US20040011691A1 - Protective insert for commercial packaging of fragile stackable items - Google Patents
Protective insert for commercial packaging of fragile stackable items Download PDFInfo
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- US20040011691A1 US20040011691A1 US10/198,543 US19854302A US2004011691A1 US 20040011691 A1 US20040011691 A1 US 20040011691A1 US 19854302 A US19854302 A US 19854302A US 2004011691 A1 US2004011691 A1 US 2004011691A1
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- United States
- Prior art keywords
- protective insert
- chambers
- cone
- top wall
- end chamber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/44—Integral, inserted or attached portions forming internal or external fittings
- B65D5/50—Internal supporting or protecting elements for contents
- B65D5/5028—Elements formed separately from the container body
- B65D5/503—Tray-like elements formed in one piece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/44—Integral, inserted or attached portions forming internal or external fittings
- B65D5/48—Partitions
- B65D5/48024—Partitions inserted
- B65D5/48042—Strip provided with series of folding lines forming the partitions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
- B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
- B65D81/127—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material
- B65D81/133—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material of a shape specially adapted to accommodate contents, e.g. trays
Definitions
- the present invention relates to packaging of fragile stackable items, such as edible cones and the like. More particularly, the present invention relates to a protective insert for separating, supporting and protecting fragile stackable items stacked within a container.
- large quantities of edible cones 102 are typically packaged in a substantially rectangular container 100 (e.g., a box) when sold for commercial use.
- Edible cones 102 are placed within each other to form a cone stack 104 .
- a plurality of rows of cone stacks 104 are placed within the container 100 .
- a cone holder 106 is typically used to hold the cone stacks 104 at spaced intervals.
- the cone holder 106 is often a piece of cardboard, paperboard or plastic supported a distance above the bottom of the container 100 and having a number of openings 108 configured to receive the pointed ends of the cone stacks 104 .
- corrugated paperboard 200 is typically used as a protective insert.
- the corrugated paperboard 200 may be folded so as to form multiple three-walled chambers 202 , each having a first side wall 204 , a second side wall 206 and a back wall 208 .
- the sidewalls 204 & 206 of the chambers 202 may be positioned between the cone stacks 104 of a row of cone stacks 104 to ensure that the cone stacks 104 do not touch each other.
- the three-walled chambers 202 of the folded corrugated paperboard 200 do not cover the open end (i.e., the top) of the cone stacks 104 and therefore do not provide a protective layer between the edible cones 102 and the top of the box 100 .
- Folded corrugated paperboard 200 has been the protective insert of choice for packaging edible cones 102 because it is an inexpensive commodity.
- the use of folded corrugated paperboard 200 as a packaging insert has drawbacks.
- the act of folding the corrugated paperboard 200 and holding it in the proper three-walled configuration while inserting it between cone stacks 104 is time consuming and thus limits the number of containers 100 of edible cones 102 that can be packaged during a given time period.
- constant repetition of the folding action has been found to trigger carpel-tunnel syndrome in line-workers. Workers suffering from carpel-tunnel syndrome may work more slowly, miss work more often and possibly file workers compensation claims.
- corrugated paperboard 220 is not all that strong or shock-absorbent, which leads to more breakage of edible cones 102 than is necessary.
- the present invention meets the above-described need by providing a protective insert for use in packaging a plurality of fragile stackable items, such as edible cones.
- the protective insert comprises a plurality of laterally-aligned chambers that are configured to fit a stack of edible cones.
- each chamber is formed by the union of a first sidewall, a second sidewall, a back wall and a top wall.
- the chambers are each configured to fit a stack of edible cones and may be substantially semi-cylindrical in shape.
- the protective insert comprises a unitary construction that may be made from foam, plastic or any other suitable material.
- a top flange may be connected to the top wall of the protective insert.
- the top flange may extend length-wise at least partially along the length of the protective insert.
- the top flange may be connected to the front edge of the top walls and may extend width-wise beyond the back edge of the top walls.
- the plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber.
- a first side flange may be connected to the first side wall of the first end chamber and a second side flange may be connected to the second side wall of the second end chamber.
- Another aspect of the invention provides a method of packaging a plurality of cone stacks using the inventive protective inserts.
- the method comprises optionally placing a cone holder into a container near the bottom of the container.
- the cone holder is configured to receive the pointed end of each of the cone stacks.
- a first row of cone stacks is placed into the container such that the pointed end of each cone stack is received by the cone holder.
- a second row of edible cones is also placed into the container such that the pointed end of each cone stack in the second row is received by the cone holder.
- a protective insert is placed in between the first row of cone stacks and the second row of cone stacks, such that the top wall of each chamber of the protective insert is positioned above the open end of the cone stacks in the second row and each of the cone stacks in the second row fits within one of the chambers of the protective insert. This packing method is repeated until all intended cone stacks and protective inserts are placed within the container.
- FIG. 1A is a perspective view of an exemplary prior art package of edible cones
- FIG. 1B is a sectional view of an exemplary prior art package of edible cones
- FIG. 1C is a perspective view of an exemplary prior art cone holder typically used within a package of edible cones
- FIG. 2 is an illustration of an exemplary piece of corrugated paperboard used as a packaging insert for packaging edible cones;
- FIG. 3 comprising FIG. 3A, FIG. 3B and FIG. 3C, illustrates various view of an exemplary protective insert of the present invention
- FIG. 4 comprising FIG. 4A, FIG. 4B, FIG. 4C and FIG. 4D, illustrates an exemplary package for shipping edible cones in accordance with the present invention.
- FIG. 5 illustrates an alternative embodiment of the present invention wherein two inventive protective inserts may be used to surround a cone stack from all sides.
- the present invention provides an improved protective insert for bulk packaging of fragile stackable items for delivery to commercial establishments.
- the protective insert of the present invention is a one-piece, pre-formed construction, meaning that no assembly or preparation is required by the packager.
- the protective insert comprises a plurality of laterally-aligned chambers that are designed to shield multiple sides, including the tops, of cone stacks 104 within a container 100 .
- the protective insert may be made from a foam material (e.g., polystyrene, etc.), plastic or any other suitable material.
- the one-piece protective insert is formed using a molding process.
- the one-piece protective insert may be made from extruded material and thermo-formed using a mold.
- FIGS. 1 A- 1 C illustrate certain aspects of a typical commercial-grade package of edible cones 102 .
- a number of edible cones 102 are typically placed within each other to form a cone stack 104 .
- a plurality of rows of cone stacks 104 are placed within the container 100 and are usually supported at spaced intervals by a cone holder 106 .
- the cone holder 106 may be a piece of cardboard, paperboard, plastic or other suitable lightweight material that is supported a distance above the bottom of the container 100 and has a number of openings 108 configured to receive the pointed ends of the cone stacks 104 .
- FIGS. 3 A- 3 E show a front, back and sectional view, respectively, of an exemplary protective insert 300 .
- the protective insert 300 comprises a plurality of laterally-aligned chambers 302 A-E. Each chamber 302 A-E is formed by the union of multiple walls.
- a first chamber 302 A is formed by the union of a first sidewall 304 A, a second sidewall 306 A, a back wall 308 A and a top wall 310 A
- a second chamber 302 B is formed by the union of a first sidewall 304 B, a second sidewall 306 B, a back wall 308 A and a top wall 310 B
- a third chamber 302 C is formed by the union of a first sidewall 304 C, a second sidewall 306 C, a back wall 308 C and a top wall 310 C
- a fourth chamber 302 D is formed by the union of a first sidewall 304 D, a second sidewall 306 D, a back wall 308 D and a top wall 310 D
- a fifth chamber 302 E is formed by the union of a first sidewall 304 E, a second sidewall 306 E, a back wall 308 E and a top wall 310 E.
- the chambers 302 A-E do
- each chamber 302 A-E of an exemplary inventive protective insert 300 is described herein as having distinct chamber walls, i.e., each chamber 302 A-E has its own first sidewall 304 A-E, its own second sidewall 306 A-E, its own back wall 308 A-E, and its own top wall 310 A-E.
- each chamber 302 A-E has its own first sidewall 304 A-E, its own second sidewall 306 A-E, its own back wall 308 A-E, and its own top wall 310 A-E.
- the unitary (one-piece) construction of the protective insert 300 may mean that certain of such walls are distinct as a conceptual matter only.
- a single top wall 310 may extend substantially across all chambers 302 A-E.
- adjacent chambers may share a common sidewall (e.g., the second side wall 306 A of one chamber 302 A may also serve as the first sidewall 304 B of another chamber 302 B).
- a common sidewall e.g., the second side wall 306 A of one chamber 302 A may also serve as the first sidewall 304 B of another chamber 302 B.
- the chambers 302 A-E are each configured to shield multiple sides of a cone stack 104 and may thus have a cross-section that is similar in shape and size to that of an edible cone 102 .
- the chambers 302 A-E are substantially semi-cylindrical in shape (i.e., semi-circular in cross-section) and have a diameter that is slightly larger than that of a typical edible cone.
- the chambers 302 A-E may alternatively be formed to have a circular cross-section (resulting in a sleeve-like structure that encircles a cone stack 104 ), a semi-square or square crosssection, a semi-polygonal or polygonal cross-section, or any other shape cross-section.
- the overall protective insert 300 is preferably substantially rectangular in shape, so as to fit neatly within a typical container 100 (e.g., a box), as shown in the sectional views of an edible cone package of FIGS. 3 D-E.
- the dimensions of the protective insert 300 may be varied to fit containers 100 of varying sizes.
- the inventive protective insert 300 may alternatively be formed into other any suitable shape to fit within any particular container 100 configuration.
- Each top wall 310 A-E of each chamber 302 A-E has a length and a width.
- the length of each top wall 310 A-E is substantially equal to a lateral distance across the associated chamber 302 A-E.
- the width of each top wall 310 A-E is bounded by a front edge 312 A-E (shown in FIG. 3A) and a back edge 314 A-E (shown in FIG. 3B).
- Each back edge 314 A-E is the location where a back wall 308 A-E joins a top wall 310 A-E.
- a top flange 316 may be connected to the top walls 310 A-E of each chamber 302 A-E.
- the top flange 316 may extend length-wise at least partially along the length of the protective insert 300 .
- the top flange 316 may be connected to the front edges 312 A-E of each top wall 310 A-E and may extend widthwise, possibly beyond the back edges 314 A-E of each top wall 310 A-E.
- the top flange 316 may alternatively be connected to the top wall 310 A-E of each chamber 302 A-E in any other suitable manner.
- the plurality of chambers 302 A-E comprises a first end chamber 302 A, a second end chamber 302 E and a plurality of middle chambers 302 B-D.
- a first side flange 318 A may be connected to the first side wall 304 A of the first end chamber 302 A and a second side flange 318 B may be connected to the second side wall 306 E of the second end chamber 302 E.
- the side flange 316 may also extend widthwise, possibly beyond the back edges 314 A-E of each top wall 310 A-E.
- a lip 320 may extend substantially perpendicularly from the top flange 316 and/or the side flanges 318 A&B. The lip 320 , which may vary in size and shape, may help the protective insert to fit more snugly within a container 100 .
- FIGS. 3 D-E illustrate front and back sectional views, respectively, of an exemplary protective insert 300 positioned within a container 100 of edible cones 102 .
- the protective insert 300 is positioned within the container 100 so as to be behind (relatively speaking) a row of cone stacks 104 .
- Each cone stack 104 in the row fits within one of the chambers 302 A-E of the protective insert 300 .
- the top flange 316 and side flanges 318 A&B provide an additional layer of shock-absorbent material between the container 100 and the edible cones 102 and may also provide for a more snug fit within the container 100 .
- the exemplary protective inset 300 is shown as having a height that causes the bottom of the protective insert 300 to rest on or near the cone holder 106 within the container 100 . Those skilled in the art will appreciate, however, that it is not necessary for the protective insert 300 to rest on or near the cone holder 106 .
- the height of the protective insert 300 may be such that at least some, if not most or all, of the edible cones 102 within a cone stack 104 are shielded by a chamber 302 A-E.
- the dimensions of the protective insert 300 may be varied depending on the size and configuration of the container 100 (which may be dictated by the size and configuration of the cone stacks 104 .) It may be desirable to minimize the height of the protective insert 300 in order to reduce the material costs and shipping weight.
- FIGS. 4 A-D illustrate an exemplary package 400 for shipping edible cones 102 in accordance with the present invention.
- the exemplary package 400 comprises the container 100 having disposed therein a number of rows of cone stacks 104 .
- Each cone stack 104 has a pointed end (i.e., bottom) and an open end (i.e., top).
- the cone stacks 104 may be supported at spaced intervals by a cone holder 106 .
- a protective insert 300 of the present invention is inserted behind (relatively speaking) each row of cone stacks 104 . With such an arrangement, a protective insert 300 is positioned between each successive row of cone stacks 104 .
- each protective insert 300 shields a row of cone stacks 104 from behind, on each side and from the top.
- the front side of a row of cone stacks 104 is protected by the back wall 308 (and optionally by the top flange 316 and side flanges 318 A&B) of the protective insert 300 that is positioned in front of that row of cone stacks 104 (i.e., the protective insert that is positioned behind the next successive row of cone stacks 104 ).
- a method of packaging edible cones 102 using the inventive protective inserts 300 is provided.
- the method optionally comprises placing a cone holder 106 into a container 100 near the bottom of the container 100 .
- the cone holder 106 may be configured to receive the pointed end of each of the cone stacks 104 that are to be placed in the container 100 .
- a first row of cone stacks 104 is placed into the container 100 such that the pointed end of each cone stack 104 is received by the cone holder 106 .
- a second row of cone stacks 104 is also placed into the container 100 such that the pointed end of each cone stack 104 in the second row is received by the cone holder. This process is repeated until the container is filled with the desired number of rows of cone stacks 104 .
- a protective insert 300 may then be placed in between the first row of cone stacks 104 and the second row of cone stacks 104 , such that the top wall 310 A-E of each chamber 302 A-E of the protective insert 300 is positioned above the open end of the cone stacks 104 in the second row and each of the cone stacks 104 in the second row fits within one of the chambers 302 A-E of the protective insert 300 .
- the first row of edible cones 104 may be substantially near a side of the container 100 and a second protective insert 300 may be placed between the side of the container 100 and the first row of cones 104 , such that the top wall 310 A-E of each chamber 302 A-E of the second protective insert 300 is positioned above the open end of the cone stacks 104 in the first row and each of the cone stacks 104 in the first row fits within one of the chambers 302 A-E of the second protective insert 300 .
- additional protective inserts 300 may be placed between each two successive rows of cone stacks 104 .
- Cone stacks 104 may be placed into the container 100 by an automated packing machine. As each row of cone stacks 104 is placed into the container 100 , a line-worker may manually insert a protective insert 300 into the container 100 behind the row of cone stacks 104 . Alternatively, the line-worker may wait until all rows of cone stacks 104 are placed within the container 100 before inserting the protective inserts 300 .
- two protective inserts 300 of the present invention may be used to surround a cone stack 104 from all sides.
- the two protective inserts 300 may be positioned on opposite sides of the cone stack 104 , each having its chambers 302 facing each other.
- This configuration create a sleeve-like structure that surrounds the cone stack 104 .
- such an alternative configuration may be accomplished using one protective insert 300 that is designed with chambers 302 A-E having for example a circular crosssection, as opposed to two protective inserts 300 each designed with chambers 302 A-E having a semi-circular cross-section.
Abstract
A one-piece protective insert comprising a plurality of laterally-aligned chambers each configured to fit a stack of fragile items, such as edible cones. Each chamber is formed by the union of a first sidewall, a second sidewall, a back wall and a top wall. A top flange and side flanges may be connected to the protective insert. In packaging multiple cone stacks, a protective insert is placed in between a first row of cone stacks and a second row of cone stacks, such that the top wall of each chamber of the protective insert is positioned above the open end of the cone stacks in the second row and each of the cone stacks in the second row fits within one of the chambers of the protective insert. This packing method is repeated for all successive rows of cone stacks within the container.
Description
- The present invention relates to packaging of fragile stackable items, such as edible cones and the like. More particularly, the present invention relates to a protective insert for separating, supporting and protecting fragile stackable items stacked within a container.
- As shown in FIGS.1A-1C, large quantities of edible cones 102 (e.g. 300 ct.) are typically packaged in a substantially rectangular container 100 (e.g., a box) when sold for commercial use.
Edible cones 102 are placed within each other to form acone stack 104. A plurality of rows ofcone stacks 104 are placed within thecontainer 100. Acone holder 106 is typically used to hold thecone stacks 104 at spaced intervals. Thecone holder 106 is often a piece of cardboard, paperboard or plastic supported a distance above the bottom of thecontainer 100 and having a number ofopenings 108 configured to receive the pointed ends of thecone stacks 104. - With reference to FIGS.2A-2C, in order to further support the
cone stacks 104 within thecontainer 100 and to protect theedible cones 102 against breakage during transport,corrugated paperboard 200 is typically used as a protective insert. Thecorrugated paperboard 200 may be folded so as to form multiple three-walled chambers 202, each having afirst side wall 204, asecond side wall 206 and aback wall 208. Thesidewalls 204 & 206 of thechambers 202 may be positioned between thecone stacks 104 of a row ofcone stacks 104 to ensure that thecone stacks 104 do not touch each other. However, the three-walled chambers 202 of the foldedcorrugated paperboard 200 do not cover the open end (i.e., the top) of thecone stacks 104 and therefore do not provide a protective layer between theedible cones 102 and the top of thebox 100. - Folded
corrugated paperboard 200 has been the protective insert of choice for packagingedible cones 102 because it is an inexpensive commodity. However, in high-volume cone packaging facilities, the use of foldedcorrugated paperboard 200 as a packaging insert has drawbacks. In particular, the act of folding thecorrugated paperboard 200 and holding it in the proper three-walled configuration while inserting it betweencone stacks 104 is time consuming and thus limits the number ofcontainers 100 ofedible cones 102 that can be packaged during a given time period. In addition, constant repetition of the folding action has been found to trigger carpel-tunnel syndrome in line-workers. Workers suffering from carpel-tunnel syndrome may work more slowly, miss work more often and possibly file workers compensation claims. Furthermore, corrugated paperboard 220 is not all that strong or shock-absorbent, which leads to more breakage ofedible cones 102 than is necessary. - Accordingly, there remains a need for an improved protective insert for use in bulk packaging of
edible cones 102 for shipment to commercial establishments. The improved protective insert should not require repetitive folding or assembly actions and should provide superior protection against edible cone breakage. - The present invention meets the above-described need by providing a protective insert for use in packaging a plurality of fragile stackable items, such as edible cones. The protective insert comprises a plurality of laterally-aligned chambers that are configured to fit a stack of edible cones. In one embodiment, each chamber is formed by the union of a first sidewall, a second sidewall, a back wall and a top wall. The chambers are each configured to fit a stack of edible cones and may be substantially semi-cylindrical in shape. The protective insert comprises a unitary construction that may be made from foam, plastic or any other suitable material.
- In certain embodiments, a top flange may be connected to the top wall of the protective insert. The top flange may extend length-wise at least partially along the length of the protective insert. The top flange may be connected to the front edge of the top walls and may extend width-wise beyond the back edge of the top walls. The plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber. A first side flange may be connected to the first side wall of the first end chamber and a second side flange may be connected to the second side wall of the second end chamber.
- Another aspect of the invention provides a method of packaging a plurality of cone stacks using the inventive protective inserts. The method comprises optionally placing a cone holder into a container near the bottom of the container. The cone holder is configured to receive the pointed end of each of the cone stacks. A first row of cone stacks is placed into the container such that the pointed end of each cone stack is received by the cone holder. A second row of edible cones is also placed into the container such that the pointed end of each cone stack in the second row is received by the cone holder. A protective insert is placed in between the first row of cone stacks and the second row of cone stacks, such that the top wall of each chamber of the protective insert is positioned above the open end of the cone stacks in the second row and each of the cone stacks in the second row fits within one of the chambers of the protective insert. This packing method is repeated until all intended cone stacks and protective inserts are placed within the container.
- These and other aspects, features and embodiments of the invention will become apparent from the following detailed description of certain exemplary embodiments, the appended drawings and the claims.
- The invention is illustrated by the accompanying drawings in which like numerals represent like elements and in which:
- FIG. 1A is a perspective view of an exemplary prior art package of edible cones;
- FIG. 1B is a sectional view of an exemplary prior art package of edible cones;
- FIG. 1C is a perspective view of an exemplary prior art cone holder typically used within a package of edible cones;
- FIG. 2, comprising FIG. 2A, FIG. 2B and FIG. 2C, is an illustration of an exemplary piece of corrugated paperboard used as a packaging insert for packaging edible cones;
- FIG. 3, comprising FIG. 3A, FIG. 3B and FIG. 3C, illustrates various view of an exemplary protective insert of the present invention;
- FIG. 4, comprising FIG. 4A, FIG. 4B, FIG. 4C and FIG. 4D, illustrates an exemplary package for shipping edible cones in accordance with the present invention; and
- FIG. 5 illustrates an alternative embodiment of the present invention wherein two inventive protective inserts may be used to surround a cone stack from all sides.
- The present invention provides an improved protective insert for bulk packaging of fragile stackable items for delivery to commercial establishments. The protective insert of the present invention is a one-piece, pre-formed construction, meaning that no assembly or preparation is required by the packager. The protective insert comprises a plurality of laterally-aligned chambers that are designed to shield multiple sides, including the tops, of
cone stacks 104 within acontainer 100. The protective insert may be made from a foam material (e.g., polystyrene, etc.), plastic or any other suitable material. In certain embodiments the one-piece protective insert is formed using a molding process. For example, the one-piece protective insert may be made from extruded material and thermo-formed using a mold. - Exemplary embodiments of the inventive protective insert will be described herein with respect to packaging of
edible cones 102, such as ice cream cones. Those skilled in the art will appreciate, however, that the protective insert may be adapted for use in packaging other fragile stackable items, such as cups, bowls, novelty items, etc. As mentioned above, FIGS. 1A-1C illustrate certain aspects of a typical commercial-grade package ofedible cones 102. A number ofedible cones 102 are typically placed within each other to form acone stack 104. A plurality of rows ofcone stacks 104 are placed within thecontainer 100 and are usually supported at spaced intervals by acone holder 106. Thecone holder 106 may be a piece of cardboard, paperboard, plastic or other suitable lightweight material that is supported a distance above the bottom of thecontainer 100 and has a number ofopenings 108 configured to receive the pointed ends of the cone stacks 104. - An exemplary embodiment of the protective insert of the present invention is shown and described with reference to FIGS.3A-3E. FIGS. 3A-3B show a front, back and sectional view, respectively, of an exemplary
protective insert 300. Theprotective insert 300 comprises a plurality of laterally-alignedchambers 302A-E. Eachchamber 302A-E is formed by the union of multiple walls. In particular, afirst chamber 302A is formed by the union of afirst sidewall 304A, asecond sidewall 306A, aback wall 308A and atop wall 310A; asecond chamber 302B is formed by the union of afirst sidewall 304B, asecond sidewall 306B, aback wall 308A and atop wall 310B; athird chamber 302C is formed by the union of afirst sidewall 304C, asecond sidewall 306C, aback wall 308C and atop wall 310C; afourth chamber 302D is formed by the union of afirst sidewall 304D, asecond sidewall 306D, aback wall 308D and atop wall 310D; afifth chamber 302E is formed by the union of afirst sidewall 304E, asecond sidewall 306E, aback wall 308E and atop wall 310E. As illustrated in FIG. 3A, thechambers 302A-E do not include a bottom wall. - The
chambers 302A-E of an exemplary inventiveprotective insert 300 are described herein as having distinct chamber walls, i.e., eachchamber 302A-E has its ownfirst sidewall 304A-E, its ownsecond sidewall 306A-E, itsown back wall 308A-E, and its owntop wall 310A-E. Those skilled in the art will appreciate, however, that the unitary (one-piece) construction of theprotective insert 300 may mean that certain of such walls are distinct as a conceptual matter only. As a practical matter, for example, a single top wall 310 may extend substantially across allchambers 302A-E. In addition, adjacent chambers (e.g., 302A and 302B) may share a common sidewall (e.g., thesecond side wall 306A of onechamber 302A may also serve as thefirst sidewall 304B of anotherchamber 302B). Accordingly, any description of distinct chamber walls is meant only to clearly illustrate exemplary embodiments of the present invention and is not intended to limit the scope thereof. - The
chambers 302A-E are each configured to shield multiple sides of acone stack 104 and may thus have a cross-section that is similar in shape and size to that of anedible cone 102. In a preferred embodiment, thechambers 302A-E are substantially semi-cylindrical in shape (i.e., semi-circular in cross-section) and have a diameter that is slightly larger than that of a typical edible cone. Of course, thechambers 302A-E may alternatively be formed to have a circular cross-section (resulting in a sleeve-like structure that encircles a cone stack 104), a semi-square or square crosssection, a semi-polygonal or polygonal cross-section, or any other shape cross-section. The overallprotective insert 300 is preferably substantially rectangular in shape, so as to fit neatly within a typical container 100 (e.g., a box), as shown in the sectional views of an edible cone package of FIGS. 3D-E. The dimensions of theprotective insert 300 may be varied to fitcontainers 100 of varying sizes. The inventiveprotective insert 300 may alternatively be formed into other any suitable shape to fit within anyparticular container 100 configuration. - Each
top wall 310A-E of eachchamber 302A-E has a length and a width. The length of eachtop wall 310A-E is substantially equal to a lateral distance across the associatedchamber 302A-E. The width of eachtop wall 310A-E is bounded by a front edge 312A-E (shown in FIG. 3A) and aback edge 314A-E (shown in FIG. 3B). Eachback edge 314A-E is the location where aback wall 308A-E joins atop wall 310A-E. - In certain embodiments, a
top flange 316 may be connected to thetop walls 310A-E of eachchamber 302A-E. Thetop flange 316 may extend length-wise at least partially along the length of theprotective insert 300. Thetop flange 316 may be connected to the front edges 312A-E of eachtop wall 310A-E and may extend widthwise, possibly beyond the back edges 314A-E of eachtop wall 310A-E. Thetop flange 316 may alternatively be connected to thetop wall 310A-E of eachchamber 302A-E in any other suitable manner. The plurality ofchambers 302A-E comprises afirst end chamber 302A, asecond end chamber 302E and a plurality ofmiddle chambers 302B-D. Afirst side flange 318A may be connected to thefirst side wall 304A of thefirst end chamber 302A and asecond side flange 318B may be connected to thesecond side wall 306E of thesecond end chamber 302E. Theside flange 316 may also extend widthwise, possibly beyond the back edges 314A-E of eachtop wall 310A-E. A lip 320 may extend substantially perpendicularly from thetop flange 316 and/or the side flanges 318A&B. Thelip 320, which may vary in size and shape, may help the protective insert to fit more snugly within acontainer 100. - FIGS.3D-E illustrate front and back sectional views, respectively, of an exemplary
protective insert 300 positioned within acontainer 100 ofedible cones 102. As shown, theprotective insert 300 is positioned within thecontainer 100 so as to be behind (relatively speaking) a row of cone stacks 104. Eachcone stack 104 in the row fits within one of thechambers 302A-E of theprotective insert 300. Thetop flange 316 and side flanges 318A&B provide an additional layer of shock-absorbent material between thecontainer 100 and theedible cones 102 and may also provide for a more snug fit within thecontainer 100. - The exemplary
protective inset 300 is shown as having a height that causes the bottom of theprotective insert 300 to rest on or near thecone holder 106 within thecontainer 100. Those skilled in the art will appreciate, however, that it is not necessary for theprotective insert 300 to rest on or near thecone holder 106. The height of theprotective insert 300 may be such that at least some, if not most or all, of theedible cones 102 within acone stack 104 are shielded by achamber 302A-E. As mentioned above, the dimensions of theprotective insert 300 may be varied depending on the size and configuration of the container 100 (which may be dictated by the size and configuration of the cone stacks 104.) It may be desirable to minimize the height of theprotective insert 300 in order to reduce the material costs and shipping weight. - FIGS.4A-D illustrate an
exemplary package 400 for shippingedible cones 102 in accordance with the present invention. Theexemplary package 400 comprises thecontainer 100 having disposed therein a number of rows of cone stacks 104. Eachcone stack 104 has a pointed end (i.e., bottom) and an open end (i.e., top). The cone stacks 104 may be supported at spaced intervals by acone holder 106. Aprotective insert 300 of the present invention is inserted behind (relatively speaking) each row of cone stacks 104. With such an arrangement, aprotective insert 300 is positioned between each successive row of cone stacks 104. Thechambers 302A-E of eachprotective insert 300 shield a row ofcone stacks 104 from behind, on each side and from the top. The front side of a row of cone stacks 104 is protected by the back wall 308 (and optionally by thetop flange 316 and side flanges 318A&B) of theprotective insert 300 that is positioned in front of that row of cone stacks 104 (i.e., the protective insert that is positioned behind the next successive row of cone stacks 104). - According to another aspect of the invention, a method of packaging
edible cones 102 using the inventiveprotective inserts 300 is provided. The method optionally comprises placing acone holder 106 into acontainer 100 near the bottom of thecontainer 100. Thecone holder 106 may be configured to receive the pointed end of each of the cone stacks 104 that are to be placed in thecontainer 100. A first row of cone stacks 104 is placed into thecontainer 100 such that the pointed end of eachcone stack 104 is received by thecone holder 106. A second row of cone stacks 104 is also placed into thecontainer 100 such that the pointed end of eachcone stack 104 in the second row is received by the cone holder. This process is repeated until the container is filled with the desired number of rows of cone stacks 104. - A
protective insert 300 may then be placed in between the first row ofcone stacks 104 and the second row ofcone stacks 104, such that thetop wall 310A-E of eachchamber 302A-E of theprotective insert 300 is positioned above the open end of the cone stacks 104 in the second row and each of the cone stacks 104 in the second row fits within one of thechambers 302A-E of theprotective insert 300. The first row ofedible cones 104 may be substantially near a side of thecontainer 100 and a secondprotective insert 300 may be placed between the side of thecontainer 100 and the first row ofcones 104, such that thetop wall 310A-E of eachchamber 302A-E of the secondprotective insert 300 is positioned above the open end of the cone stacks 104 in the first row and each of the cone stacks 104 in the first row fits within one of thechambers 302A-E of the secondprotective insert 300. In a like fashion, additionalprotective inserts 300 may be placed between each two successive rows of cone stacks 104. - Cone stacks104 may be placed into the
container 100 by an automated packing machine. As each row of cone stacks 104 is placed into thecontainer 100, a line-worker may manually insert aprotective insert 300 into thecontainer 100 behind the row of cone stacks 104. Alternatively, the line-worker may wait until all rows ofcone stacks 104 are placed within thecontainer 100 before inserting the protective inserts 300. - In an alternative embodiment, shown by way of example in FIG. 5, two
protective inserts 300 of the present invention may be used to surround acone stack 104 from all sides. The twoprotective inserts 300 may be positioned on opposite sides of thecone stack 104, each having its chambers 302 facing each other. This configuration create a sleeve-like structure that surrounds thecone stack 104. As mentioned previously, such an alternative configuration may be accomplished using oneprotective insert 300 that is designed withchambers 302A-E having for example a circular crosssection, as opposed to twoprotective inserts 300 each designed withchambers 302A-E having a semi-circular cross-section. - Although the present invention has been described with reference to certain exemplary embodiments thereof, those skilled in the art will recognize that changes may be made thereto in form and detail without departing from the spirit and scope of the invention. Features and aspects of the present invention have been described and/or depicted by way of example only and are therefore not intended to be interpreted as required or essential elements of the invention. The specific embodiments described herein are thus given by way of example only. The invention is to be limited only as defined by the following claims.
Claims (33)
1. A protective insert for use in packaging a plurality of edible cones comprising:
a plurality of laterally-aligned chambers each formed by a union of a first sidewall, a second sidewall and a back wall, each chamber configured to fit a stack of edible cones;
a top wall extending at least partially over each of the plurality of chambers; and
wherein the plurality of chambers and the top wall comprise a unitary construction.
2. The protective insert of claim 1 , wherein the top wall has a length and a width, the length being substantially equal to a lateral distance across the plurality of chambers; and
wherein the protective insert further comprises a top flange connected to the top wall and extending length-wise at least partially along the length of the top wall.
3. The protective insert of claim 2 , wherein the width of the top wall is bounded by a front edge and a back edge, the back edge being a location where the back wall of each chamber the joins the top wall; and
wherein the top flange is connected to the front edge of the top wall and extends width-wise beyond the back edge of the top wall.
4. The protective insert of claim 2 , wherein the plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber; and
wherein the protective insert further comprises a first side flange connected to the first side wall of the first end chamber and a second side flange connected to the second side wall of the second end chamber.
5. The protective insert of claim 1 , wherein the plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber; and
wherein the protective insert further comprises a first side flange connected to the first side wall of the first end chamber and a second side flange connected to the second side wall of the second end chamber.
6. The protective insert of claim 1 , wherein the unitary construction is made from foam.
7. The protective insert of claim 1 , wherein the unitary construction is made from plastic.
8. The protective insert of claim 1 , wherein the unitary construction is formed using a molding process.
9. The protective insert of claim 1 , wherein each of the plurality of chambers is substantially semi-cylindrical in shape.
10. The protective insert of claim 1 , wherein the plurality of chambers comprises five chambers.
11. A protective insert for use in packaging a plurality of edible cones comprising:
a plurality of laterally-aligned chambers each formed by a union of a first sidewall, a second sidewall, a back wall and a top wall, each chamber configured to fit a stack of edible cones;
a top flange extending at least partially over each top wall of the plurality of chambers; and
wherein the plurality of chambers and the top flange comprise a unitary construction.
12. The protective insert of claim 11 , wherein each top wall has a width that is bounded by a front edge and a back edge, the back edge being a location where the back wall joins the top wall; and
wherein the top flange is connected to the front edge of each top wall and extends width-wise beyond the back edge of each top wall.
13. The protective insert of claim 12 , wherein the plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber; and
wherein the protective insert further comprises a first side flange connected to the first sidewall of the first end chamber and a second side flange connected to the second sidewall of the second end chamber.
14. The protective insert of claim 11 , wherein the plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber; and
wherein the protective insert further comprises a first side flange connected to the first side wall of the first end chamber and a second side flange connected to the second side wall of the second end chamber.
15. The protective insert of claim 11 , wherein the unitary construction is made from foam.
16. The protective insert of claim 11 , wherein the unitary construction is made from plastic.
17. The protective insert of claim 11 , wherein the unitary construction is formed using a molding process.
18. The protective insert of claim 11 , wherein each of the plurality of chambers is substantially semi-cylindrical in shape.
19. The protective insert of claim 11 , wherein the plurality of chambers comprises five chambers.
20. A method of packaging a plurality of cone stacks using protective inserts, each protective insert comprising a plurality of laterally-aligned chambers each formed by a union of a first sidewall, a second sidewall, a back wall and a top wall, each chamber configured to fit an cone stack, each cone stack having a pointed end and an open end, the method comprising:
placing a cone holder into a container having a bottom and a top, the cone holder being placed near the bottom of the container and being configured to receive the pointed end of each of the plurality of cone stacks;
placing a first row of cone stacks into the container such that the pointed end of each cone stack in the first row is received by the cone holder;
placing a second row of edible cones into the container such that the pointed end of each cone stack in the second row is received by the cone holder; and
placing a protective insert between the first row of cone stacks and the second row of cone stacks, such that the top wall of each chamber of the protective insert is positioned above the open end of the cone stacks in the second row and each of the cone stacks in the second row fits within one of the chambers of the protective insert.
21. The method of claim 20 , wherein the first row of cones is substantially near a side of the box; and
wherein the method further comprises placing a second protective insert between the side of the container and the first row of cones, such that the top wall of each chamber of the second protective insert is positioned above the open end of the cone stacks in the first row and each of the cone stacks in the first row fits within one of the chambers of the second protective insert.
22. The method of claim 20 , wherein the protective insert is made from foam.
23. The method of claim 20 , wherein the protective insert is made from plastic.
24. The method of claim 20 , wherein each of the chambers of the protective insert is substantially semi-cylindrical in shape.
25. The method of claim 20 , wherein the protective insert further comprises a top flange extending at least partially over each top wall of the plurality of chambers;
wherein each top wall of the plurality of chambers has a width that is bounded by a front edge and a back edge, the back edge being a location where the back wall joins the top wall;
wherein the top flange is connected to the front edge of each top wall and extends width-wise beyond the back edge of each top wall; and
wherein the protective insert is placed in the container such that the top flange extends at least partially above the first row of cones.
26. A package of edible cones comprising:
a container;
a plurality of rows of cone stacks disposed within the container, each cone stack having a pointed end and an open end; and
a plurality of protective inserts disposed within the container, each protective insert comprising a plurality of laterally-aligned chambers each formed by a union of a first sidewall, a second sidewall, a back wall and a top wall, each protective insert positioned behind one of the rows of cone stacks such that each of the cone stacks fits within one of the chambers of the protective insert.
27. The package of edible cones recited in claim 26 , wherein the protective insert further comprises a top flange extending at least partially over each top wall of the plurality of chambers.
28. The package of edible cones recited in claim 27 , wherein each top wall of the plurality of chambers has a width that is bounded by a front edge and a back edge, the back edge being a location where the back wall joins the top wall;
wherein the top flange is connected to the front edge of each top wall and extends width-wise beyond the back edge of each top wall; and
wherein the protective insert is positioned such that the top flange extends at least partially above the row of cones.
29. The package of edible cones recited in claim 26 , wherein the plurality of chambers comprises a first end chamber, a second end chamber and a plurality of middle chambers positioned between the first end chamber and the second end chamber; and
wherein the protective insert further comprises a first side flange connected to the first side wall of the first end chamber and a second side flange connected to the second side wall of the second end chamber.
30. The package of edible cones recited in claim 26 , wherein the protective insert is made from foam.
32. The package of edible cones recited in claim 26 , wherein the protective insert is made from plastic.
33. The package of edible cones recited in claim 26 , wherein the protective insert is formed using a molding process.
34. The package of edible cones recited in claim 26 , wherein each of the plurality of chambers is substantially semi-cylindrical in shape.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/198,543 US20040011691A1 (en) | 2002-07-17 | 2002-07-17 | Protective insert for commercial packaging of fragile stackable items |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/198,543 US20040011691A1 (en) | 2002-07-17 | 2002-07-17 | Protective insert for commercial packaging of fragile stackable items |
Publications (1)
Publication Number | Publication Date |
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US20040011691A1 true US20040011691A1 (en) | 2004-01-22 |
Family
ID=30443133
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/198,543 Abandoned US20040011691A1 (en) | 2002-07-17 | 2002-07-17 | Protective insert for commercial packaging of fragile stackable items |
Country Status (1)
Country | Link |
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US (1) | US20040011691A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20030230581A1 (en) * | 2002-06-18 | 2003-12-18 | Wark Christopher Garrison | Container with a distributed-loading base |
US7621424B1 (en) * | 2005-11-16 | 2009-11-24 | Tino Antonacci | Container for ice cream cones |
JP2015212153A (en) * | 2014-05-01 | 2015-11-26 | 長谷川製菓株式会社 | Cushioning material for container and packing method using the same |
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US6705469B2 (en) * | 2001-10-31 | 2004-03-16 | Xerox Corporation | One-piece foldable protective shipping container/insert |
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2002
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Publication number | Priority date | Publication date | Assignee | Title |
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US20030230581A1 (en) * | 2002-06-18 | 2003-12-18 | Wark Christopher Garrison | Container with a distributed-loading base |
US7621424B1 (en) * | 2005-11-16 | 2009-11-24 | Tino Antonacci | Container for ice cream cones |
JP2015212153A (en) * | 2014-05-01 | 2015-11-26 | 長谷川製菓株式会社 | Cushioning material for container and packing method using the same |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: GEMINI PACKAGING, INC., GEORGIA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:AUTLER, HENRY;MEIER, CARL;REEL/FRAME:013270/0852;SIGNING DATES FROM 20020807 TO 20020812 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |