NZ618610B2 - Packaging system - Google Patents

Abstract

packaging system 10 for the transportation of an elongate product 12, comprises at least two spaced apart cleat units 14 through which the product 12 is supported. Each cleat unit 14 includes a lower cleat , an upper cleat 24 and side upright supports 20 that interconnect the lower and upper cleats at the ends of the lower and upper cleats to form a space 22 through which the product is supported. The side upright supports 20 and cleats interconnect by a pocket interconnection 18. One cleat unit 14 can be stacked above another cleat unit 14 by positively locating the ends of the stacked cleat units relative to each other through the side upright support 20. s at the ends of the lower and upper cleats to form a space 22 through which the product is supported. The side upright supports 20 and cleats interconnect by a pocket interconnection 18. One cleat unit 14 can be stacked above another cleat unit 14 by positively locating the ends of the stacked cleat units relative to each other through the side upright support 20.

Description

PACKAGING SYSTEM Field of the Invention The present invention relates to a packaging system used in the ortation of an elongate or extruded product.

Background Elongate products, such as ium or plastic extrusions, are typically long products that are fragile and/or easily damaged. Due to the nature of such products, they are often transported in batches or groups that can be difficult to handle, due to the size, weight, shape and fragility of the batches or groups.

Thus the transportation and storage of such elongate and ed products presents unique difficulties.

Typically, these products will be stacked for transportation, with timber skids, cleats or pallets used to vertically separate groups of the products. r, whilst timber is cheap and thus commonplace for such purposes, it is liable to move or become loose in t, resulting in damage to the products, and may not present an appropriate e for lifting the groups of products after transportation (eg. using a forklift). Packing straps are used to tie the stacked products, however those products can still shunt relative to each other in transit. Furthermore, the straps can damage the surface of the products and leave g to support the products after the straps have been removed and before removal of the products from the transportation surface — such a surface being, for example, the flat bed of a flat bed truck, a train carriage or shipping container.

Timber skids and cleats are rarely reused due in part to their inconsistent sizing, and the consequent difficulty in locating appropriately sized timber skids and cleats for a particular application, but also due to the costs associated with recycling and freighting empty skids and cleats. 3O An alternative, recyclable, system fortransporting elongate or extruded products has been proposed, which involves ent of products in a three- sided metal skip. However, the metal skips are heavy, expensive and occupy a lot of space even when empty, thus making them difficult to be ffectively returned to a product supplier. Such metal skips are also of fixed dimensions and are thus only suitable for use with products or groups of products of a d range of dimensions.

It is desired therefore to provide a packaging system which overcomes one or more of the abovementioned disadvantages of current packaging systems, or at least provides a useful alternative.

Summary of the invention in accordance with the present invention, there is provided a packaging system for the transportation of an te product, comprising at least two spaced apart cleat units through which the product is supported, each cleat unit including a lower cleat, an upper cleat and side upright supports that interconnect the lower and upper cleats to form a space through which the product is supported wherein the side upright supports and cleats interconnect by a pocket interconnection.

The upper and lower cleats may be of planar, generally rectangular, form and include a pocket located at each corner of the respective cleat for receiving one of the upright supports.

The upper and lower cleats may e a hollow interior for receiving, h a side slot, a reinforcing planar member.

The upper and lower cleats may include a strapping recess oriented centrally along a length of the cleats for accommodating a strap.

The pockets of the lower cleats may be closed to form upper and lower biind recesses. Contrastingly, the s of the upper cleats may be open to allow the upright supports to pass therethrough such that one cleat unit can be stacked above another cleat unit by ocking upright supports in the lower cleat unit with the lower blind recesses in the upper cleat unit. More broadly, one cleat unit can be stacked above another cleat unit by interlocking upper 3O ends of the upright supports in the lower cleat unit with pockets in the lower cleats of the upper cleat unit Brief Description of the Drawings Preferred embodiments of the present invention will now be described by way of non-limiting example only, with reference to the anying drawings, in which: Figure 1 is a top perspective view of a packaging system in use; Figure 2 shows a perspective view of a cleat unit of the packaging system of Figure 1; Figure 3 is a bottom perspective view of an upper cleat of the cleat unit of Figure 2; Figure 4 is a top perspective view of the upper cleat of Figure 3; Figure 5A is a bottom perspective View of a lower cleat of the cleat unit of Figure 2; Figure SB is a close-up l bottom perspective view of a lower cleat; Figure 6 is a top ctive view of the lower cleat of Figure 5A; Figure 7 is an exploded view of a cleat unit; and Figure 8 is a top perspective view of a packaging system packaging stacked elongate products.

Detailed Description A packaging system 10, as shown in Figure 1, is used for the transportation of an elongate product 12. The packaging system 10 includes four cleat units 14 through which the product is supported.

It will be appreciated that a packaging system 10 may include two or more cleat units 14 as appropriate to support a particular te product 12.

Moreover, the cleat units 14 can be spaced as appropriate to, for example, accommodate a particuiar elongate product 12 or to account for different types of cleat al. For example: heavier elongate products 12 may require a r number of cleat units 14 to be used in order to adequately support its weight; a product 12 with non-uniform weight distribution may require non- uniform cleat unit 14 distribution along its ; and cleat units 14 made from tighter materials may warrant the use of more cleat units 14 in order to properly support the elongate product 12, without damage to either the te t 12 or cleat units 14.

In packaging systems heretofore available, the planks or pallets are generally fixed in on relative to one another or are simply sandwiched between two products 12 (or a product 12 and the transport surface) to be retained in on. The former allows little variability in length and must therefore be assembled to suit the particular dimensions of an elongate product 12. The latter allows shunting and movement of elongate products 12, and is simply a support for the weight of the elongate product 12.

Therefore, in contrast to packaging systems heretofore available, packaging system 10 can be adapted to support elongate products 12 of different sizes and weights for transportation on the transport surface.

Each cleat unit 14, as shown in Figure 2, es a lower cleat 16, an upper cleat 18 and side upright ts 20. The side upright supports 20 interconnect the tower and upper cleats 16, 18 at a pocket interconnection 30, 20i, and a space 22 is formed between upright supports 20 through which the product 12 is ted.

The cteat units 14 can form a substantially rigid structure so that there is little or no relative movement of the lower and upper cleats 16, 18 during transportation. Thus ng of cleat units 14 against each other can be ted.

The pocket interconnection 30, 20i is formed by a pocket-type of engagement between a recess and a protruding member. in the embodiment of the packaging system illustrated, the pocket interconnection includes a pocket 30 located at each end of both the upper and lower cleats 16, 18, adapted to receive a protruding part of the upright support 20, which is specifically illustrated in Figure 7 as the ends 20i of t supports 20.

It is however understood that the pocket interconnection could include a e connection where the cleats, rather than providing pockets, instead 3O provide protruding inserts or lugs or the like, that are receivable in pockets that could be formed at the ends of the upright supports 20.

While two side upright supports 20 are shown at either end of the lower and upper cleats 16, 18, it will be iated that one or more side upright supports 20 may be used at either end, though use of at least two such side upright supports 20 is preferred for the purpose of stability and ty.

In the present embodiment, the lower and upper cleats 16, 18 include a hollow or 24 (visible through side slot 26) for receiving a reinforcing planar member 28. ln the present case, the interior of the upper cleat 18 is empty, whereas that ofthe lower cleat 16 is occupied by a reinforcing planar member As shown in Figure 1, the reinforcing planar members 28 extend along an underside of the elongate product 12 effectively increasing the area of the t surface n the cleat units 14 and the product 12. The increased contact area of the combination of the lower cleat 16 and reinforcing planar member 28 distributes the weight of the product 12 over a greater surface area and thus reduces the risk of damage to the surface or surface finish of the product 12. Moreover, the increased contact area between the packaging system 10 and the elongate product 12 can increase the friction required to slide the product 12 from the space 22 between the lower and upper cleats 16, 18, thereby reducing the likelihood of undesired movement of the elongate product 12 when in t.

An upper cleat 18, as shown in Figure 3, is ofa planar, generally rectangular, form. The upper cleat 18 includes a pocket 30 d at each corner for receiving an end of one of the side upright supports 20.

The upper cleat 18 includes two beams 321, 32ii that extend, in use, laterally across the elongate product 12. The beams 32i, 32ii are connected by a plate 34 spanning between the beams 32i, 32ii along substantially the entire length f.

The beams 32i, 32ii provide al rigidity to the cleat unit 14 in the vertical direction (Le. normal to the top surface of the elongate product 12), whereas both beams 32L 32ii and the plate 34 provide flexural rigidity in the horizontal plane (i.e. a plane parallel to the top surface of the elongate product 12).

A degree of torsional rigidity is also provided by end piates 35.

A reinforcing planar member 28 (as shown in the lower cleat 18 in Figure 2) can be received in the hollow interior 24 in the direction ted by arrow X. in the present case, the reinforcing planar member 28 will only extend into one of said beams 32i, until it comes into abutment with an internal wall 38 of that beam (the internal wall 38 of the second beam 32ii being more easily visible in Figure 3).

The reinforcing planar member 28 of the present embodiment therefore extends out one side of the upper cleat 18. However, it will be appreciated that the al walls 38 may also include slots similar to slots 26 (as shown in Figure 2), such that the reinforcing planar member 28 extends through a first side slot 26i in a first beam 32i, underneath plate 34 and into a second side slot 26ii (shown in broken lines) in a second beam 32ii. Thus the reinforcing planar member 28 can extend out one or both sides of the upper cleat 18.

As shown in Figure 4, the upper cleat 18 also includes on its upper e a central recess 36 defined by the plate 34 and side walls 38. The recess 36 s along the length of the cleat 18 and into end slots 40 that extend from recess 36 towards the lower cieat 16. ageously. a strap (not shown) or sling may be received in the recess 36 and slots 40 to more securely retain the cleat unit 14 in position.

Since the recess 36 and slots 40 are recessed into the cleat 18, a strap used with the packaging system 10 will not shift, longitudinally relative to the product 12, off the upper cleat18.

A lower cleat 16, as shown in Figures 5A and 5B, is similar to the upper cleat 18 except that its s 30i are blind (is. do not extend through the lower cleat 16 but are instead blocked off by a plate 42). A side upright support is thus inserted into the top of each pocket 30i and comes into abutment against the plate 42, thereby maintaining the end of the side upright support 20 in on within the pocket 30i. 3O As an alternative to the plates 42, each pocket 30i may provide an internal constriction 44, as shown in Figure 58. Such an internal constriction 44 would allow one side upright support 20 to be inserted into the top of the pocket 30i, while another side upright support 20 is inserted into the bottom of the pocket 30i. Both side upright supports 20 would then abut the internal constriction 44 (or internal plate as the case may be). As such, the constriction 44 (or internal plate) in the pocket 30i effectively creates upper and lower blind recesses allowing cleat units 14 to be stacked atop one another by interlocking side upright supports 20 in a lower cleat unit 14 with the lower blind recesses in the upper cleat unit 14 (discussed further in on to Figure 8).

The internal constriction 44 would also allow the pocket 30i of the lower cleat 16 to be received over a lug or other feature that is fixed to the transport surface (not shown). In so doing, the lower cleat 16, and thus the entire cleat unit 14, would be rigidly positioned ve to the transport surface.

While not ly necessary, the plate 34 of the upper cleat 18, which is a closed or solid plate, is replaced in the lower cleat 16, by an open sleeve 46 as shown in Figures 5A and 6. A reinforcing planar member 28 can be thus received through the slot 26 in one side of the lower cleat 16, and extend through the sleeve 46 to the other side of the lower cleat 16. if desired, the reinforcing planar member 28 can extend out both sides of the lower cleat 16.

Since the lower cleat 16 is that which provides most t to the weight of the elongate product 12, it will generally be desirable that the lower cleat 16 be provided with the reinforcing planar member 28 in preference to the upper member 18.

The hollow interior 24 of the lower cleat 16 also presents a tine slot into which the tines of a forklift (not shown) can be inserted to lift the elongate product 12 rdiy off the truck. Similarly, the elongate product 12 may be lifted from the side by insertion of tines into the es 47, as shown in Figure 5A, of a plurality of lower cleats 16. Lifting elongate products 12 from the side can thus be facilitated by spacing the lower cleats 16 along an elongate product 12 at intervals matching the distance between the tines, or similar, of a forklift or other lifting machine (eg a gantry crane using slings passing through the recesses 47). Advantageously, by uring the lower cleats 16 in this manner, t between a forklift and an te product 12 can be substantially avoided, thus reducing the risk of damage to the elongate product The sleeve 46 may also be ed by a hollow or solid central beam (not shown). Accordingly, reinforcing planar members 28 could extend into the slots 26 in the same manner as described in relation to the upper cleat 18 but stop short at the solid beam. Replacing the sleeve 46 with a hollow or solid beam strengthens the lower cleat 16 and also increases its structural rigidity.

The lower cleat 16 also includes a recess 48 and slots 50 that are respectively similar to recess 36 and slots 40 as shown in Figure 4. The recess 48 and slots 50 allow the lower cieat 16 to be independently secured to the transport surface (not . This concept is discussed further in relation to Figure 8.

An exploded View of an ative cleat unit 52 is shown in Figure 7.

Whilst the upper cleat 18, side upright supports 20 and reinforcing planar member 28 are as before described and wiil thus need not be described in further detail, the sleeve 46 of the lower cleat 16 has been replaced by a plate 54 similarto plate 34 of the upper cleat 18 as shown in Figures 3 and 4.

By replacing the sleeve 46 with a plate 54, a channel 56 is created, for ing an insert 58. In some embodiments, the lower and upper cleats 16, 18 will be fabricated from steel and as such present a hard surface to the elongate product 12. To reduce the risk of damage to the surface or surface finish of the elongate t 12, the insert 58 can be fabricated from a softer material, eg. timber, composite, etc, to bear against the elongate product 12 and thereby at least mitigate potentially damaging contact between the elongate product 12 and the lower cleat 16. Alternatively, the insert 58 may be fabricated from a rubberised material, or other material having a relatively high coefficient of friction, so that the lower cleat 16 effectively “grips” the elongate product 12. it is ly the case that te products 12 are desired to be 3O transported in stacks, such as that shown in Figure 8. While the cleat units 14i surrounding the upper elongate product 12i may be oned independently of the cleat units t4ii surrounding the lower eiongate product 12ii, it can often be advantageous to align the cleat units 14i, 14ii atop one another as shown.

Where the pockets of the lower cleat 16i of the upper cleat unit 142 n no plate 42 or constriction 44, as discussed in relation to Figures 5A and SB, each of the side upright supports 20 can extend h both cleat units 14L 14ii that are stacked atop one another. Alternatively, the side upright supports 20 may extend from the lower cleat 16ii of the lower cfeat unit 14ii through the upper cleat 18ii of the lower cieat unit 14ii, and into the pocket of the lower cleat 163i of the upper cleat unit 14i. in such circumstances, the constriction 44 can be particularly advantageous as it presents upper and lower blind recesses to side upright supports 20 extending into the pocket from both above and below respectively. Moreover, it is preferred that separate side upright supports 20 are used for each cieat unit 14i, 14ii, since it allows the cleat units 14i, 14ii to each remain intact when the upper cleat units 14i, along with the corresponding elongate product 12i, are unloaded from the lower cleat units 14ii.

By inclusion of the recesses 36, 48 and slots 40, 50 of the upper and lower cleats 18, 16 as discussed above in relation to Figures 4 and 6, the upper cleat 18ii of the lower cleat unit 14ii, and/or the lower cleat 16f of the upper cleat unit 14i, can be secured by straps to the transport surface. As such, those cleats 16i, 18ii provide an intermediate securement to the stack of elongate products 12 to assist in ting movement thereof. instead of providing an upper cleat 18ii of the lower cleat unit 14ii, and a lower cleat 16i of the upper cleat unit 14i, one of the cleats 16i, 18ii (the “intermediate” cleat) can function as both cleats 16i, 18ii. In effect this would define a cleat unit 14 having an upper cleat18i on top of an upper te product 12i, a lower cleat16ii beneath a lower elongate product 12ii and an intermediate cleat between the two elongate products 12i, 12ii. Provided the ediate cleat (not shown) ns a slot 26 and/or recess 47, as discussed above in relation to Figures 5A and 6, a lifting machine (eg. a forklift) 3O will be able to engage the intermediate cleat and lift the upper te product 12i off the lower elongate product 12ii. Such an arrangement would also -10.. reduce the amount of handling required to position the lower and upper cleats 16, 18.

In contrast to heretofore known packaging systems, the cleat units 14i, 14ii can interlock through the side upright supports 20. In so doing, the stack of elongate products 12 can remain stable even after strapping has been removed.

Due to the simple construction of the cleat units 14, assembly and disassembly of the cleat units 14 is simple. Also, each of the cleats 16, 18 is of substantially uniform shape, thus allowing the cleat units 14 to be embled and stacked for return to, for example, a dispatch department thereby encouraging recycling of the packaging system.

Since the spacing of the cleat units 14 is determined by the particular application, the lower and upper cleats 16, 18 can be fabricated from timber, plastic, , any other appropriate material or combination thereof as desired, and the number of cleat units 14 adjusted to suit that application.

Accordingly, light weight materials can be selected for applications, particular where manual handling of the cleat units 14 is required (eg. to reduce strain on the r). in addition, damage to one of the lower and upper cleats 16, 18 or side upright supports 20 does not result in the entire cleat unit 14 becoming useless. d only the damaged part need be repaired or ed for the cleat unit 14 to once again be rendered functional.

For smaller elongate ts 12 cages or mesh (not shown) can be fastened to the cleat units 14 along the sides of the elongate products 12 to preclude those elongate products 12 from escaping from between the side upright supports 20. Also, the shape of the reinforcing planar members 28 can be d to suit a surface of the elongate t 12. Therefore, if a cylindrical elongate product 12 is desired to be transported, the reinforcing planar members 28 may present a concave surface to the elongate product 12.

Advantageously, the cleat units 14 can reduce damage to the elongate products 12 when they are d on top of one another, since the side upright supports 20 positively locate the ends of cleat units 14i, 14ii relative to each other as shown in Figure 8. in so doing, the weight of an elongate product 12i is transferred downwardly to the transport surface through the side t supports 20, rather than through an elongate product 12ii that is lower in the stack. This also eliminates the ng effect as the cleat units 14 surrounding all of the elongate products 12 can be made to move in unison.

It will be understood to s skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention.

In the claims which follow and in the preceding description of the invention, except where the context requires ise due to express language or necessary implication, the word “comprise" or variations such as “comprises” or "comprising" is used in an inclusive sense, is. to specify the presence of the stated es but not to preclude the presence or addition of further features in various embodiments of the invention. -12..

THE

Claims (10)

1. NG THE INVENTION ARE AS FOLLOWS:

. A packaging system for the ortation of an elongate product, comprising at least two spaced apart cleat units through which the product is supported, each cleat unit including a lower cleat, an upper cleat and side upright supports that interconnect the lower and upper cleats at the ends of the lower and upper cleats to form a space through which the product is supported, wherein the side upright supports and cleats interconnect by a pocket interconnection 10 whereby one cleat unit can be stacked above another cleat unit by positively iocating the ends of the stacked cleat units relative to each other through the side upright supports.

. The packaging system as claimed in claim 1, wherein each upper 15 and lower cleat is of a , generally rectangular, form with a pocket of the pocket interconnection being located at each corner of the tive cleat for ing one of the upright supports.

. The packaging system as claimed in claim 1, wherein the pocket 20 interconnection includes pockets provided in the upper and lower cleats and parts of the upright supports that protrude into the pockets.

. The ing system as claimed in any one of the preceding claims, wherein the cleats include a hollow interior for receiving, through a 25 side slot, a reinforcing planar member.

. The packaging system as claimed in claim 4, n the hollow interior is open through one side of the cleat to the other side. 30 . The packaging system as claimed in claim 4, wherein the hollow interior is open to only one side of the cleat. -13..

7. The packaging system as claimed in any one of the preceding claims, including a strapping recess oriented along a length of the cieats for accommodating a strap. 5

8. The ing system as claimed in claim 7. wherein the strapping recess lies between two pockets located at each end of the cleat.

9. The packaging system as claimed in claim 2, or claim 3 or 4 when dependent on claim 2, wherein the pockets of the lower cleats are 10 closed to form upper and lower blind recesses, while the pockets of the upper cleats are open to allow the upright supports to pass therethrough.

10.The packaging system as claimed in any one of the preceding claims, 15 y one cleat unit is stacked above another cleat unit by interlocking upper ends of the t supports in the lower cleat unit with pockets in the lower cleats of the upper cleat unit.