GB2358171A - A top or staging element or lid for packaging stacked articles - Google Patents

Abstract

A top or staging element 1 for packaging loose articles of different size, shape and fragility in bulk, comprises layers joined together to provide a unitary sheet structure having first 2 and second (3, fig. 3a) major surfaces, the first surface 2 including strengthening means 4 adapted to enable the structure to resist twisting and bending. Preferably the element 1 has a void space (2a, fig. 3a), between the layers which may contain a substantially rigid member comprising a frame. The strengthening means 4 may be provided integrally in the material of the first major surface 2, being disposed substantially in the centre area of the first major surface 2, and may include a plurality of substantially arcuate ribs 5 and valleys 6. The first major surface 2 may also comprise of a flat area 7 about the periphery, which may mirror support formations on the base of a fork-lift pallet. A flange (11, fig. 3) may be disposed about the periphery and at an obtuse angle to the second major surface (3), which enables a number of elements 1 to be stacked for storage and transportation (fig. 4), and two gaps (12, fig. 3) may be formed in the flange(11) for ease of handling. The element 1 could be orientated on top of a package, for example, a stack of bottles or tins (fig. 1), the stack of items could be dimensioned so to co-ordinate with the peripheral flange (11) in order to help retain them in position. Means to hold the whole package together may be provided by straps, bands, string or by shrink wrapping, which may be applied either vertically or horizontally around the package. The element 1 may be made from thermoplastic material such as HDPE.

Description

2358171 A STAGING ELEMENT The invention relates to a staging element, a

package including a said element, a method of packaging including the use of a said element and a packaging kit 1. 1 including a said element.

Loose articles which need to be shipped in bulk from one place to another are conveniently shipped by packing the articles together to form a single transportable package. As is commonly practiced, packages of this type can be moved about easily using fork-lift trucks, containers etc, especially when the package includes a pallet base which can include means to engage the tines of a fork-lift. A huge variety of goods is shipped in this way every day, all around the world.

It is generally well known in the art that to produce a single, stable, transportable package from a large number of smaller, often irregularly shaped and breakable items requires the use of additional packaging elements. Put simply, a box can be considered a packaging element in this context, with items to be transported fitting within the walls of the box. It has been found more convenient however to form packages from a number of separate elements, such as a base, a top or staging element and some kind of sides, with means to hold the whole together. This introduces a certain amount of flexibility so that packages of different sizes can be built which can accommodate articles of different sizes and shapes and fragility. The items are usually arranged in layers one on top of the other, the bottom layer resting on a pallet adapted for lifting by a forklift with optionally, dividers between each layer of items. A lid or stage is usually provided on the top layer which, along with a sleeve or sides of some kind strengthens the package and helps prevent the items from coming adrift from the sides of the package. Means to hold the whole together is applied, which can take the form of strapping, bands, 2 shrink wrapping or even string, applied vertically and/or horizontally around th c package.

From this description it will be apparent that packages of this type are primarily collection of loose articles bound together in some way, and that during transportation they will be subject to stresses and strains which must be resisted ot accommodated without the package disintegrating. In addition, there are stress(, and strains within the structure itself which result, for example from the weight of individual layers on other layers, from the means which holds the package, together, and also from other packages which may be stacked on top. It is art object of the present invention to try to mitigate problems arising from these factors.

According to the invention there is provided a staging element for packagingl comprising layers joined to provide a unitary sheet structure having first and second major surfaces, the first surface including strengthening means adapted tci enable the structure to substantially resist twisting and/or bending. Thel combination of these features of construction result in a staging element which 1,Cl convenient to manufacture as well as giving increased strength and durability in use.

It is preferred that the element includes a void space between the layers. The void space may be provided with a substantially rigid member and the rigid mernbeill may comprise a frame. This assists in maintaining the rigidity of the structure.

The strengthening means may comprise formations integrally formed in the material of the first major surface. The strengthening means may comprise 4, plurality of substantially arcuate formations. It is preferred that the strengthening,' means is disposed in a substantially central area of the first ma or surface. It is, j further preferred that the first major surface includes a substantially flat area, the 3 substantially flat area being disposed around the periphery of the first major surface. The shape of the substantially flat area may for example mirror the pattern of support formations on the base of a folk-lift pallet.

The staging element may include a flange disposed about the periphery of the second major surface and it is preferred that the flange is disposed to form an obtuse angle with the second major surface. This helps retain items in the package and makes the element nest for easy stacking.

The staging element may preferably be formed from a thermoplastic material such as HDPE.

According to a second aspect of the invention there is provided a package comprising a base, a plurality of stacked items and a staging element as defined hereinabove.

According to a third aspect of the invention there is provided a method of packagmg including the step of constructing a package with a staging element as defined hereinabove.

According to a fourth aspect of the invention there is provided a packaging kit for providing packaging for goods, including a base, and a staging element as defined hereinabove.

The invention will further be described by way of example and with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a package; Figure 2 is a perspective plan view of an article according to the invention; Figure 3 is a perspective underplan view of the article of Figure 2; Figure 3 a is a sectional view of part of the article of Figure 2; 1:

Figure 4 is a part side view of a stack of the articles shown in Figures 2 and 3; Figure 5 is a plan view of an alternative embodiment of article; Figure 6 is a underplan view of the article of Figure 5; Figure 7 is a plan view of a tool used for forming the article of Figure 2; Figure 8 is a section along line A-A in Figure 7; and Figure 9 is a perspective view of the tool of Figure 7.

Referring to Figures 2 to 6 of the drawings there is illustrated a staging element -J for packaging comprising layers joined to provide a unitary sheet structure having first 2 and second 3 major surfaces. The first surface 2 including strengthening means 4 adapted to enable the structure to substantially resist twisting and/o.t bending.

Figure 1 is an illustration of the type of packaging for which the invention it suitable. A pallet base has stacked on it layers of bottles, with pads in between tli(i layers. The package is topped by a plane sheet of material such as plywood.

In Figure 2 it can be seen that the element 1 comprises a generally flat sheet which is formed from a thermoplastic material such as HDPE. The element has a twiii, sheet formation as illustrated in Figure 3a, that is it is formed by fusing two sheet.' of material together in a mould with the application of heat and a vacuum. As will be apparent to the skilled person this method of formation provides a unitary structure with an air gap or void space 2a in between the sheets. For the avoidance of doubt the void space is completely sealed ftom contact with the outside and may include structures such as ribs or supports between the sheets. In this embodiment a rigid &ame of wood (not shown) is provided in the void space.

The first major surface 2 has formed in it the strengthening means 4 which in this embodiment is a senes of generally arcuate ribs 5 and valleys 6, these features being provided with as smooth a profile as possible. This prevents accretion of dirt. The strengthening means 4 is formed in the central portion of the first major surface 2 and is surrounded on all four sides by a substantially flat area 7. The void area beneath the flat area 7 is occupied by the rigid frame which helps to provide rigidity and support thereto. In this embodiment the flat area 7 is provided with extensions 8 which extend from each inner edge into the central strengthening area.

In the centre of the strengthening means 4 a further substantially flat part 9 is provided with, at its centre, a recess or dimple 10. As far as possible, all surfaces and interfaces between surfaces are made as smooth and curved as possible.

Referring to Figure 3 the underside of the article of Figure 1 is illustrated. The underside is formed by the second major surface 3 and is planar, and has a peripheral flange 11. The peripheral flange 11 is not perpendicular to the second major surface 3, but rather leans away from it at an obtuse angle. Two gaps 12 are formed in the peripheral flange 11. As illustrated in Figure 4, the flange 11 enables a number of elements 1 to be stacked for storage and transportation. The gaps 12 in the flange 11 are provided for ease of handling.

6 In the embodiment illustrated in Figures 5 and 6 the configuration is generally lh same as that illustrated in Figures 2 and 3, however in Figures 5 and 6 the first major surface 2 is provided with a perpendicular flange 13 and the second major 11 surface 3 has a flange with comer portions removed.

Figures 7 to 9 illustrate details of a mould tool 14 used for formiing th(,_ strenLytheninL, means 4 in the first major surface 2.

In use, the element I oriented as shown in Figure 1 is placed on top of a packag( which could, for example, be a stack of bottles or tins resting on a pallet. Tht, stack of bottles or tins would be built up to a desired height with layers separated, by pads as is known in the art and the staging element I is placed on top of thq topmost layer. It is most convenient if a stack of items has been dimensionec such that the flange I I of the staging element I co-ordinates with edges of thq 1 items in the stack in order to help retain them in position. Once the staging element I has been applied to the packaging, compression straps can be applied around the package from top to bottom to keep the package together. When they are in place, the compression straps provide a compressive force onto the staging element 1 which in turn spreads the load evenly down through the package thereby obviating damage to the stacked items. When the package is being transportedi shifting of items within the package occurs and the bending and twisting forcesi, which result are substantially resisted by the staging element I by virtue of the strengthening means 4.

As will be appreciated, the flat area 7, extensions 8 and flat part 9 all provide a convenient surface upon which another package can be stacked and the configuration of these areas can be varied for example to correspond to the, J configuration of the bottom of a particular kind of folk-lift pallet (not shown). In.

particular the flat areas enable pallets with suction feet to stick onto the element 1.

II i 11 I I 1 1 i 7 a - From the description of this embodiment of the invention it will be apparent that the invention provides a considerable number of advantages which assist in providing stable and secure packages.

8

Claims (18)

1. A staging element for packaging, comprising layers joined to provide a.

unitary sheet structure having first and second major surfaces, the first, surface including strengthening means adapted to enable the structure to substantially resist twisting and/or bending.

2. An element according to claim 1, including a void space between the layers. 1:

3. An element according to claim 2, including a substantially rigid member m the void space.

1:

4. An element according to claim 3, the substantially rigid member:

comprising a ftame.

5. An element according to any preceding claim, the strengthening means, comprising formations integrally formed in the material of the first major: surface.

6. An element according to any preceding claim, the strengthening means, comprising a plurality of substantially arcuate formations.

7. An element according to any preceding claim, the strengthening means, being disposed in a substantially central area of the first major surface.

An element according to any preceding claim, the first major surface, including a substantially flat area.

9 9. An element according to claim 8, the substantially flat area being disposed about the periphery of the first major surface.

10. An element according to claim 9, the shape of the substantially flat area mirroring support formations on the base of a fork-lift pallet.

11. An element according to any preceding claim, including a flange disposed about the periphery of the second major surface.

12. An element according to claim 11, the flange being disposed to form an obtuse angle with the second major surface.

13. An element according to any preceding claim, comprising a thermoplastic material.

14. An element according to claim 13, comprising HDPE.

15. An element substantially as hereinbefore described, with reference to the accompanying drawings.

16. A package, comprising a base, a plurality of stacked items, and a staging element as defined in any of claims 1 to 15.

17. A method of packaging including the step of providing a package with a staging element as defined in any of claims 1 to 15.

18. A packaging kit for providing packaging for goods, including a base, and a staging element as defined in any of claims 1 to 15.