WO2004108559A1

WO2004108559A1 - Packaging for suspended support of article

Info

Publication number: WO2004108559A1
Application number: PCT/GB2004/002534
Authority: WO
Inventors: Nathan Albert Anderton; Douglas Allan
Original assignee: Ds Smith (Uk) Limited
Priority date: 2003-06-11
Filing date: 2004-06-11
Publication date: 2004-12-16
Also published as: GB0313487D0

Abstract

There is disclosed packaging and an element (1000) for use in packaging. There is disclosed a packaging element (1000) for an article, said element comprising first support means adapted to locate and to support a said article and second support means adapted to, suspensively support and to locate said article, such that in use a said article is secured against lateral movement and that major surfaces thereof are spaced from the packaging element. This means that none of the major exterior surfaces of the article, which may be painted or otherwise decorated touch the packaging and are thus not able to be damaged, etc. during transportation. An example of packaging an article utilising the packaging element is the packaging of a car prior to assembly.

Description

PACKAGING FOR SUSPENDED SUPPORT OF ARTICLE

The invention relates to packaging, and particularly for an element for use in packaging.

Packaging has been used over an extended period to package, transport, store and present articles so that they are at least protected from damage for example during transport. Packaging materials include laminated or heavy-duty corrugated board, heavy duty plastic and timber. One use of packaging is to protect pressed car parts as they are transported from their pressing and manufacturing point to a remote assembly line. The assembly line may be on a different site, or in a different country. Prior art methods of packaging protect the pressed part by packaging them in individual packaging units. Transport of a whole vehicle in parts, from a manufacturing and pressing facility to an assembly line can be expensive, both in terms of packaging material and in the shipping and transportation space taken up by the packaging.

It is accordingly an object of the invention to seek to mitigate these disadvantages of prior packaging.

According to the invention there is provided a packaging element for an article, said element comprising first support means adapted to locate and to support a said article and second support means adapted to suspensively support and to locate said article, such that in use a said article is secured against lateral movement and that major surfaces thereof are spaced from the packaging element.

The invention advantageously provides that none of the major exterior surfaces, which may be painted or otherwise decorated do not touch the packaging and are thus not able to be damaged, scratched etc. during transportation.

Preferably more than one article can be packaged and supported within the packaging element. Accommodating more than one article within a single packaging element significantly reduces the space required for transporting the articles. A corresponding reduction in the quantity of packaging materials required, compared to individually packaged components, is achieved. This leads to a reduction in both materials' costs and the associated costs, freight charges etc for shipping and handling the packaged articles.

The support means may be arranged to comprise any number of further support means for supporting one or more additional articles to be packaged. The support means are provided at any suitable position within the packaging element to provide sufficient security and support for the article. The material of the packaging element may be any material suitable for and required by the article being packaged. Examples of suitable materials may include cardboard, sheet steel, plastic or card. Alternatively, other materials such as single ply, two ply, two wall cardboard or heavy duty corrugated board may be used as appropriate depending upon the article to package.

A particular example of packaging an article utilising such a packaging element is the packaging of a vehicle prior to assembly.

A vehicle, for example, a car, comprises a number of pressed metal components, for example panels, wheel arches, doors. At the pressed metal stage of manufacture the vehicle body is termed in the art "body in white" to refer to the pressed metal components only. In the preferred example all of the components required for assembling one complete side of the car are packaged in a single packaging element. Alternatively, the articles required for the assembly of the whole vehicle (i.e the whole "body in white") could be packaged in a single packaging element.

Preferably the packaging material is triple ply or triple wall corrugated cardboard of 15 mm thickness. This material advantageously provides a preferred strength to weight ratio suitable for packaging vehicle parts.

Embodiments of the present invention will now be described by way of example only, and with reference to the accompanying drawings, in which:-

Figure 1 shows, in plan view, a blank of a section of an element in accordance with an embodiment of the invention;

Figure 2 shows, in plan view, a blank of another section of an element in accordance with an embodiment of the invention;

Figures 3 a and 3b show, in plan view, blanks of sections of an element in accordance with an embodiment of the invention;

Figures 4a, 4b, 4c, 4d and 4e show, in plan view, blanks of sections of an element in accordance with an embodiment of the invention;

Figures 5a, 5b and 5c show, in plan view, respective blanks of sections of an element in accordance with an embodiment of the invention;

Figures 6a, 6b and 6c show, in plan view, respective blanks of sections of an element in accordance with an embodiment of the invention;

Figure 7 shows, in plan view, a blank of a supporting section for an element in accordance with an embodiment of the invention; Figures 8 to 11 show perspective views of section blanks arranged to form a part assembled element in accordance with an embodiment of the invention;

Figures 12 and 13 show perspective views of a fully assembled element in accordance with an embodiment of the invention and containing packaged articles;

Figure 14 shows a perspective view of another side of an element in accordance with an embodiment of the invention.

Referring to the drawings there is shown a packaging element 1000 for an article, said element comprising first support means adapted to locate and to support a said article and second support means 51, 52 adapted to suspensively support and to locate said article, such that in use a said article is secured against lateral movement and that major surfaces thereof are spaced from the packaging element 1000.

In the preferred embodiment the blanks are die cut from sheets of packaging material preferably fabricated from three ply corrugated cardboard material.

Referring now to Figures 1 to 7, the section blanks are slotted and fitted together as set out below in order to form a packaging element embodying the invention. The packaging element is shown assembled in Figures 8 to 13. Figures 8 to 13 illustrate the progress of the construction and assembly operation.

Blank A is folded along score lines 100, 110 and sealed with a suitable sealing means for example an adhesive such as an epoxy between tabs 1, of sides 3 and side walls 2. Folded blank A forms tray base unit 1001. Blank B is a length division piece. In the following description a "length division" refers to a piece arranged in a direction substantially parallel to the longest side of the tray 1001 and used for dividing the base area of tray 1001 along its longest side. Analogously, the term "width division" is used in the following description to refer to a piece of packaging material arranged a direction substantially parallel to the shorter side of the tray 1001. Blank B extends the full length of base tray 1001 and is arranged to stand in tray 1001 in the direction and orientation shown in Figure 8 with profiled slots 20 and 21 uppermost.

Blank C is a length division. Blank C is arranged substantially parallel to blank B within tray 1001, as shown in Figure 8. Blank C extends the full length of tray 1001 and is arranged with slot 40 uppermost.

Blank D is a length division. Blank D is arranged substantially parallel to blank B and blank C within tray 1001, as shown in Figure 9. Blank D is arranged with profiled slot 41 resting on base tray 1001. Blank D is folded at fold line 400 to engage with blank C. Blank C, cut 401 is slotted into blank D, cut 402. Blank E is a short length division arranged substantially parallel to blanks B and C in tray 1001. Blank E is arranged to stand between blank B and blank C. Cut 404 of blank E is arranged to slot into cut 403 of blank D.

Blank F is a width division arranged to stand vertically in tray 1001 in a direction substantially parallel to the side wall 3 of tray 1001, as shown in Figure 8. Blank F is arranged to engage with blanks B, C and E. Cut 201 of blank B is inserted into cut 301 of blank F, cuts 302 and 303 of blank F are inserted into cuts 405 and 406 of blank C and blank E respectively. Blank G is a width division arranged to stand substantially vertically and substantially parallel to side walls 3 of tray 1001. Blank G engages with blank B, blank C and blank D in a slotted arrangement in a similar manner to that described for blank F. Specifically, cut 304 of blank G is slotted into cut 202 of blank B and cut 305 is slotted into cut 407 of blank C and cut 306 of blank G is slotted into cut 408 of blank D.

Blanks H and J are further width divisions arranged substantially parallel to blanks G and F. Blank H is arranged to engage with blanks B and D in the following manner. Cut 501 of blank H engages with cut 203 of blank B, cut 502 of blank H engages with cut 409 of blank D, cut 503 of blank A engages with cut 410 of blank C, as shown in Figure 8.

Blank J is arranged substantially parallel to blank H and engages with blank B and C and D in the following manner. Cut 504 of blank J engages with cut 204 of blank B, cut 505 of blank J engages with cut 411 of blank C and cut 506 of blank J engages with cut 412 of blank D.

Blank K is a small width division arranged substantially parallel to width divisions blanks J and H. Blank K is arranged as a width division in between blanks F and H. Blank K engages with blanks B and C in the following manner. Cut 510 of blank K engages with cut 211 of blank B, cut 511 of blank K engages with cut 418 of blank C.

Blank M is folded along fold lines 600 and arranged to engage with blanks B and H in the following manner. Cut 601 engages with cut 205 of blank B and cut 202 of blank M is arranged to slot into cut 507 of blank H.

Additional parts of the packaging element will now be described. Blank N is folded along fold lines 610 and 620 and engages with blank B by slotting cut 603 of blank N into cut 209 of blank B and cut 604 of blank N into cut 208 of blank B.

The assembly thus far is illustrated in Figure 8 in perspective view.

With the packaging element constructed thus far an article to be packaged, in the preferred embodiment pressed parts of half of the "white body" of a car, can be packaged securely. Certain articles 1005 - 1009, such as Side member and closing front assembly 1006, are shown packaged in Figure 9.

Figure 9 additionally shows blank P not shown in Figure 8. Blank P is folded along fold lines 630 and 640 and is arranged to engage blank B by slotting cut 605 of blank P into cut 207 of blank B and by slotting cut 606 of blank P into cut 206 of blank B.

In the preferred embodiment a rear wheel arch 1005 is supported by the packaging element comprising blank B, blank N and blank P. This is illustrated in Figures 9 and 10.

Furthermore, Figure 10 illustrates how a pressed car bodyside assembly 1010 can be inserted and hung from the profiled slots 50 and 51 in width division blanks J and H. The pressed car bodyside assembly 1010 is supported, by blanks J and H and C and B. The underside of the roof and door frame section is suspensively supported by the profiled slots 50 and 51 and the front upper windscreen section and lower rear windscreen section of the car bodyside 1010 engage with and are supported by profiled slots 20 and 21 in blank B. The sill on the lower portion of the car bodyside assembly 1010 is supported on the upper edge of blank C. A further part of the packaging element is constructed from blank Q. Blank Q is folded along fold line 450 and arranged to engage with blank B and blank F as follows. Cut 413 of blank Q is slotted into cut 210 of blank B and cut 414 of blank Q is slotted into cut 307 of blank F.

In the preferred embodiment blank Q forms part of the packaging element that supports part of the pressed dash assembly and is illustrated in Figure 10.

Blank R is used as a further part of the packaging element and is illustrated, in use in Figures 11, 12 and 13. Blank R engages with blanks G, J and H as follows. Cut 415 of blank R is slotted into cut 308 of blank G, cut 416 of blank R is slotted into cut 508 of blank J and cut 417 of blank R is slotted into cut 509 of blank H.

In the preferred embodiment Blank R is used for packaging a further part of the pressed car "white body" to be packaged, namely the car doors. Blank R packages and spaces the front 1012 and rear door 1013 from the pressed car bodyside assembly. Use of blank R enables close packing of the doors 1012, 1013 in proximity to the pressed car bodyside assembly and the other components of the "white body" but maintains space between the articles in order that they are separated from each other during transport and shipping to protect them from damage.

Door panels 1012, 1013 are accommodated in profile slots 53 and 52 in blank J and H respectively. Blank R is inserted in between the lower door panels and the main body panel in order to separate and protect the door panels from the main body panel. The lower sills of the door panels are supported on the upper edge of blank D. The position of the door panel and the use of blank R are shown in Figure 11, 12 and 13. The assembled packaged article with the preferred embodiment is fully illustrated in Figures 12 and 14, showing between them all four sides of the packaging with the article, as set out below and numbered in the figures.

In the preferred embodiment the article to be packaged is half a pressed car body namely:

- Bodyside complete assembly 1010

- Fender assembly complete 1005

- Side member and closing front assembly 1006

- Valance complete assembly 1007

- Extension assembly rear side member 1008

- 'A' post closing assembly 1009

- Dash lower assembly 1011

- Front and rear doors 1012, 1013

- Dash upper upper 1014

- Fuel cap 1015

- Dash lower 'X' member 1016

- Rear parcel shelf 1020

- Dash upper lower 1021

- Reinforced valance to 'A' post 1022

- Sill inner assembly 1031

- Body rear assembly 1030 Finally the packaging element is completed by adding a cap 1002 and two wraparound ears 1003, 1004. The cap 1002 is fabricated from a blank identical to the blank A shown in Figure 1 and made up as for base tray 1001. The cap is fitted to the top of the article in a complimentary way to the tray 1001. For ease of handling and transport wraparound ears are made up. Blank S shows one of two identical elements that are used to protect the packaged article. In use S is folded along fold lines 701 and 702 and wrapped around the packaging element. The fold lines are arranged to be substantially parallel to the edges of the tray 1001 and cap 1002. Two blanks S are used to form ears 1003, 1004 to cover the packaged article. The ears are positioned inside the tray 1001 and cap 1002. The entire package may then be banded round with a suitable adhesive or banding or bonding means to hold the package together securely for transportation and shipping.

By this arrangement a whole half a pressed car "white body" can be packaged and advantageously packing is such that no exterior painted surfaces are in contact with the packaging element. The internal dimensions (of ears inside tray 1001) of the packaging element of the preferred embodiment are height 1530 cm, width 730 cm and length 3790 cm. The external dimensions (outside inside tray 1001) of the packaging element of the preferred embodiment are height 1550 cm, width 790 cm and length 3840 cm.

It will be appreciated that the above described embodiments are given by way of example only and that various modifications thereto may be made without departing from the scope of the invention.

For example whole/part of vehicle may be packaged and other shapes and structures of packaging could be used depending on the shape of the article to be packaged. Also different articles of a half car body could be sited in different areas of the above-described packaging element. Other examples of parts of a pressed car body that may be supported and packaged in the packaging element include; floor assembly, roof assembly, boot/trunk assembly.

Furthermore the construction and assembly operation could be simplified by coding the blanks, slots, cuts etc with colour, numbers etc. Numbers may be coded using an embossing or printing technique.

Claims

1. A packaging element for an article, said element comprising first support means adapted to locate and to support a said article and second support means adapted to suspensively support and to locate said article, such that in use a said article is secured against lateral movement and that major surfaces thereof are spaced from the packaging element.

2. A packaging element according to claim 1, wherein none of the major exterior surfaces of a said article touch the packaging element.

3. A packaging element according to claim 1 or claim 2, wherein the packaging element is adapted to support and locate a plurality of said articles within the packaging element.

4. A packaging element according to any preceding claim, wherein the support means are arranged to comprise further support means for supporting one or more additional said articles.

5. A packaging element according to any preceding claim, wherein the support means are provided at a position within the packaging element, wherein the position of the support means are arranged to provide substantially sufficient security and support for the said article.

6. A packaging element according to any preceding claim, wherein the packaging element comprises a material suitable for packaging the said article the material having a suitable strength to weight ratio.

7. A packaging element according to claim 6, wherein the material is cardboard, sheet steel, plastic or card.

8. A packaging element according to claim 6, wherein the material is single ply, two ply, two wall cardboard or heavy duty corrugated board.

9. A packaging element according to any preceding claim, wherein the said article is a vehicle prior to assembly.

10. A packaging element according to any preceding claim, wherein the said vehicle comprises a number of pressed metal components.

11. A packaging element according to claim 9 or claim 10, wherein the vehicle is a car.

12. A packaging element according to claim 11, wherein the pressed metal component are panels, wheel arches, doors or other parts of the body in white.

13. A packaging element according to any of claims 10 to 12, wherein the said article comprises the components required for assembling one complete side of a vehicle and wherein the packaging element is adapted to package the components in a single packaging element.

14. A packaging element according to claim 13, wherein the said article comprises the components required for assembly of a whole vehicle in a single packaging element.

15. A packaging element according to any preceding claim, further comprising blanks, slots or cuts.

16. A packaging element according to any preceding claim, wherein parts of the packaging element are coded with colour.

17. A packaging element according to any preceding claim, wherein parts of the packaging element are coded with numbers.

18. A packaging element according to claim 16 or 17, wherein coding is provided using an embossing or printing technique.

19. An apparatus for manufacturing a packaging element according to any preceding claim.

20. An apparatus for assembly of a packaging element of any of claims 1 to 18.

21. A method of assembling the packaging element of any of claims 1 to 18.