EP4089022A2

EP4089022A2 - Packed roof window product

Info

Publication number: EP4089022A2
Application number: EP22172990.8A
Authority: EP
Inventors: Erik Andersen
Original assignee: VKR Holding AS
Current assignee: VKR Holding AS
Priority date: 2021-05-12
Filing date: 2022-05-12
Publication date: 2022-11-16
Also published as: EP4089022A3

Abstract

A packed roof window product comprising a plurality of differently sized roof window related product components contained in a cardboard box (2), wherein a collection of flashing and/or covering components (31, 32) is contained in a carton made from paper or cardboard and arranged inside the cardboard box.

Description

Technical Field

The present invention relates to a packed roof window product comprising a plurality of differently sized roof window related product components contained in a cardboard box.

Background Art

When installing windows in a roof it is vital to ensure that the roof window itself is securely attached to the roof structure and that the joint between the roof window and the roof structure is properly weatherproofed. It is therefore important that all components of roof window products, such as the roof window itself or a flashing assembly for a roof window, are used and are used in the right way. To facilitate this, the components are typically arranged in the box in an intended order of use and small components, such as screws, are kept in plastic bags. Furthermore, blocks of expanded polystyrene or similar shock absorbing material are used for protecting the product and/or for keeping the components in the intended position within the box. An example of a packed roof window, where these principles are used, is known from EP2748071B1 and an example of a packed flashing assembly for a roof window is known from EP1710163B1 .
While these packaging have worked very well, there is an ever increasing demand for delivering products that are more environmentally friendly.

Summary of Invention

With this background, it is an object of the invention to provide a packed roof window product, which has a smaller climate footprint, without increasing the risk of errors in the installation of the product and maintaining a good protection of the product during transportation. It is noted that "roof window product" is intended to cover not only a roof window, but also products associated with the installation of a roof window, such as flashing assemblies, and products intended for being installed on a roof window, such as shutters.
This and further objects are achieved with a packed roof window product of the kind mentioned in the introduction, which is furthermore characterised in that a collection of flashing and/or covering components is contained in a carton made from paper or cardboard and arranged inside the cardboard box.
Flashing and covering components are typically made of sheet metal, such as aluminium and cobber, and such components made from aluminium are typically painted and lacquered. As flashing or covering components will be at least partially visible in the installed state of the roof window product, it is important that they are not scratched or deformed. Even more importantly, a deformation is to be avoided as it may have a negative influence on the weatherproofing function of the flashing or covering components.
Traditionally, large components of a roof window product, such as flashing and covering components, have been kept in place in the cardboard box by being attached to the box by means of an adhesive or by being fixated between blocks of expanded polystyrene (EPS), and some have been covered by a protective plastic film to prevent them from being scratched. Smaller components traditionally have been attached to the cardboard box or to larger components, for example by means of an adhesive, and/or wrapped in plastic, thereby also preventing them from scratching or otherwise damaging other components.
By providing the collection of flashing and/or covering components in a carton, the flashing and/or covering components are prevented from moving around in the cardboard box, thus reducing the risk of them being jammed between other component, and the possibility for contact with other components, which might result in scratches, is also reduced. This means that the need for fixating or covering other components may be reduced. Furthermore, by arranging flashing and/or covering components in a carton the need for blocks of material attached to the cardboard box for retaining them may also be reduced. Arranging the collection of flashing and/or covering components in a carton may thus contribute to a reduction in the total material consumption.
Another advantage is that while the use of adhesives, plastic and EPS requires that the packaging material will have to be separated in different fractions for recycling, the carton belongs to the same fraction as the cardboard box. This considerably increases the likelihood of the packaging material being recycled instead of just being disposed of as combustible waste and reduces the risk of recyclable material being polluted by other materials.
Another potential advantage of using a carton is that it may at the same time retain items and prevent scratching. Thereby, one carton may potentially replace both an EPS block and a protective film or a plastic bag, thus potentially reducing either the total material consumption or the number of separate pieces of packaging material to be manufactured and recycled. A reduction of the number of separate pieces of packaging material may in turn reduce the risk of them being lost or forgotten.
A still further potential advantage of using a carton made from paper or cardboard is that it may be biologically degradable. Light-weight packaging items, such as plastic wrappings, films and EPS, are easily caught by wind when installing a roof window product on a roof of a building and may end up in nature or other places where it cannot be collected by the installer. While it is of course not the intention to leave packaging material behind, a biodegradable carton does little harm.
In one embodiment the carton containing the collection of flashing and/or covering components has a size and/or shape matching an inner dimension of the cardboard box so that the carton is prevented from moving in at least one direction.
In one embodiment a carton is attached to the cardboard box. This may allow the carton to retain other components in an intended positioning within the cardboard box, thus serving substantially the same purpose as the EPS blocks known from EP1710163B1 .
A carton may be attached to the cardboard box, to another carton or to another component of the roof window product by means of a glue or an adhesive. Alternatively, or as a supplement, mechanical fasteners, such as staples or a hook-and-loop type fastener, such as Velcro^®, may be used. Alternatively, or as a supplement, attachment may be achieved by providing the carton with a physical structure, such as a hook-shaped projection allowing it to engage with a component of the product.
Other components of the roof window product may also be provided in one or more cartons, which is particularly considered advantageous for other sensitive components, which may be damaged by contact with other components. One example of such other sensitive components is electronic components, such as wires, photovoltaic elements, sensors, batteries or remote controls, which will often have limited strength. In one embodiment, where the packed product includes a roof window, a carton is attached to a handle bar of the roof window adapted for use in opening and closing the roof window. In the packed state of roof windows such handle bars are often arranged in a disengaged state to make the roof window take up as little space as possible and a fixation member in the form of a specially shaped block of EPS is used to keep the handle bar in place during handling and transportation of the packed roof window product. A carton attached to the handle bar may replace the EPS block, while at the same time serve to retain other components of the roof window product.
It may also be advantageous to arrange components, which are likely to cause damage to other components, in a carton. One example of such components is mounting brackets for connecting a roof window to a roof structure as they are relatively heavy and often have sharp edges or corners. Another example is fasteners, such as screws, nails or clamps, which have sharp ends and which due to their small size can move around in the cardboard box if not retained.
A carton can also be used for keeping one or more components in a folded and/or compressed state. Examples of components, which can advantageously be delivered in a folded state, are wires and cables. Examples of components, which can advantageously be delivered in a compressed state, are sealing strips and insulating components, thereby reducing their size and the packed state and potentially allowing the use of a smaller cardboard box.
A shock absorbing material may be provided inside the carton, for example to protect ends of the flashing and/or covering components, or the shock absorbing material may be arranged between the flashing and/or covering components. In one embodiment, two flashing and/or covering components, each having a concave shape, are arranged opposite each other such that their concavities form a common inner space, and a block of a shock absorbing is arranged in this common inner space. This may contribute to retaining the flashing and/or covering components, to keeping sharp edges of these flashing and/or covering components from damaging other components, and to preventing deformation of the flashing and/or covering components. The shock-absorbing material is preferably also made from paper or other plant fibres.
In one embodiment, where the packed roof window product includes a roof window, a carton is arranged on the pane of the roof window between the pane and the cardboard box, possibly with a slip sheet between the carton and the pane to avoid scratching of the pane. Traditionally, shock-absorbing material is arranged on the side of the pane, which is intended to face the exterior in the mounted state of the roof window, to protect both the pane and covering members on the sash and/or frame of the window, which typically project above the surface of the pane. The carton may reduce or eliminate the need for such shock-absorbing material while at the same time retaining other components of the roof window product.
In one embodiment, where the packed roof window product includes a roof window, a carton is arranged along a frame of the roof window between the frame and the cardboard box. In this position, the carton may contribute to keeping the roof window in an intended position inside the cardboard box and/or to protecting the roof window in case the package is dropped or handled in a rough manner. It may thus replace at least some of the shock-absorbing material, which is traditionally used for this purpose. A similar effect may be achieved by arranging one or more cartons along one or more sides of a cardboard box containing another roof window related product.
While in the above embodiments the collections of components have been described as comprising components of a particular type made from the same or like materials, it is to be understood that a collection of components may comprise components of different types. As an example, insulating components and flashing components to be arranged in parallel with each other along a side of a roof window may be provided as a collection of components. As another example, mounting brackets and the fasteners intended for attaching them to a roof window and/or a roof structure may be provided as a collection of components.
It is to be understood that while paper and cardboard are usually made from wood-fibres, other plant fibres including fibres originating from straw, bamboo, bagasse, esparto, other grasses, hemp, flax and cotton may also be used, including combinations of different types of fibres. In Europe, up to 5% of alternative materials, such as the glue or adhesive, is acceptable, but a maximum of 3% is recommended.

Brief Description of Drawings

In the following description embodiments of the invention will be described with reference to the schematic drawings, in which

Fig. 1 is a perspective view of a cardboard box containing a packed roof window product in the form of a flashing assembly,
Fig. 2 is a perspective view of a cardboard box corresponding substantially to that in Fig. 1, but where some components of the flashing assembly are packed in cartons,
Fig. 3 is a perspective view of another cardboard box containing a packed roof window product,
Fig. 4 is a perspective exploded view of a roof window with packaging material and a carton containing a collection of components,
Fig. 5 corresponds to Fig. 4 but showing the packaging material and the carton in the positions, in which it will be located when inside a cardboard box as the one in Fig. 3, and where elements underneath the pane of the window are also seen,
Fig. 6 is a perspective view of a piece of packaging material corresponding to that shown at the bottom of the roof window in Fig. 5 and a carton arranged in a cavity therein,
Fig. 7 is a perspective view of an upper end of a roof window with packaging material corresponding substantially to that shown in Fig. 5, where a carton containing a collection of components is positioned on the pane,
Fig. 8 is a perspective view of an upper end of a roof window with packaging material corresponding substantially to that shown in Fig. 5 seen from the opposite side of the pane, and where a carton containing a collection of components has replaced a piece of packaging material, and
Figs 9 and 10 show details of the carton in Fig. 8.

Description of Embodiments

Referring initially to Fig. 1 which shows a cardboard box 2 packed with a roof window related product, here in the form of a flashing assembly 3, which consists of a large number of components. The cardboard box 2 is of a rectangular configuration having two major sides 21, 22 and four minor sides 23, 24 extending between the two major sides, and it is opened and closed by swinging an entire major side 21. The components of the flashing assembly 3 are retained in the cardboard box 2 by blocks 41 of expanded polystyrene (EPS) and by paper ribbons 7. While this has worked well, the paper ribbons 7 may not be sufficient to prevent damages to the flashing and covering components 31, 32 of the flashing assembly 3. To solve this problem, a collection of flashing and covering components, including the large component 32 seen in Fig. 1, has been arranged in a carton 65 in Fig. 2, and smaller components with a potential for damaging other components have been arranged in another carton 66. The flashing component 31 remains without packaging material, as the risk of it being damaged is now considerably reduced, but it is to be understood that it too could be arranged in a carton.
Both the cardboard box 2 and the biggest carton 65 have a rectangular shape and the length of the carton 65 is seen to match the inner length of the cardboard box 2. The smaller cartons 66 is seen to extend between a minor side 24 of the cardboard box 2 and the carton 65, serving to keep the biggest carton 65 in place inside the cardboard box 2 and keep it from damaging component 31, thereby reducing the need for dedicated packaging material serving only to space the components apart. The smaller carton 66 may be attached at least temporarily to the cardboard box 2 by strips of glue or an adhesive to keep it in the intended position.
Turning now to Fig. 3 another cardboard box 1 for containing a roof window product comprising a plurality of differently sized roof window related product components and packaging material components is shown. As described with reference to Fig. 1, this cardboard box is also of a rectangular configuration having two major sides 11 and four minor sides 13, 14 extending between the two major sides (only one of the major sides and two of the minor sides being visible in this view). The shorter of the minor sides 13 is here shown in a partially assembled state. In the assembled state, the side sections 13' will extend perpendicular to the major sides 11. In this embodiment the cardboard box 1 is configured for being opened as illustrated by the arrows P. This type of cardboard box is typically used for heavy products such as roof windows with a glass pane.
It is to be understood that the cardboard boxes 1, 2 shown are merely examples, and that the cardboard box may have another shape to better fit the shape and dimensions of the roof window product.
Likewise, it is to be understood that in the following the same reference numbers will be used for elements having substantially the same function, even if not identical.
Figs 4 and 5 show how blocks 42-47 of shock absorbing material have traditionally been arranged around and on a roof window 5 before the roof window is arranged in a cardboard box as the one shown in Fig. 3.
Rectangular blocks 42, 43 of shock absorbing material extend along side frame members 51 and a top frame member of the window frame of the roof window 5, and liners 61 made from cardboard compensate for irregularities in the shape of the sides of the roof window. A block 44 of a more complex shape extends along a bottom frame member 52 and has a cavity 44a for a carton 62 containing a collection of components. The four blocks 42-44 of shock absorbing material will be arranged at the four minor sides of the cardboard box 1 in the packed state of the roof window 5.
The pane 53 of the roof window 5 is protected by two elongate blocks 45 of shock absorbing material, which are arranged on the pane, so that they will be located between the roof window 5 and the major side 11 of the cardboard box 1 in the packed state. A paper liner or slip sheet (not shown) may be provided between the elongate blocks 45 and the pane 53 to protect the pane from scratching.
In Fig. 5 the pane has been shown as transparent so that additional blocks 46, 47 of shock absorbing material arranged on a handlebar 54 of the roof window 5are visible. These blocks 46, 47 serve to retain the handlebar 54, keeping it in an intended position in relation to the pane 53 and to the cardboard box 1 in the packed state.
Any of the blocks 42-47 of shock absorbing material may be replaced by a carton containing a collection of components, depending on the size and other physical properties of the components.
The carton 62, which is also shown in Fig. 6, is accommodated within the cavity 44a of the block 44 of shock absorbing material and will be positioned between the window frame of the roof window and the cardboard box in the packed state, thus being prevented from moving around in the cardboard box during handling and transportation. Due to its size and to it being protected by the block 44 of shock absorbing material, the carton 62 is particularly suitable for containing a collection of relatively fragile components, for example electronic components, such as wires, cables, photovoltaic elements, sensors, batteries, or remote controls, or a collection of metal components, such as mounting brackets to prevent them from damaging other components. Recesses 44b at opposite sides of the cavity 44a allow an installer to easily retrieve the carton 62 from the block 44 by putting his finger into the recess and lifting the side carton.
Fig. 7 shows an upper end of a roof window 5 corresponding substantially to the roof window shown in Fig. 5. As can be seen, a paper ribbon 7 is here used to retain a block 45 of shock absorbing material relative to the roof window 5 and further to retain a carton 63. The carton 63 is arranged on the window pane 53 and contains a collection of components for use in installing the roof window, such as covering or flashing components. When the packed roof window of Fig. 5 is contained in a cardboard box, the carton 63 will be located between the pane 53 and the cardboard box. The carton 63 is made from cardboard and has a lid 63a which is longer than the remaining sides of the carton 63, allowing the lid 63a to extend across the block 45 and in between the roof window 5 and block of shock absorbing material or carton 43 extending along the top frame member of the roof window. The paper ribbon 7 attaches the lid 63a to the block 45, thereby retaining the carton 63 in relation to the roof window 5. If necessary, a slip sheet (not shown) of paper material can be arranged between the carton 63 and the pane 53 to prevent the carton from scratching the pane.
Referring now to Fig. 8 which shows the upper end of a roof window corresponding substantially to that shown in Fig. 5 but seen from the side, which is intended to be the interior side in the mounted state of the roof window. A carton 64 containing a collection of components has replaced the blocks 46, 47 of shock absorbing material of the embodiment of Fig. 5. The carton 64 is attached to the handle bar 54 and has the dual purpose of retaining the handle bar 54, keeping it in an intended position in relation to the pane 53 and the cardboard box in the packed state, and of containing a collection of components. The carton 64 attaches to the handlebar 54 by a physical structure of the carton, namely a recess 641 provided across the carton, which recess is configured for engaging the handlebar 54 and has projections 642 for improving the attachment. The carton 64 is in this embodiment made from corrugated cardboard.
Details of another embodiment of the carton 64 are shown in Figs 9-10, Fig. 9 showing the carton 64 seen in a direction substantially parallel to the handle bar 54 when mounted as in Fig. 8 and Fig. 10 showing it from above.
The shape of the recess 641 matches the cross-sectional shape of the handle bar 54 of the roof window as seen in Fig. 8. In this case, the shape is adapted for use with a VELUX roof window, but other roof windows may require a different shape of the recess.
The side wall 643 of the carton 64 defining the end of the recess 641 consists of three layers of cardboard, whereas the parts of the carton 64 extending along the length of the recess 641, including the projections 642, only comprise a single layer. This provides a combination of relative strength and stiffness, which facilitate attachment, detachment and possibly reattachment of the carton 64. As is well-known to the skilled person, cartons as shown in Figs 8-10 are often used for containing remote controls, manuals and similar items, which are not to be used by the installer of the roof window, but by the end user. Such cartons are typically removed by the installer during installation of the roof window and then reattached afterwards. At that time, the handle bar 54 has been moved from the delivery position shown in Fig. 8 to a position further from the pane and closer to the sash and frame, and the carton is attached with the opposite side facing the pane, so that it is easily accessible to the end user. The embodiment of the recess 641 and projections 642 shown in Figs 8-10 facilitates this reattachment of the carton.

List of reference numerals

1: Cardboard box
11: Major side
13: Minor side
13': Section of minor side
14: Minor side
2: Cardboard box
21: Major side
22: Major side
23: Minor side
24: Minor side
3: Flashing assembly
31: Component
32: Component
41-47: Blocks of shock absorbing material
44a: Cavity
44b: Recesses
5: Roof window
51: Side frame member
52: Bottom frame member
53: Pane
54: Handle bar
55: Top frame member
56: Top sash member
61: Side liner
62: Carton
63: Carton
63a: Lid of Carton
64: Carton
641: Recess
642: Projection
643: Side wall
65: Carton
66: Carton
7: Paper ribbon
P: Opening of box

Claims

A packed roof window product comprising a plurality of differently sized roof window related product components contained in a cardboard box (1, 2),
characterised in that
a collection of flashing and/or covering components is contained in a carton (62, 63, 64, 65, 66) made from paper or cardboard and arranged inside the cardboard box (1, 2).
A packed roof window product according to claim 1, wherein a carton (66) is attached to the cardboard box (1, 2).
A packed roof window product according to one or more of the preceding claims, wherein a carton (62, 63, 64, 65, 66) is attached to the cardboard box (1, 2), to another carton or to another component of the roof window product by means of a glue, an adhesive, a mechanical fastener, such as a staple or a hook-and-loop type fastener, and/or a physical structure of the carton.
A packed roof window product according to one or more of the preceding claims, wherein a carton (65) has a size and/or shape matching an inner dimension of the cardboard box (1, 2).
A packed roof window product according to one or more of the preceding claims, wherein a shock absorbing material is provided inside a carton, said shock absorbing material preferably being made from paper or cardboard.
A packed roof window product according to one or more of the preceding claims, including a roof window (5), wherein a carton is arranged along a frame of the roof window (5) between the frame and the cardboard box (1, 2).
A packed roof window product according to one or more of the preceding claims, including a roof window (5), wherein a carton (63) is arranged on the pane (53) of the window (5) between the pane and the cardboard box (1, 2).
A packed roof window product according to claim 7, wherein a slip sheet is arranged between the carton (63) and the pane (53).
A packed roof window product according to one or more of the preceding claims and including a roof window (5), wherein a carton (64) is attached to a handle bar (54) of the window (5) adapted for use in opening and closing the window (5).
A packed roof window product according to one or more of the preceding claims, wherein a carton (62) contains components chosen from the group consisting of: sealing strips, insulating components, cables, wires, photovoltaic elements, sensors, batteries, remote controls, mounting brackets, and fasteners.