped modular units to be distributed as desired at the destination.
loading a plurality of articles in a predetermined array on a pallet to form a column of articles, the pallet being capable of being lifted from any of the four sides using the tines of a forklift truck;
wrapping a flexible cling film under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit;
placing a plurality of the palletized film-wrapped modular units in a horizontal side-by-side relationship; and wrapping a flexible cling film under tension around the vertical outer periphery of the plurality of palletized film-wrapped modular units to form a masterpackge, whereby removal of the film from around the vertical periphery of the masterpackage after arrival at the destination permits the plurality of individually wrapped modular units to be distributed as desired at the destination.
8. The method of claim 7, wherein each of the articles comprises a bundle of builder's shims.
9. The method of claim 8, further comprising shrink wrapping the bundle of builder's shims comprising each of the articles with a flexible cling film around the vertical outer periphery of the bundle.
10. A method of shipping a plurality of unitized masterpackages to a selected destination in a truck trailer having a defined interior width, each of the masterpackages comprising a plurality of modular units comprising a plurality of articles in a predetermined array, each of the modular units being supported by a pallet capable of being lifted from any of the four sides using the tines of a forklift truck, the method comprising:
loading a plurality of articles in a predetermined array on a rectangular pallet to form a column of articles having sides having dimensions substantially in the ratio of x:y, wherein x is less than y, and x and y are integers, whereby the side corresponding to x is the short side of the column and the side corresponding to y is the long side of the column, the pallet being capable of being lifted from any of the four sides using the tines of a forklift truck;
wrapping a flexible cling film under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit;
placing four of the palletized film-wrapped modular units in a horizontal two-by-two relationship;
wrapping a flexible cling film under tension around the vertical outer periphery of the palletized film-wrapped modular units in the horizontal two-by-two relationship to form a unitized masterpackage having sides substantially in the ratio of x:y, whereby the side corresponding to x is the short side of the masterpackage and the side corresponding to y is the long side of the masterpackage, and loading the unitized masterpackages in a truck trailer in a pattern wherein x of the masterpackages are placed in a first line with their short sides adjacent each other and y of the masterpackages are placed in a second line adjacent the first line with their long sides adjacent each other, the masterpackages forming a group of x + y masterpackages having a rectangular exterior boundary, the group of masterpackages having a width substantially extending the full width of the interior of the truck trailer.
loading a plurality of articles in a predetermined array on a rectangular pallet to form a column of articles having sides having dimensions substantially in the ratio of x:y, wherein x is less than y, and x and y are integers, whereby the side corresponding to x is the short side of the column and the side corresponding to y is the long side of the column, the pallet being capable of being lifted from any of the four sides using the tines of a forklift truck;
wrapping a flexible cling film under tension around the vertical outer periphery of the column to form a vertically wrapped palletized modular unit;
placing four of the palletized film-wrapped modular units in a horizontal two-by-two relationship;
wrapping a flexible cling film under tension around the vertical outer periphery of the palletized film-wrapped modular units in the horizontal two-by-two relationship to form a unitized masterpackage having sides substantially in the ratio of x:y, whereby the side corresponding to x is the short side of the masterpackage and the side corresponding to y is the long side of the masterpackage, and loading the unitized masterpackages in a truck trailer in a pattern wherein x of the masterpackages are placed in a first line with their short sides adjacent each other and y of the masterpackages are placed in a second line adjacent the first line with their long sides adjacent each other, the masterpackages forming a group of x + y masterpackages having a rectangular exterior boundary, the group of masterpackages having a width substantially extending the full width of the interior of the truck trailer.
11. The method of claim 10, wherein the column has dimensions at least equal to the dimensions of the pallet.
12. The method of claim 10, wherein x:y = 3:4.
13. The method of claim 10, wherein each of the articles comprises a bundle of builder's shims.
14. The method of claim 13, further comprising shrink wrapping the bundle of builder's shims comprising each of the articles with a flexible cling film around the vertical outer periphery of the bundle.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US93255397A | 1997-09-17 | 1997-09-17 | |
| US08/932,553 | 1997-09-17 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2235508A1 true CA2235508A1 (en) | 1999-03-17 |
Family
ID=29401921
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2235508 Abandoned CA2235508A1 (en) | 1997-09-17 | 1998-04-22 | Stretch-wrapped modular masterpackage and method of making same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2235508A1 (en) |
-
1998
- 1998-04-22 CA CA 2235508 patent/CA2235508A1/en not_active Abandoned
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