US20160176609A1

US20160176609A1 - Packaging for Shipping of Hazardous Fluid Containers

Info

Publication number: US20160176609A1
Application number: US14/975,140
Authority: US
Inventors: Keith Allan Currie; John Ernesto Cruz
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-12-18
Filing date: 2015-12-18
Publication date: 2016-06-23

Abstract

A fiberboard package is disclosed. The fiberboard package includes an outer box having box sidewalls and foldable flaps at the top and bottom of the sidewalls, a first honeycomb pad placed in the bottom in the box, a spacer element placed in the box bracing all the sidewalls of the box defining an enclosed space, at least one inner sleeve placed on the first honeycomb pad and within the enclosed space defined by the spacer element, at least one can placed inside the at least one inner sleeve and a second honeycomb pad placed over the at least one can, the at least one inner sleeve and the spacer element.

Description

RELATED APPLICATIONS

The current application claims priority to a provisional application 62/093,539 filed on Dec. 18, 2014.

FIELD OF THE INVENTION

The invention relates generally to packaging and more particularly to a fiberboard package for safely holding, handling and transporting containers of hazardous fluids.

BACKGROUND OF THE INVENTION

Certain chemicals, because of their corrosive or other characteristics, are deemed hazardous, and as such require protective measures when shipped. The danger always exists that the containers for these substances, whether they be liquid or granular, will rupture or open as a consequence of the jolts and impacts typically encountered in transit. For example, many corrosive substances are sold in one gallon cylindrical cans with friction fitted lids or standard one gallon F-style containers, which are rectangular prismatic in form and have top handles and offset top nozzles. While these containers will accept a moderate amount of abuse without opening or rupturing, they have their limits, and one would not want to entrust it to a delivery service—at least when it contains a hazardous material—without some extra measure of protection.
The aspects of the present disclosure disclosed herein allow for the safe shipment and storage of such containers with reduced risk of damage and potentially costly leakage or rupturing. The present disclosure is a package of simple and inexpensive construction, with minimal number parts consisting almost entirely of corrugated and solid fiberboard, which can be readily discarded because it decomposes in landfills or is easily incinerated without producing harmful byproducts of combustion. The fiberboard package protects cylindrical and F-style cans against impacts, drops, heavy vibrations, and pressure changes during transport by aircraft. The package is also able to withstand stresses caused when transported in stacks. These and other advantages of the present disclosure will become apparent through the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top view of an outer box in its prepared, folded state in accordance with a first embodiment present disclosure.

FIG. 2 is a top plan drawing of the outer box of FIG. 1 lying flat prior to being folded.

FIG. 3 is a top plan drawing of an antistatic plastic bag lying flat in accordance with a first embodiment present disclosure.

FIG. 4 is a perspective view of a honeycomb pad in accordance with a first embodiment present disclosure.

FIG. 5A is a top plan drawing of the honeycomb pad of FIG. 4.

FIG. 5B is a side plan drawing of the honeycomb pad of FIG. 4.

FIG. 6 is a top view of a spacer element lying flat prior to being folded in accordance with a first embodiment present disclosure.

FIG. 7 is a top perspective view of the spacer element of FIG. 6 in its folded state.

FIG. 8A is a top plan drawing of the spacer element of FIG. 6 prior to being folded.

FIG. 8B is a side plan drawing of the spacer element of FIG. 6 prior to being folded.

FIG. 9 is a perspective view of an inner sleeve in accordance with a first embodiment present disclosure.

FIG. 10 is another perspective view of the inner sleeve of FIG. 9.

FIG. 11 is a top plan view of the inner sleeve of FIG. 9 lying flat prior to being folded.

FIG. 12 is a perspective view of a can, which is to be placed and securely held in the outer box in accordance with the first embodiment of the present disclosure.

FIG. 13 is a flowchart of a method for packaging a can, in accordance with the first embodiment of the present disclosure.

FIGS. 14-21 show perspective views of the outer box at various stages of the process by which the package is assembled in accordance with the first embodiment of the present disclosure.

FIG. 22 is a top view of a mostly-assembled package in accordance with the first embodiment of the present disclosure with modified dimensions to be able to hold two cans.

FIG. 23 is a top view of a mostly-assembled package in accordance with the first embodiment of the present disclosure with modified dimensions to be able to hold four cans.

FIG. 24 is a top view of a single wall, outer box in its prepared, folded state in accordance with the second embodiment of the present disclosure.

FIG. 25 is a top plan drawing of the outer box of FIG. 24 lying flat prior to being folded.

FIG. 26A is a top view of an unfolded honeycomb pad in accordance with the second embodiment of the present disclosure.

FIG. 26B is a top view of the folded honeycomb pad of FIG. 26A.

FIG. 27A shows top plan drawing of the honeycomb pad of FIG. 26A.

FIG. 27B shows side plan drawing of the honeycomb pad of FIG. 26A.

FIG. 28 is a perspective view of a spacer element in its prepared, folded state in accordance with the second embodiment of the present disclosure.

FIG. 29A shows top plan drawing of the spacer element of FIG. 28 (prior to being folded).

FIG. 29B shows side plan drawing of the spacer element of FIG. 28 (prior to being folded).

FIG. 30A is a sheet of solid fiberboard material used for preparing an inner sleeve in accordance with the second embodiment of the present disclosure.

FIG. 30B is the inner sleeve prepared using sheet of FIG. 30A.

FIG. 30C shows a top plan drawing of the sheet of FIG. 30A.

FIG. 30D shows the top view of the sleeve element of FIG. 30B.

FIGS. 31-35 show perspective views of the outer box at various stages of the process by which the package is assembled in accordance with the second embodiment of the present disclosure.

FIG. 36A shows a top view of an alternative configuration of the honeycomb pad (prior to being folded) in accordance with the second embodiment of the present disclosure, which allows the package to hold two cylindrical cans.

FIG. 36B shows a top view of the folded state of the honeycomb pad of FIG. 36A.

FIG. 37A shows a top view of an alternative configuration of the spacer element (prior to being folded) in accordance with the second embodiment of the present disclosure, which allows the package to hold two cylindrical cans.

FIG. 37B shows a perspective view of the folded state of the spacer element of FIG. 37A.

FIG. 38 is a top view of a mostly-assembled package in accordance with the second embodiment of the present disclosure with modified dimensions and the alternately configured pads and spacer of FIGS. 36A,B and 37A,B, respectively, which allows the package to hold two cylindrical cans;

FIG. 39A shows a top view of an alternative configuration of the honeycomb pad (prior to being folded) in accordance with the second embodiment of the present disclosure, which allows the package to hold four cylindrical cans.

FIG. 39B shows a top view the folded state of the honeycomb pad of FIG. 39A.

FIG. 40A shows a top view an alternative configuration of the spacer element (prior to being folded) in accordance with the second embodiment of the present disclosure, which allows the package to hold four cylindrical cans.

FIG. 40B shows a perspective view of the folded state of the spacer element of FIG. 40A.

FIG. 41 is a top view of a mostly-assembled package in accordance with the second embodiment of the present disclosure with modified dimensions and the alternately configured pads and spacer of FIGS. 39A, B and 40A, B, respectively, which allows the package to hold four cylindrical cans.

DETAIL DESCRIPTIONS OF THE INVENTION

The following detailed description is provided with reference to the figures. Exemplary, and in some case preferred, embodiments are described to illustrate the disclosure, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations in the description that follows. The present disclosure is related to a package constructed to protect containers of hazardous fluids from damage during storage and shipment. In particular, the figures relate to two main embodiments of the disclosure including packaging a rectangular prismatic can (for example, one gallon F-style can) and packaging a cylindrical can (for example, one gallon cylindrical cans).
The disclosure relates to a fiberboard package. The fiberboard package includes an outer box having box sidewalls and foldable flaps at the top and bottom of the sidewalls, a first honeycomb pad placed in the bottom in the box, a spacer element placed in the box bracing all the sidewalls of the box defining an enclosed space, at least one inner sleeve placed on the first honeycomb pad and within the enclosed space defined by the spacer element, at least one can placed inside the at least one inner sleeve and a second honeycomb pad placed over the at least one can, the at least one inner sleeve and the spacer element.

First Embodiment

A first embodiment of the present disclosure is described with reference to FIG. 1 through FIG. 23. The package of the present disclosure according to the first embodiment is preferably constructed to accommodate rectangular prismatic cans. In the first embodiment, the package comprises generally an outer box (shown in FIGS. 1-2), a plastic bag (shown in FIG. 3), two identical honeycomb pads (one of which is shown in FIGS. 4, 5A, 5B), a spacer element (shown in FIGS. 6-8), and a sleeve (shown in FIGS. 9-11).
FIG. 1 illustrates a top view of an outer box 100 in its prepared, folded state in accordance with a first embodiment present disclosure. The outer box 100 may be a standard design corrugated fiberboard box, such as that available from Supply One™ of Rockwell, N.C. The outer box 100 has four sidewalls 102-108, a bottom face 110 formed by four foldable overlapping flaps 110A-110D and a top face 112 formed by four foldable overlapping flaps 112A-112D. As shown in FIG. 1, the bottom four flaps 110A-110D are closed, while the top four flaps 112A-112D are open.
FIG. 2 is a top plan drawing of the outer box 100 of FIG. 1 lying flat prior to being folded. The outer box 100 also includes a joint panel 202, which is used to join the sidewalls. The outer box 100 may be manufactured from a single wall fiberboard blank comprising a fluted corrugated sheet sandwiched between two flat liner boards. The corrugated sheet may include C Flutes, but other common flute sizes may be utilized.
Further, multiple score lines are formed in the blank to define the boundaries of the flaps (110A-110D, 112A-112D) and sidewalls 102-108. For example, the blank may be scored near the edges parallel to the longest dimension to define the boundaries (204-208) of the flaps 112A-112D. Further, the blank may be scored near the edges parallel to the longest dimension to define the boundaries (216-220) of the flaps 110A-110D. Moreover, the blank may also be scored at intervals perpendicular to the longest dimension to define the boundaries (210-214) of the sidewalls 102-108. The blank is then cut along designated lines (204-208 and 216-220) to allow the flaps to bend freely. The box is prepared for packaging by folding the flaps (110A-110D, 112A-112D) and sidewalls 102-108 along the score lines into the shape shown in FIG. 1 and binding the joint panel 202 to the adjacent side panel; for example, via an adhesive. The outer box 100 has a volume with unequal length, width, and depth. As an example, FIG. 2 shows dimensions of the outer box. All dimensions are in inches.
FIG. 3 is a top plan drawing of a plastic bag 300 lying flat in accordance with a first embodiment present disclosure. The plastic bag 300 is of standard nature having a generally rectangular shape when laid flat; for example, similar to the ones available from Laddawn™, Devens, Mass. The plastic bag 300 is sized so that, when expanded, its interior volume is larger than that of the outer box 100 and has a substantially longer depth than the outer box 100. The plastic bag 300 may be formed with any typical organic polymers, such as but not limited to polyethylene. Further, it may be impregnated with antistatic additives. As an example, FIG. 3 shows dimensions of the plastic bag. All dimensions are in inches.
FIG. 4 is a perspective view of a honeycomb pad 400 in accordance with a first embodiment present disclosure. The honeycomb pad 400 is a rectangular panel. It may be made using a die cut fiberboard honeycomb material; for example, similar to the one that available from Multiwall Packaging™, Gary, Ind. The honeycomb material comprising cells 404 sandwiched between two flat linerboards 406 and 408.
FIG. 5A is a top plan drawing of the honeycomb pad 400 showing the top face 406. FIG. 5B is a side plan drawing of the honeycomb pad 400 showing the side face 410. The length and width of the honeycomb pad 400 is slightly less than that of the outer box 100 so that they may be easily inserted in the outer box 100 and fit snuggly therein. As an example, FIGS. 5A and 5B show dimensions of the honeycomb 400. All dimensions are in inches. Two such honeycomb pads are used as described in further detail in conjunction with FIGS. 14-21 below.
FIG. 6 is a top view of a spacer element 600 lying flat prior to being folded in accordance with a first embodiment present disclosure. The spacer element 600 may be made from a rectangular panel of die cut fiberboard honeycomb material; for example, similar to the one that available from Multiwall Packaging™, Gary, Ind. The spacer element 600 comprises a single top liner board 602 and four individual sections 604-610 of honeycomb material, wherein each section 604-610 of the honeycomb material is sandwiched between the top liner board 602 and an associated bottom liner board.
FIG. 7 is a top perspective view of the spacer element 600 in its folded state. The honeycomb material includes multiple cells 702. FIG. 8A is a top plan drawing and FIG. 8B is a side plan drawing of the spacer element 600 prior to being folded. The top linerboard 602 is scored along three lines 612-616 as shown in FIGS. 6, 8A and 8B, which form the boundaries of the four sections of honeycomb material 604-610 and allow them to independently fold thereabout. The spacer element 600 is prepared by folding the top linerboard 602 about the three score lines 612-616 to form a rectangular tube as shown in FIG. 7, wherein the top liner board 602 forms the interior wall that line the lumen, and the four bottom liner boards of each section form the outer wall 704 thereof.
The length and width of the spacer element 600 in the prepared, folded state are slightly less than that of the outer box 100 so that they may be easily inserted and fit snuggly therein, as described in further detail in conjunction with FIGS. 14-21 below. As an example, FIGS. 8A and 8B show dimensions of the spacer element 600. All dimensions are in inches.
FIG. 9 is a perspective view of an inner sleeve 900 in accordance with a first embodiment present disclosure. FIG. 10 is another perspective view of the inner sleeve 900 of FIG. 9. FIG. 11 is a top plan view of the inner sleeve 900 lying flat prior to being folded. The inner sleeve 900 may be manufactured from a solid fiberboard blank, which is scored along lines 1102-1108 to form five adjacently aligned side panels 1110-1118 as shown in FIG. 11.
The top flaps 1120-1122 and the bottom flaps 1124-1126 extend perpendicularly from the edges of the second side panel 1112 and the fourth side panel 1116 respectively. The flaps are perforated along their connecting joint to permit them to fold freely thereabout. The inner sleeve 900 is prepared for packaging by folding the side panels into the state as shown in FIGS. 9-10, wherein the inner sleeve 900 has a top formed by the two overlapping flaps 1120-1122 extending from one side of the second panel 1112 and the fourth panel 1116 respectively. A bottom is similarly formed by the two overlapping flaps 1124-1126 extending from the opposite side of the second panel 1112 and the fourth panel 1116 respectively. A four-faced side wall is formed using the five side panels 1110-1118, wherein the two outermost side panels, i.e., the first side panel 1110 and the fifth side panel 1118 overlap to form one of the four side walls. The first side panel 1110 and the fifth side panel 1118 are bound together via packing tape or other adhesive means.
The length and width of the sleeve in the prepared, folded state are slightly less than that of the dimensions of the lumen formed by the spacer element so that the sleeve may be easily inserted and fit snuggly into the spacer, as described in further detail in conjunction with FIGS. 14-21 below. As an example, FIG. 11 shows dimensions of the inner sleeve 900. All dimensions are in inches.
The middle side panel, i.e., the third side panel 1114, may have a semicircular cutout 1128 formed in one edge thereof. The end of the inner sleeve 900 with the semicircular cutout is deemed the top, and the end opposite the semicircular cutout is deemed as the bottom of the inner sleeve 900. The bottom flaps 1124-1126 may be sealed with packing tape prior to packaging.
FIG. 12 is a perspective view of a can 1200, which is to be placed and securely held in the outer box 100 in accordance with the first embodiment of the present disclosure. The can 1200 is a one gallon F-style can. The can 1220 has a typical rectangular prismatic shape with top handle 1202 and offset top nozzle with a screw cap 1204. The F-style can is used as an example. The present disclosure is applicable for other can designs and shapes as well. An F-style can is packaged with the first embodiment of the present disclosure as described in reference to FIGS. 14-21.
FIG. 13 is a flowchart of a method 1300 for packaging the can 1200, in accordance with the first embodiment of the present disclosure. At step 1302, the bottom foldable flaps 110A-110D of the outer box 100 are sealed to close the bottom end and to obtain the configuration of the outer box 100 as shown in FIG. 1. The bottom foldable flaps 110A-110D may be taped in an H-style pattern; for example using a water-activated fiber reinforced paper tape. Then at step 1304, the outer box 100 is turned over so that the top end is turned up and the top flaps 112A-112D are opened up.
Thereafter, a plastic bag 300 may be placed inside the outer box 100 through the open top end and pushed down to the bottom of the box, as shown in FIG. 14. FIGS. 14-21 show perspective views of the outer box at various stages of the process by which the package is assembled in accordance with the first embodiment of the present disclosure. The plastic bag 300 is pulled open so that bag lines the sidewalls of the outer box 100. The plastic bag 300 has a greater depth than the outer box 100; therefore, the ends of the plastic bag 300 are left exposed on the open end of the outer box 100. In FIG. 14, the outer box 100 is shown in dotted lines as the outer box is below the plastic bag 300. Further, as shown in the legend 1400, a specific patterned line is used to indicate the contours of the plastic bag 300 when placed in the outer box 100. For the sake of clarity, the contours are not shown in further drawings below.
Then at step 1306, the honeycomb pad 400 is placed in the plastic bag 300 and pushed to the bottom of the plastic bag 300 (and the outer box 100) as shown in FIG. 15. As previously described, the honeycomb pad 400 is dimensioned to fit snuggly in the outer box 100 and is therefore unable to shift side to side.
Next, at step 1308, the spacer element 600, prepared in the folded state for packaging (as shown in FIG. 7 above), is placed on top of the honeycomb pad 400 as shown in FIG. 16. The spacer element 600 lines with the sidewalls 102-108 of the outer box 100. As previously described, the spacer element 600 is dimensioned to fit snuggly within the outer box 100.
Thereafter, at step 1310, the inner sleeve 900, prepared in the folded state for packaging (as shown in FIG. 9), is inserted into the lumen created by the spacer element 600 with the semicircular cutout 1128 facing up, as shown in FIG. 17. The semicircular cutout 1128 allows the interior of the inner sleeve 900 to be viewed from the outside when the top flaps of the inner sleeve 900 are folded shut, allowing packagers to make sure that the can is not packaged upside down.
The inner sleeve 900 is pushed down until it rests on top of the honeycomb pad 400 placed below. As previously described, the inner sleeve 900 is dimensioned to fit snuggly within the spacer element 600. The top of the inner sleeve 900 may also lies flush with the top of the spacer element 600.
Then, at step 1312, the can 1200 is placed in the inner sleeve 900 as shown in FIG. 18. The inner sleeve 900 fits snuggly around the can 1200. The two top flaps of the sleeve are overlapped on top of the can 1200 to close the inner sleeve 900. The top flaps may be taped shut with packing tape to further secure the can 1200 inside the sleeve 900.
Next, at step 1314, a honeycomb pad 1900 (identical to the honeycomb pad 400) is placed on top of the closed inner sleeve 900 and the spacer element 600 as shown in FIG. 19. The honeycomb pad 1900 fits snuggly in the outer box 100.
As shown in FIG. 20, with all of the components inside the outer box 100, the exposed ends of the plastic bag 300 are folded over top of the honeycomb pad 1900 and secured with tape (for example, plastic sealing tape) to ensure that the contents of the package are completely sealed.
Finally, at step 1316, the top flaps of the outer box 100 are closed and taped in an H-style pattern (for example, with water-activated fiber reinforced paper tape) completing the package. The series of snug fits between the outer box 100, the honeycomb pads 400 and 1900, the spacer element 600, and the inner sleeve 900 to prevent motion of the can 1200 within the package and also cushion it against drops, impacts, vibrations, and heavy weight placed on the package.
It is to be appreciated that the preceding concepts of the first embodiment of the present disclosure may obviously apply to the packaging of more than one F-style can in a single package. As shown in FIGS. 22-23, the dimensions of the outer box 100, the honeycomb pads 400 and 1900, and the spacer element 600 may be modified in order to accommodate more than one inner sleeves and thus more than one cans. FIG. 22 is a top view of a mostly-assembled package with two sleeves 2202-2204 and two cans 2206-2208 held therein. Similarly, FIG. 23 is a top view of a mostly-assembled package with four sleeves 2302-2308 and four cans 2310-2316 held therein. Although these configurations are considered optimum, the size of the various components of the package may be modified to accommodate even more cans.
Further, the packaging may include absorbent elements between the can 1200 and the inner sleeve 900. The absorbent element may be made using resinous foam material comprises cellular phenol-formaldehyde resin.

Second Embodiment

A second embodiment of the present disclosure is described with reference to FIGS. 24-41. The package of the present disclosure according to the second embodiment is preferably constructed to accommodate cylindrical cans, but comprises substantially similar parts as described above. In the second embodiment, the package comprises generally an outer box 2400 (as shown in FIG. 24-25), two identical honeycomb pads (one of which is shown in FIGS. 26, 27A, 27B), a spacer element (shown in FIGS. 28, 29A, 29B), and a sleeve (as shown in FIG. 30).
FIG. 24 is a top view of a single wall, outer box in its prepared, folded state. As shown in FIG. 24, the outer box 2400 is a standard corrugated fiberboard box of substantially the same construction as the outer box 100 of the first embodiment, albeit with different dimensions to account for the different dimensions of a cylindrical can. The outer box 2400 has four sidewalls 2406-2412, a bottom face 2404 formed by four foldable overlapping flaps 2404A-2404D and a top face 2402 formed by four foldable overlapping flaps 2402A-2402D. Therefore, the outer box 2400 is also prepared for packaging in the same manner. As an example, FIG. 25 shows dimensions of the outer box 2400. All dimensions are in inches. FIG. 25 is a top plan drawing of the outer box of FIG. 24 lying flat prior to being folded.
FIG. 26A is a top view of an unfolded honeycomb pad in accordance with the second embodiment of the present disclosure and FIG. 26B is a top view of the folded honeycomb pad. The honeycomb pad 2600, like the one of the first embodiment, is configured from a rectangular panel of die cut fiberboard honeycomb material, wherein honeycomb material includes cells is sandwiched between two flat liner boards.
The honeycomb pad 2600 is formed with one circular cutout 2602 centered on one half of the honeycomb pad 2600. Further, two quarter-circle cutouts 2604-2606 are formed on opposite corners of one edge 2608 of the longest dimension of the honeycomb pad 2600. Moreover, a semicircular cutout 2610 is formed at the midpoint of the longest dimension of the honeycomb pad on the edge 2612 opposite the two quarter circle cutouts 2604-2606. The honeycomb pad 2600 is folded at the midpoint of its largest dimension along a scored line 2614, shown in FIG. 26B, prior to packaging. The length and width of the honeycomb pad 2600 in the prepared, folded state are slightly less than that of the outer box 2400 so that it may be easily inserted and fit snuggly therein, as will be described hereinafter in reference to FIGS. 31-35. Two identical honeycomb pads may be prepared in this manner. As an example, FIGS. 27A and 27B shows dimensions of the honeycomb pad 2600. All dimensions are in inches. FIG. 27A shows top plan drawing of the honeycomb pad 2600 and FIG. 27B shows side plan drawing of the honeycomb pad 2600.
As shown in FIGS. 28, 29A, 29B, a spacer element 2800 is of substantially the same construction as the spacer element 600 of the first embodiment, albeit with different dimensions to account for the different dimensions of a cylindrical can. FIG. 28 is a perspective view of a spacer element in its prepared. Therefore, the spacer element 2800 is also prepared for packaging in the same manner. The spacer element 2800 includes four sidewalls 2802-2808, wherein the sidewalls are separated by score lines 2810-2814. As an example, FIGS. 29A and 29B shows dimensions of the spacer element 2800. All dimensions are in inches. FIG. 29A shows top plan drawing of the spacer element 2800 and FIG. 29B shows side plan drawing of the spacer element 2800.
FIG. 30A is a sheet 3004 of solid fiberboard material used for preparing an inner sleeve 3002 shown in FIG. 30B. The inner sleeve 3002 is a thin-walled cylinder manufactured from a sheet of solid fiberboard material 3004. The inner sleeve 3002 is dimensioned to have an outer circumference substantially the same as the circumference of the circular cutout in the honeycomb pad 2600 so that the inner sleeve 3002 may fit snuggly therein. FIG. 30C shows a top plan drawing of the sheet of solid fiberboard material 3004 along with the associated dimensions. FIG. 30D shows the top view of the inner sleeve 3002 and thickness of the sheet of solid fiberboard material 3004.
Additionally, the inner circumference of the inner sleeve 3002 may be substantially the same as that of a typical one gallon cylindrical can so that it can may fit snuggly therein. This will be further described hereinafter in reference to FIGS. 31-35. FIGS. 31-35 show perspective views of the outer box at various stages of the process by which the package is assembled in accordance with the second embodiment of the present disclosure.
Now, with reference to FIGS. 31-37, the package of the second embodiment of the present disclosure may be assembled as follows. First, as with the first embodiment, the flaps on the bottom of the outer box 2400 may be taped in an H-style pattern, to close the bottom end. The outer box 2400 is then turned over so that the top end, still open, faces up.
Then, as shown in FIG. 31, the honeycomb pad 2600, prepared in the folded state for packaging, is placed in the bottom of the outer box 2400 with the circular cutout 2602 facing up. As previously described, the honeycomb pad is dimensioned to fit snuggly in the box and is therefore unable to shift side to side.
Next, as shown in FIG. 32, the inner sleeve 3002 is pressed into the circular cutout 2602 of the honeycomb pad 2600. As previously described, the inner sleeve 3002 is dimensioned to fit snuggly within the circular cutout 2602.
Thereafter, as shown in FIG. 33, the spacer element 2800, prepared in the folded state for packaging, is placed on top of the honeycomb pad 2600 and fit snuggly around the inner sleeve 3002, lining the sidewalls of the outer box 2400 and stabilizing the inner sleeve 3002.
Then, as shown in FIG. 34, a cylindrical can 3402 is placed in the inner sleeve 3002. The inner sleeve 3002 fits snuggly around the cylindrical can 3402.
Next, as shown in FIG. 35, a honeycomb pad 3502 (identical to the honeycomb pad 2600), prepared in the folded state for packaging, is placed on top of cylindrical can 3402 with the circular cutout facing down, fitting over the top of the cylindrical can 3402, locking the inner sleeve 3002, and securing the cylindrical can 3402 in place.
Finally, the top flaps of the outer box 2400 are closed and taped in an H-style pattern completing the package.
It is to be appreciated that the preceding concepts of the first embodiment of the present disclosure may obviously apply to the packaging of more than one cylindrical can in a single package.
With reference to FIGS. 36A, B-37A, B, the honeycomb pads and the spacer element may be reconfigured in order to accommodate two sleeves and thus two cylindrical cans. In this case, the dimensions of the outer box are also modified to accommodate two cylindrical cans. FIG. 36A shows a top view of an alternative configuration of the honeycomb pad 3600 (prior to being folded) and FIG. 36B shows a top view of the folded state of the honeycomb pad 3600. As shown in FIG. 36A (open state) and 36B (folded state), the honeycomb pad 3600 may be enlarged so that two circular cutouts 3602-3604 may be made there through.
FIG. 37A shows a top view of an alternative configuration of the spacer element 3700 (prior to being folded) and FIG. 37B shows a perspective view of the folded state of the spacer element 3700. As shown in FIG. 37A (open state) and 37B (folded state), the spacer element 3700 may be extended with five score lines 3702-3710 made thereon, allowing the spacer element 3700 to be folded five times and create two cells 3712-3714. FIG. 38 is a top view of a mostly-assembled package with an enlarged outer box 3802, modified honeycomb pad 3804, modified honeycomb spacer 3806, two sleeves 3808-3810, and two cylindrical cans 3812-3814 held therein.
With reference to FIGS. 39-41, the honeycomb pads and the spacer element may be reconfigured in order to accommodate four sleeves and thus four cylindrical cans. In this case, the dimensions of the box are also modified to accommodate four cylindrical cans.
FIG. 39A shows a top view of an alternative configuration of the honeycomb pad 3900 (prior to being folded) and FIG. 39B shows a top view the folded state of the honeycomb pad 3900. As shown in FIG. 39A (open state) and FIG. 39B (folded state), the honeycomb pad 3900 may be enlarged so that four circular cutouts 3902-3908 can be made therethrough.
As shown in FIG. 40A (open state, top view) and FIG. 40B (folded state, perspective view), the spacer element 4000 may be extended with four score lines 4002-4008 made thereon, allowing the spacer element 4000 to be folded four times and create two cells 4010-4012. Similarly, two more cells are created, such that there are 4 cells in total. FIG. 41 shows a top view of a mostly-assembled package with an enlarged box 4102, modified honeycomb pad 4104, and two modified honeycomb spacers 4106-4108 arranged to form four cells in which four sleeves 4110-4116 and thus four cylindrical cans 4118-4124 are held. Although these configurations are considered optimum, the size of the various components of the package may be modified to accommodate even more cylindrical cans.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention.

Claims

What is claimed is:

1. A fiberboard package comprising:

an outer box having box sidewalls and foldable flaps at the top and bottom of the sidewalls;

a first honeycomb pad placed in the bottom in the box;

a spacer element placed in the box bracing all the sidewalls of the box defining an enclosed space;

at least one inner sleeve placed on the first honeycomb pad and within the enclosed space defined by the spacer element;

at least one can placed inside the at least one inner sleeve;

a second honeycomb pad placed over the at least one can, the at least one inner sleeve and the spacer element.

2. The fiberboard package of claim 1, wherein the fiberboard package further includes a plastic bag placed inside the box through the open top end and pushed down to the bottom of the box, wherein the plastic bag is pulled open so that bag lines with the sidewalls of the box, wherein the bag has a greater depth than the box and the ends of the bag are left exposed on the open end of the box.

3. The fiberboard package of claim 1, wherein the can is shaped in one of rectangular prismatic shape and a cylindrical shape.

4. The fiberboard package of claim 3, wherein the at least one inner sleeve is shaped such that the at least one can snuggly fits in the at least one inner sleeve.

5. The fiberboard package of claim 3, wherein the at least one inner sleeve is shaped in one of rectangular prismatic shape and a cylindrical shape, based on the shape of the at least one can.

6. The fiberboard package of claim 1, wherein the at least one can is an F-style container.

7. The fiberboard package of claim 3, wherein the first honeycomb pad includes at least one circular hole to receive the at least one inner sleeve and the at least one can.

8. The fiberboard package of claim 1, wherein at least one of the first honeycomb pad, the second honeycomb pad, and the spacer element is made of a fiberboard honeycomb material.

9. The fiberboard package of claim 1, wherein the outer box is made of corrugated fiberboard.

10. The fiberboard package of claim 1, wherein the at least one inner sleeve is made from a solid fiberboard blank.

11. The fiberboard package of claim 1, wherein fiberboard package is used to store hazardous materials comprising at least one corrosive, flammable and poisonous liquids and solids.

12. A package assembly for containing hazardous materials, the package assembly comprising:

a plastic bag placed inside the box through the open top end and pushed down to the bottom of the box, wherein the plastic bag is pulled open so that bag lines with the sidewalls of the box, wherein the bag has a greater depth than the box and the ends of the bag are left exposed on the open end of the box.

a first honeycomb pad placed in the bottom in the box;

at least one can placed inside the at least one inner sleeve, wherein the at least one can is shaped in one of rectangular prismatic shape and a cylindrical shape;

13. The package assembly of claim 12, wherein at least one of the first honeycomb pad, the second honeycomb pad, and the spacer element is made of a fiberboard honeycomb material.

14. The package assembly of claim 12, wherein the outer box is made of corrugated fiberboard and the at least one inner sleeve is made from a solid fiberboard blank.

15. A method for packaging a can containing hazardous materials, the method comprising:

sealing the bottom foldable flaps of an outer box having sidewalls and foldable flaps at the top and bottom of the sidewalls;

opening the foldable flaps of the top side;

placing a first honeycomb pad in the bottom in the box;

placing a spacer element in the box bracing all the sidewalls of the box defining an enclosed space;

placing at least one inner sleeve on the first honeycomb pad and within the enclosed space defined by the spacer element;

placing at least one can inside the at least one inner sleeve;

placing a second honeycomb pad over the at least one can, the at least one inner sleeve and the spacer element; and

closing the foldable flaps of the top side.

16. The method of claim 15, further includes placing a plastic bag inside the outer box through the open top end and pushed down to the bottom of the box, wherein the plastic bag is pulled open so that bag lines with the sidewalls of the box, wherein the bag has a greater depth than the box and the ends of the bag are left exposed on the open end of the box.

17. The method of claim 15, wherein the at least one can is shaped in one of rectangular prismatic shape and a cylindrical shape, wherein the at least one inner sleeve is shaped such that the at least one can snuggly fits in the at least one inner sleeve.

18. The method of claim 17, wherein at least one of the first honeycomb pad and the second honeycomb pad includes a circular hole to receive the at least one sleeve and the at least one can.

19. The method of claim 15, wherein at least one of the first honeycomb pad, the second honeycomb pad and the spacer element is made from a solid fiberboard blank.

20. The method of claim 15, wherein the outer box is made of corrugated fiberboard and the at least one inner sleeve is made from a solid fiberboard blank.