US2004626A - Means and method for packaging sheet materials - Google Patents

Description

G. L. HANN June 11, 1935.

- MEANS AND METHOD FOR PACKAGING SHEET MATERIALS Filed April 28, 1932 RM W W w L m M w mm f Patented June 11, 1935 MEANS AND METHOD FOR PACKAGING SEE! MATEREALS George L. Hann, Staten Island, N. Y., assignor to United States Gypsum Company, Chicago, 111., a corporation of Illinois Application April 28, 1932, Serial No. 608,047

6 Claims.

The present invention relates to improved shipping packages and methods of packaging and more particularly relates to the packaging of sheet materials so as to prepare the same to, I

-' which is of unusually simple, sound and eflicient withstand the rigors of transportation.

with more or less success. Some of the methodsevolved have been relatively efficient but withal prohibitive in cost as compared to the value of the material being shipped. Other and less expensive methods have been inefficient due to the insufficient protection afforded the sheets and/or the inability of the packageto withstand hard usage. Particularly perplexing have been these problems where the shipment of relatively heavy materials such as composition wallboards is involved, where it is a requisite that the materials be shipped in as large units as possible consistent with handling facilities, because of the bulk of the material compared with its value. Such a package must protect the sheets against all ordinary damaging infiuences of handling and transshipment, must be as simple as possible to construct and handle, must be compact and, above all, must be economical.

It is therefore an object of the present invention to provide a shipping package, particularly adapted for sheet materials, which will withstand all ordinary usages of transportation and which is of such a compact, unitary construction as to afiord protection to the goods even where the shipment must be protected against unusually vigorous handling, or other external conditions.

Another object of the invention resides in the provision of a sturdy, inexpensive skid construction adapted to form a. foundation for the package.

Another object is to provide a shipping package for sheet materials which is bound together with suitable strands and in which the edges of the package are protected against the cutting or crushing action of the strands under compression.

Another object is to provide packaging for sheet materials which is of less weight and which adds less bulk to the shipment than means heretofore used for the same purpose.

Another object is to provide a shipp Package construction and which is of such low cost that it need not be returned to the shipper, as has been the practice with the more expensive types of crates, packings, etc., heretofore employed for similar purposes.

A further object of the invention is to provide va simple expeditious, "economical method of Figure 2 is a plan view of a preferred form of skid construction;

Figure 3 is a cross section taken on line 6-4! of Fig. l; m

Figure 4 illustrates a method of handling the completed package; and

Figure 5 is a perspective view type of angle corner protector found particularly desirable.

While the present invention contemplates the packaging of many difierent types of sheet material, I have found it particularly well suited for sheet material of a more or less fragile nature, such as wallboard II), which is rendered practically useless for intended purposes by damage to the edges or body portion, andwhich it has always been' diflicult to transport economically due to the large percentage of waste by breakage where the packaging was of light construction, and due to the excessive cost of packaging Where a large factor of damage resistance was desired. Cementitious wallboards, such as gypsum boards or other boards wholly or partially comprising plastic materials, present a. decided problem because in addition to being rather fragile they are relatively bulky and heavy, It has therefore been the custom heretofore to ship such boards only in relatively small bundles. My shipping package has been found to meet all requirements very satisfactorily and permits of the shipment of relativcly large stacks of board as single units. The elements of the package preferably comprise a skid, indicated generally by the numeral ll, consisting of skids or runners l2 and platform l3; enclosing means M to cover the exposed surfaces of a particular I of the stack of boards l; binding strands l; and corner protectors 16.

The skid member II is preferably constructed entirely of wood, chiefly because that is the cheapest material available, but is may be wholly or partially made of metallic parts. The skids I2 are preferably a pair of suitable timbers extending the length of the platform l3; and the platform l3 preferably comprises longitudinal members I! and transverse members l8 in close end-abutting cooperation, said members I! and I8 being secured to the skids I2 by suitable means such as nails 20, substantially as shown in Fig. 2. While the members "3 of the platform are essential for spacing the skids l2 and for providing a base for the stack of sheets ill, the members ll serve chiefly as fillers and spacers between the members l8 to provide a rectangular, uni-planular base for reception of -the stack. The square abutment of these platform members I! and I8, it is evident, rigidifies the skid unit and imparts considerable resistance to skewing due to severe usage. All the members of the skid means H are preferably made upin duplicate according to predetermined dimensions for the various sizes of skids required for the variable sizes of sheets to be packed. By this procedure parts for many skid members may be made according to a schedule of standards and may be produced in quantity, the cost per unit being thereby correspondingly reduced. I have found, for example,

that in a plaster boardplant a good source of -lumber for the members l1 and I8 of the skid means resides in the boards or slats used for protecting the ends of the large rolls of paper employed for covering sheets on the faces of the plaster board. This lumber is used to protect the ends of the rolls during shipment and handling prior to use and has heretofore been considered so much waste which has generally been burned. No doubt there are other or similar sources of waste lumber that may be used for, the purpose available in almost any plant in which my shipping package might be found of value. The cost of the package is, of course, reduced in proportion as this waste material is utilized.

The enclosing means I! preferably comprises relatively stiff panels, which may be wood or any other suitable means, such as rejected sheets of the material being shipped. For example, where wallboard is being shipped, I have found that the least expensive-and most abundantly available material is that which is known as bulls or dunnage, that is, imperfect pieces of board such as may have been imperfectly manufactured or which may have been damaged during manufacture or handling and which are waste, generally thrown in a scrap heap to be disposed of in a suitable manner. A good percentage of this cull material is in the form of large pieces or sheets,

and I make use of these by cutting them to substantially the required sizes for protecting the exposed faces of the stack. In order to secure additional protectionto the top of the stack, the enclosing means It on the sides of the stack may be of greater vertical dimensions than the stack to be enclosed, so that the ends may be folded over to form flaps Ida which overlap the top of the stack. Another piece of the enclosing means l4 may then be placedon top of the stack over the flaps Ila (see Fig. 3). The utility of covering the stack with the enclosing means It is manifold. Not only are the exposed parts of the sheets in the stack: protected against damage by scraping or concussion, but where the sheets are such as may become objectionably soiled or discolored by soot, dirt, water, or the like, they are effectively protected thereagainst by the enclosing means l4. Moreover, the enclosing means also tends to rigidify the package when it is bound into a'unit. Additional protection against damage by moisture may be obtained by wrapping the stack of boards III with a suitable waterproofing fabric 2 I, such as waterproof ed paper or the like; and, where desired, waterproof ing means may also be applied to the outside of the package.

It is generally desirable, particularly where the sheets being packaged are of a type that may.

become damaged by staining or scufling, to nail a piece'of the enclosing material, such as a panel l3a, to the face of the skid platform l3 so as to afford protection for the lowermost sheetof the stack. This surfacing panel l3a, upon being securely nailed to the skid platform l3, not only provides a. smooth-surface for the stack of sheets, but it also serves to strengthen the skid unit and rigidify the same. The use of surfacing means l3a permits of constructing the skid members of rough lumber. I have found that as a matter of convenience itis desirable to secure a panel [3a to the platform 13 as soon as the members I! and ll! of the platform have been fastened to the skids l2, so that no delays will be experienced in using the skid means due to first. having to position a panel l3a thereon.

The platform I3 is preferably of face dimensions somewhat greater than the dimensions 'of the sheets to be packed so that after the protective enclosing means It is in place against the stack such means ll will not protrude beyond the edges of the platform.

The strands l5 may comprise any suitable binding means such as wire, metallic bands, fiber or wire rope, or the like, but I have found that for shipping such sheet material as gypsum wallboard suitable steel binding wire is very satisfactory in practice. A pair of these strands l5 preferably embraces the stack and platform both longitudinally andtransversely, the strandsbeing tightened in any suitable manner so as to thoroughly and solidly tie the entire package into a relatively rigid unit.- In addition, a strand 22 may be bound around the package intermediate the upper and lower faces thereof, either under or over strands l5. This strand 22 may be omitted in certain cases, but is of advantage in that it serves particularly to keep the enclosing panels ll together at the vertical edges of the package and prevents their drawing away therefrom due to warping or bulging whereby the edges might be broken or cause'trouble in transit. Furthermore, this strand is an additional rigidifying. factor. Only one strand 22 is illustrated, but where desired a plurality of the same may be employed.

In order to permit the transverse strands to embrace the package without interference with the function of the :skids I 2, suitable kerfs 23 are preferably formed in the platform-abutting faces.of the skids l2 to permit passage of the strands ISunder theplatform l3. These kerfs '23 also provide for positioning of the strands, and prevent slipping of the strands whenthe package is scraped against another object. All the strands I5 are to a large extent prevented from slipping or crawling by reason of the fact that they become embedded to a certain extent in the edges of the timbers I1 and I8 due to compression. This is particularly advantageous for the longitudinal strands I5 as well as to prevent displacement of the same.

Obviously, where the sheet material being packed is of a relatively fragile naturefsuch as wallboard, there will be danger of the strands l5 cutting or crushing into'the comers of the stack and damaging the sheets adjacent thereto, due to the compression force these strands are made to exert in binding the assembly'flnto a unit. In particular is this danger prevalent where the enclosing means It comprises merely portions of damaged board which are likewise likely to be crushed by the compression of the strands. I have, therefore, found the comer protectors [6, which may be of any suitable type under the circumstances, particularly advantageous for interposition between the strands l5 and 22 and the edges of the stack. A type of protector which I have found very satisfactory in this connection, but to the specific features of which I make no claim except insofar as they may function in my improved combination, comprises a tempered, resilient, metallic angle. This angle member is pressed from resilient sheet steel or the like'and is formed witha pair of stiffening beads or ridges 25, which also serve as guides for the binding strands (see Fig. 5). In addition, the comer 26 of the angle member is formed somewhat in the nature of an outward arc, whereby that portion of'the corner 26 between the beads 25 is somewhat higher than at the sides of the angle. This is accomplished. by reducing the sharpness of the angle of the C01- ner 26 toward the sides of the member so that the corner assumes a more and more arcuate shape away from the ridges 25. The angle member is also formed somewhat more acutely than a right angle. Consequently, as the strands I5 and 22 are tightened, the angles IE will be forced to expand to the substantially right angular contours of the edges of the stack. Since the members it are resilient in nature, it is obvious that when they are forced to their expanded position they will function to exert a constant outward pressure upon the strands i5 and 22 due to the tendency of the angles to assume their original unCXpanded shape; and if the strands for any reason tend to become slack, the contraction of these angles it serves to a certain extent to take up the slack to keep the strands taut at all times.

Heretofore, in packaging sheet materials, such as wallboards, for export shipment or the like, it has been customary to pile the sheets loosely as manufactured in any suitable manner and place or to store the same preparatory to packaging as needed, inasmuch as the crates or similar means used to pack the sheets had to be especially constructed for each bundle, or the packing had to be carried out with special apparatus, or the materials and equipment necessary for packing required a considerable space for the purpose apart from the space available at the finishing end of the fabricating lay-out. The method of packing sheet materials, such as gypsum wallboards, for example, according to my invention is exceedingly simple yet thoroughly effective and is preferably carried on at the point where the finished sheets are delivered in the process of manufacture.

To this end, a number of ready-made skid members ll, adapted to accommodate the particular size of sheets being manufactured, are placed adjacent the point where they are to be used. One

of the skid members is suitably positioned at the delivery end of the sheet forming machine; and as the sheets are delivered a stack of sheets I0 is piled up on the skid. After a suitable number of sheets have been stacked thereon, the skid is pushed to one side and another skid is put in its place. In order to facilitate moving the bundle to a new position, the skid timbers I2 are .preferably beveled adjacent their ends, as indicated at '28, so that they may be easily rolled over such means as. lengths of pipe or rods 29, commonly employed for shifting relatively heavy objects of this nature.

After being moved over to one side, the skid and I out and placed in a railway car,-automobile truck,

or the like; or where the plant is situated adjacent a navigable body of water the package may be moved directly from the place where it is packed onto a wharf to be hoisted into the hold of a vessel. The rigidity of the completed package adapts it very readily to handling with such means as'a chain or rope sling 29, or the like, in combination with a suitable crane. Spreaders 30 are provided to keep the chains or ropes of the sling from chafing the upper edges of the package. The beveling 28 of the skid members l2 allows the sling 29, or other hoisting and shifting means, to be readily positioned under the skids.

My method of packing, it is apparent, reduces handling of the sheet materialfrom forming machine to package, and consequently minimizes the breakage and damage usually incident to such handling. The present system of packing lends itself admirably to rapid quantity production. Materials which are generally considered useless waste may be utilized in building the package, and such elements of the package as must be procured aside from the ready sources of waste materials on hand are. readily obtainable at low cost in standard units or quantities and are readily adaptable for the purpose. The various elements necessary for packaging require very little storage space prior to use, and after the package has been completed very little is added to the bulk of the stack of sheets itself. The wood, which is the preferred material of the skid member H, is

capable of withstanding much abuse and will absorb the shocks of the many blows to which the package is subject in the course of trans-shipment. My package is so thoroughly bound into a unit that there is no danger of the stack skewing due to slipping of the sheets, because the sheets are not only held together in frictional engage-. ment by compression of the strands I5, but the enclosing means l4 also serve to hold the same in alignment should the package sufler extraordinary concussions, such, for example, as where the package may be dropped during hoisting or is carried sharply against an unyielding surface. The edges of the stack are thoroughly protected against cutting or crushing by the strands, and the strands themselves are securely retained against 81mm or crawling. Moreover, should there be any tendency of the strands to slacken through stretching or by becoming embedded in the wood of the skid member, the contraction ofthe protectors IE will serve to a certain extent to take up the slack so as to keep the strands taut. The materials required for building up the package are of such an inexpensive character that they need not necessarily be returned by the user of the goods packed, as the cost of such materials compared with the cost of the quantity of sheets which may be shipped as a unit is'so small bers l1 and I8 two inch by six inch boards.

that the same is negligible when distributed over the value of the shipment.

I have found that in the shipment of gypsum wallboard the'described type of package is unexcelled for transportation as a unit of about one hundredthree-eighth inchboards having surface dimensions of about four feet by six to ten feet; or about one hundred and fifty quarter inch boards of similar surface dimensions. The weight of the stack of boards will vary from threequarters of a ton to two tons. For this typeof shipment, the skid members l2 are preferably four by four inch timbers and the platform mem- In the shipment of wallboard, for example,- no only aresavings effected in packing the boards by utilizing my economical system of packaging, but considerable savings may also beeflected in transportation charges. It is well known to railway shippers that reduced freight rates are obtainable for open flat'car shipments. Heretofore, wallboard of any type has generally been shipped to more or less distant points in enclosed box' cars, primarily because this product is generally liable to damage by moisture if exposed to the elements. This has rendered a condition where there is, in addition to the greater cost of box car transportation, considerable expense entailed in loading or unloading the box' cars, because ordinarily the sheets are of such dimensions that they may be packed only in small units due to the limitations presented by the size of the openings in the cars as well as the limitations of weight the men handling the packages can conveniently manipulate. By utilizing my sys- 'tem, many of these problems are overcome and ,wallboard may be shipped in open flat cars, motor trucks and the like to good advantage. The sboards will be thoroughly protected against rain or snow by the waterproofing means 2|, and the skid members l2 insure that the boards will be kept out of any accumulations of water. Moreover, the packages may be loaded and unloaded from the open cars with mechanical equipment or by rolling the same over roller means 28.

After receipt by the dealer or user, ,handling and storage of the board is considerably facilitated. The skid member ll forms a means for conveniently storing or warehousing the boards, and the boards ,may be removed one or more at a time asv needed for sale or use. The stack may be shifted as desired in toto without handling a plurality of individual boards or small packages of boards, the skid member ll rendering this possible even after some of the boards have been removed-from the stack. Obviously, the ds are thus largely protected against the usua mage and breakage experienced in this phase of wallboard economics.v

I would state in conclusion that while the'illustrated examples constitute practical embodiments of my invention, I do not wish to limit myself precisely to these details, since manifestly the same may be considerably varied without departing from the spirit of the invention as defined in the appended claims.

Having thus described my invention, I claim as new and desire to secure by Letters Patent:

1. A shipping package for a'relatively large stack of composition wall boards, comprising a cling the package under substantial tension and passing over said protecting m'embers, said protecting members being in the form of an acute angle and having the line of intersection of the surfaces of the angle'outwardly convexed whereby said abutting edge portions of the covering panels are held in tightly gripping engagement by the tension of said tie wires to produce a strong, rigid covering for the package.

2. A shipping package for a relatively large stack of composition wallboards, comprising a rigid wooden base frame, panels of wastewallaboard covering all sides of said stack, including a panel placed on said base frame and having the stack placed thereon, resilient metal-angle pro- .tecting members located at intervals at the corners of the package, and tie wires encircling the package under substantial tension and passing oversaid protecting members, said waste panels being of substantial thickness and rigidity but somewhat crushable at their edges and being of such dimensions that marginal portions of certain of said panels overlap the edges of other of said panels in abutting relation at the corners of the package, said protecting members being in the form of an acute angle and having the line of intersection of the surfaces of the angle outwardly convexed, whereby said abutting marginal and edge portions'of the covering panels are held in tightly gripping interengagement by the tension of said tie wires to produce a strong, rigid covering for the package.

3. A shipping package for a stackof composition wallboards superimposed upon each other in non-slipping face to face contact, said stack being composed of a multiplicity of crushable composition wallboards of commercial length, composition wallboard panels on the outer surfaces of said stack covering the sides thereof, strong angular protecting members distributed along the edges of the package, and tie wires encircling the package under substantial tension and passing over said protecting members, the combined force exerted by the binding wires and the number of boards in the package being suflicient to produce a solid unbendable block-like package.

4. In a shipping package for a stack of composition wallboards superimposed upon each other in non-slipping face,to face contact, said stack being composed of a multiplicity of crushable composition wallboards of commercial length, a rigid base member provided at one side of the package, composition wallboard panels onthe outer surfaces of said st'ack covering the sides thereof, strong angular protecting members distributed along the edges of the package, and tie .wires encircling the package under substantial being sufllcient to produce a strong unbendable block-like package.

5. A shipping package for a stack of composition wallboards superimposed upon each other in non-slipping face to face contact, said stack being composed of a multiplicity of crushable composition wallboards of commercial length, composition wallboard panels on the outer surface of said stack covering the sides thereof, said panels being of substantial thickness and rigidity but somewhat crushable at their edges, strong angular protecting members distributed along the edges of the package, and tie wires encircling the package undersubstantial tension and passing over said protecting members, said wires exerting sufficient force upon said protecting members to force said protecting members into crushing engagement with the edges of said panels, the combined force exerted by said binding wires and the number of boards in the package being sufficient to produce a solid unbendable block-like package.

6. A shipping package for a stack of composition wallboards superimposed upon each other in non-slipping face to face contact, said stack being composed of a multiplicity of crushable composition wallboards of commercial length, a rigid base member provided at one side of the package, composition wallboard panels on the outer surface of said stack covering the sides thereof, said panels being of substantial thickness and rigidity but somewhat crushable at their edges, strong angular protecting members distributed along the edges of the package, and tie wires encircling the package under substantial tension and passing over said protecting members, said wires exerting sufficient force upon said protecting members to force produce a solid unbendable block-like package.

GEORGE L. HANN'.

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