US20040232145A1

US20040232145A1 - Packaging system

Info

Publication number: US20040232145A1
Application number: US10/441,469
Authority: US
Inventors: Keith Antal; James Johanson
Original assignee: Sonoco Development Inc
Current assignee: Sonoco Development Inc
Priority date: 2003-05-19
Filing date: 2003-05-19
Publication date: 2004-11-25
Also published as: MXPA04003705A

Abstract

A frame for packaging goods consists essentially of long, extruded edge pieces, and corner pieces. Each corner piece has projections that fit into the ends of two edge pieces, to form a rectangular frame, or three edge pieces, to form a cuboidal frame. The edge pieces are preferably L-shaped, and oriented to cradle the edges of a rectangular object fitted within the frame. In one embodiment, the projections may be in the form of three round pins in an L shape to fit into one L-shaped edge piece. In another embodiment, the corner pieces consist of two halves hinged together, so that the sides of the frame can be folded out into a straight line without being separated.

Description

FIELD OF THE INVENTION

The present invention relates to a system for packaging, handling, shipping and storing goods.

BACKGROUND OF THE INVENTION

Bulky objects are sometimes shipped mounted on a base or pallet, which supports the bottom of the object and which is often slightly larger than the object itself. The base is designed to be handled mechanically, such as by a forklift, hand truck or the like. The base serves to protect the contents by providing a relatively rigid and stable support or engagement surface. When being moved, the lifting mechanism will engage the base, typically without directly engaging the object on the base. However, such base structures typically do not provide protection for the upper portion of the objects being shipped.

Various constructions of shipping bases are known. Such shipping bases for domestic appliances and other rigid objects are often in the form of a frame made of wood that supports the appliance near the corners, where domestic appliances commonly have feet.

It has been proposed to provide vertical posts within a packaging sleeve for an object. U.S. Pat. No. 5,267,651 to Hughes shows such a post in the form of a paperboard tube. The posts are wedged between the appliance and the packaging sleeve. Similar posts are commercially available from Sonoco Products Company under the trade mark SONOPOST®.

Solid cases for goods are also known to protect their contents and to allow stacking. Cases that can be disassembled into their constituent panels for storage have been proposed, but may still be bulky, even when disassembled. U.S. Pat. No. 4,171,059 to Heller et al., for example, proposes a base in the form of a pallet with tubular feet. Upright corner posts slot into the tops of the feet, and side panels fit between the corner posts. The tops of the corner posts have points that will engage the bottoms of the feet of a similar base, to allow stacking.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a device for shipping, handling and storing goods, such as appliances and other products. The device in one embodiment comprises a shipping frame that comprises edge pieces and corner pieces. The edge pieces are preferably lengths of tube of any desired cross-sectional shape. Preferably, the tubular edge pieces are of similar cross section along their length. The corner pieces preferably have an angled form, and comprise surfaces that will abut the end faces of the edge pieces and projecting formations that are received inside the edge pieces. In this one embodiment of the present invention, at least some of the projecting formations consist of groups of pins that fit into the corners of the cross-section of the edge pieces.

The device in another embodiment comprises a shipping frame that comprises edge pieces and corner pieces. The edge pieces are preferably lengths of tube of any desired cross-sectional shape. Preferably, the tubular edge pieces are of similar cross section along their length. The corner pieces comprise surfaces that will abut the end faces of the edge pieces and projecting formations that are received inside the edge pieces. In this aspect of the present invention, the corner pieces are of angled form, and consist of parts hinged together. Each part is shaped to engage in an edge piece. In one position of the hinges, the edge pieces form a frame. In another position of the hinges, the edge pieces lie in a straight line, and the unfolded frame can be stored compactly.

The device in a third embodiment comprises a shipping frame that comprises edge pieces and corner pieces. The edge pieces are preferably lengths of tube of any desired cross-sectional shape. Preferably, the tubular edge pieces are of similar cross section along their length. The corner pieces preferably have an angled form, and comprise surfaces that will abut the end faces of the edge pieces and projecting formations that are received inside the edge pieces. In this third aspect of the invention each edge piece has a generally L-shaped cross section defined by two generally flat, perpendicular surfaces on the inside of the “L,” by two outwardly convex surfaces at the ends, by an outwardly convex surface at the outside of the angle of the “L,” and by two outwardly concave surfaces on the outsides of the arms joining the outwardly convex surface at the angle to the outwardly convex surfaces at the ends. Each corner piece has a projecting formation arranged to extend into said adjacent ends of at least two said hollow edge pieces.

The basic aspects of the present invention may be combined in a number of forms. The preferred aspects of the various constructions may be used in conjunction with one another or used alone. The various features provide certain advantages over the prior art. These advantages will be described herein and will be understood by those skilled in the art upon reviewing the description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there are shown in the drawings forms of the invention which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown. In the drawings: [0010]
FIG. 1 is an isometric view of one embodiment of shipping frame according to the invention. [0011]
FIG. 2 is an isometric view of a corner piece forming part of the shipping frame of FIG. 1, showing part of an edge piece of the shipping frame aligned with the corner piece. [0012]
FIG. 3 is a view similar to FIG. 2, showing parts of three edge pieces aligned with the corner piece. [0013]
FIG. 4 is a view similar to FIG. 3 showing the three edge pieces assembled to the corner piece. [0014]
FIG. 5 is a sectional top view taken along the line [0015] 5-5 in FIG. 4.
FIG. 6 is a sectional elevation view taken along the line [0016] 6-6 in FIG. 5.
FIG. 7 is an isometric view of a second embodiment of shipping frame according to the invention. [0017]
FIG. 8 is an isometric view of a corner piece forming part of the shipping frame of FIG. 7, showing parts of two edge pieces of the shipping frame aligned with the corner piece. [0018]
FIG. 9 is an isometric view of a third embodiment of shipping frame according to the invention, in a partly unfolded configuration. [0019]
FIG. 10 is a view similar to FIG. 8 of a corner piece forming part of the shipping frame of FIG. 9, showing parts of two edge pieces of the shipping frame aligned with the corner piece. [0020]
FIG. 11 is a fragmentary section along the line [0021] 11-11 in FIG. 10, showing the frame in a folded and a partly unfolded configuration.
FIG. 12 is an isometric view of a fourth embodiment of shipping frame according to the invention, in a partly assembled condition. [0022]
FIG. 13 is an isometric view of an alternative form of corner piece for a shipping frame as shown in FIGS. [0023] 1 to 6.
FIG. 14 is a top plan view of a corner piece as shown in FIG. 13. [0024]
FIG. 15 is a section along the line [0025] 15-15 in FIG. 14.
FIG. 16 is a top plan view of an alternative form of a corner piece as shown in FIG. 13. [0026]
FIG. 17 is a section along the line [0027] 17-17 in FIG. 16.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIGS. [0028] 1 to 6 of the accompanying drawings, where like numerals identify like elements, there is shown one form of a shipping frame according to the present invention, which is identified generally by reference numeral 20. The shipping frame 20 consists essentially of a plurality of corner pieces 22 and a plurality of edge pieces 24. The corner pieces 22 are preferably injection molded from a plastic material, such as polypropylene. The specific polymer, filler or reinforcement material can be varied to meet the specific requirements of the application for which the frame is intended. The edge pieces 24 may be molded or extruded from any suitable material, such as a fiber-reinforced plastic material or aluminum, or may be made from paperboard tubes.
The [0029] shipping frame 20 as shown in FIG. 1 is generally cuboidal, with eight corner pieces 22 at the corners of a notional cube, joined by twelve edge pieces 24 each extending along a respective edge of the notional cube. The edge pieces 24 are lengths of laminated paperboard tube. As shown, the edge pieces 24 are of identical, uniform cross section. The four edge pieces 24 extending parallel to one another in any of the three principal directions of the cube are of equal lengths. However, if the frame 20 is not to be an actual cube, edge pieces 24 extending in different principal directions may be of three different lengths. Also, the shape and cross-sectional dimensions of the edge pieces may vary, if desired.
As is best seen in FIGS. 5 and 6, the tube forming the [0030] edge pieces 24 is generally L-shaped in cross-section. More specifically, the inside of the L is formed by two flat surfaces 26. The ends of the L are formed by convexly rounded portions 28. The outside of the angle of the L is formed by a convexly rounded portion 30. The outsides of the arms of the L are formed by two concave portions 32 that join the convexly rounded portions 28 and 30 together. The rounded portions are so shaped that each of the convexly rounded portions 28 and 30 will define a circular cylindrical cavity the unbounded parts of which, facing along the legs of the L, are substantially less than 180° wide. That is to say, if a circular pin of suitable diameter is inserted into one of the convexly rounded portions 28 or 30, it will be received snugly, and will not be able to slide sideways in any direction.
Referring now especially to FIGS. 2 and 3, each of the [0031] corner pieces 22 is roughly cubical. However, at one corner of the piece 22 there is a large recess defined by three faces 34, all at right angles to each other. It is preferred that the three faces 34 be square, and all be of equal width. The three adjacent sides 36, 38 of the corner piece 22 are approximately L-shaped. As will be explained below, and as may be seen in FIGS. 3 and 4, in the assembled frame 20 each of the L-shaped sides 36, 38 abuts the end of one of the edge pieces 24, and the faces 34 are at least approximately flush with the flat faces 26 of the edge pieces 24. In the assembled frame 20, therefore, the faces 26 and 34 define, and bound the edges of the faces of, an otherwise notional cuboid enclosed within the frame 20. The frame 20 is thus well adapted to enclose and protect a cuboidal object of suitable size, such as a box.
From one of the L-shaped sides [0032] 38 (the top side as shown in FIGS. 2 to 6, the top or bottom side as shown in FIG. 1) of each corner piece 22 project three pins 40. Each pin 40 is circular cylindrical, with a rounded or frustoconical tip 42. One pin 40 is positioned at the angle of the L, and the other two pins are positioned near the ends of the arms of the L. When the end of an edge section 24 is fitted over the three pins 40, they fit snugly within the convexly rounded portions 28 and 30.
Two lugs [0033] 44 project from the L-shaped side 38 of the corner piece 22, midway along the legs of the L, on the outside of the L. These lugs then bear against the outside of the concave portions 32 of the edge piece 24, and may slightly deflect the material of the edge piece. This provides a firm friction fit to hold the edge piece 24 and the corner piece 22 together, prevents play between the two pieces, and prevents deformation of the edge piece that might loosen the engagement between the two pieces. Each lug 44 has a beveled shoulder 46, which acts as a wedge to enable the edge piece 24 to be pushed into place without catching on the corner piece 22.
Each of the other two L-shaped [0034] faces 36 of the corner piece 22 has a larger projection 50 to engage in the edge pieces 24. The projection 50 is generally L-shaped, following the L shape of the face 36, but narrower. At the end nearest the L-shaped face 38, the projection 50 ends in a quarter-round surface 52. The quarter-round surface 52 is turned towards the inside of the L. At the outside of the angle of the L, a quarter-round section 54 is provided, with its flat faces 56 approximately aligned with the outer faces 58 of the L-shaped projection 50, and its round face 59 outwards. The quarter-round section 54 is joined to the L-shaped projection 50 at the angle that is the center of the radius of the round face 59.
At the other end of the L, nearest to the [0035] other face 36 of the corner piece 22, are two quarter-round sections 60, 62, forming opposite quarters of an otherwise notional cylinder and joined together at the center of the notional cylinder. One flat face of each quarter round section 60, 62 is generally aligned with the adjacent outer face 58 of the L-shaped projection 50. As will be explained below, the three aligned faces 58, 60, 62 are open faces of hollow structures. The first quarter-round section 60 has its round face 68 outwards, facing towards the quarter-round section 54, and is joined to the L-shaped projection 50 at one end of its round face 68. The second quarter-round section 62 has its round face 70 facing inward, roughly symmetrical with the quarter-round section 52 at the opposite end of the L-shaped projection 50. The projection 50 and the quarter-round sections are hollow. The projection 50 and the quarter-round section 62 are open on the side away from the pins 40, downwards as seen in FIG. 6, and the quarter- round sections 54 and 60 are open in the opposite direction, upwards as seen in FIG. 6. The projection 50 and the quarter-round sections are aligned so that their walls join substantially continuously, which gives the simplest structure and provides a sufficiently strong connection to prevent them from separating in normal use of the shipping frame 20.
All of the round faces [0036] 52, 59, 68, 70 are covered with rows of bumps 72 molded from the plastic material of the corner piece 22. The projecting ends of the projection 50 and the quarter- round sections 54, 60, 62 have rounded or beveled edges, to assist in pushing an edge section 24 on over them. They are so dimensioned and positioned that the round faces 52, 59, 68, 70 will fit snugly within the convexly curved portions 28, 30 of the edge section 24, with the bumps 72 providing a stiff friction fit. The concave portions 32 of the edge section 24 then rest against the flat faces 36 on the outside of the L-shaped projection 50.
The three remaining [0037] faces 74, 76 of the generally cubical corner piece 22 are flat, and are preferably aligned so that, when the edge pieces 24 are mounted on the corner pieces 22, the faces 74, 76 are flush with or slightly outside the outermost parts of the edge pieces 24. Thus, when the assembled frame as shown in FIG. 1 is against a flat surface, on any side, the corner pieces 22 will contact that surface and the edge pieces 24 will be slightly spaced away from it. As may be seen from FIG. 1, the corner pieces 22 are hollow, and are open to the exterior on the face 74 opposite the flat surface 36 carrying the pins 40, which, as explained below, will usually be the top or bottom face in use. For economy of manufacture, the pins 40 are preferably hollow, and open into the hollow interior of the corner piece 22. The other two faces 76 which will usually be the vertical (and hence more visible) faces in use are solid. A separate capping piece may be added to close off the face 74, but that will not usually be necessary.
It will be understood that, because of the hollow construction and the positioning of the open sides, the entire corner piece-[0038] 22 can be molded with a simple two-part mold, the halves of which separate up and down as shown in FIG. 6. Those skilled in the art will understand that, in order to assist separation of the mold halves and removal of the molded corner piece, the surfaces shown as vertical in the drawings may in practice be molded a few degrees off vertical, so that each hollow part widens slightly towards its open end.
To assemble the [0039] packing frame 20, two edge pieces 24 with a length corresponding to the length of the final frame, two edge pieces 24 with a length corresponding to the width of the final frame, and four corner pieces 22 may first be assembled. The ends of the edge pieces 24 are aligned with the L-shaped projections 50 of the corner pieces 22 as shown in FIGS. 2 and 3, and pushed onto the corner pieces, over the L-shaped projections 50, as shown in FIG. 4. They are forced together until the ends of the edge pieces 24 abut the L-shaped faces 36 of the corner pieces 22. The amount of force necessary will be determined by how tightly the edge pieces 24 fit over the quarter-round faces 52, 59, 68, and 70 of the projection 50, and may be chosen by the designer to suit the particular use for which the frame 20 is intended. The tighter the fit, the less likely the frame is to come apart in use, but the more difficult it will be to assemble and disassemble.
As may be seen in FIG. 3, the projecting corners of the [0040] flat surfaces 34 of the corner pieces 22 may be formed into a rounded notch 74 that continues the line of the surfaces of the curved portions 28 of the adjacent edge pieces 24 until the continued surfaces meet. Instead, the projecting corners of the flat surfaces 34 of the corner pieces 22 may be left flat and square.
There is thus formed a rectangular frame, which may be placed on a flat surface with the [0041] faces 38 and the pins 40 on the corner pieces 22 facing upwards. The flat surfaces 26 and 34 of the edge pieces 24 and the corner pieces 22 then face inwards and upwards, with the upward-facing surfaces substantially in a single plane, and the inward-facing surfaces forming a rectangle above the outer edge of the upward-facing surfaces. An object of appropriate size may then be placed into the frame, resting on the upward-facing surfaces and nestling within the inward-facing surfaces.
Four [0042] further edge pieces 24, with a length corresponding to the height of the final frame, may then be aligned with the pins 40 of the corner pieces 22, as shown in FIG. 3, and placed upright onto the pins 40 as shown in FIG. 4, with the flat faces 28 of the edge pieces embracing the object.
A second rectangular frame, similar to the first, may then be placed over the top of the box, with its [0043] pins 40 extending downwards and fitting into the tops of the upright edge pieces 24. There is thus formed a cuboidal frame, as shown in FIG. 1, with edge pieces 24 embracing, holding and protecting the object within the shipping frame. The assembled frame, with its contents, may then be enclosed in a packing box or wrapped tightly, preferably in clear packing film, which prevents the frame from coming apart, as well as protecting it.
It will be understood that the order and manner of assembly of the cuboidal frame described above is only an example. The pieces of the frame may be assembled in any convenient order, manner and orientation, subject only to the geometrical constraints on inserting the object to be packed into a fully-assembled or almost fully assembled frame. As an example, two of the [0044] upright edge pieces 24 may be attached to a top rectangular frame and two to a bottom rectangular frame, and the two sub-assemblies thus created may be assembled to form the frame. With the specific form of corner piece 22 shown in FIGS. 2 and 3, it will usually be preferred to assemble rectangular frames by attaching edge pieces 24 onto the projections 50, and then to add edge pieces on the pins 40, because the projections 50 will hold the edge pieces more firmly than the pins 40.
In use, it will usually be preferred to use the frame in the orientation shown in the drawings, with the [0045] pins 40 engaging the upright edge pieces 24. As is best seen in FIG. 2, this orients the corner pieces 22 so as to provide the maximum vertical support for the edge pieces 24 forming the bottom frame. This provides the best support for an object resting on those edge pieces 24, when the frame is supported or handled through the bottom corner pieces 22.
It will be seen that in the assembled [0046] shipping frame 20 the faces 26 of the edge pieces 24 and the faces 34 of the corner pieces 22 define a notional cuboidal shape. It will be understood that the assembled shipping frame 20 is not limited to shipping a rectangular box or other cuboidal object that will fit snugly within the notional cuboidal shape. Indeed, that is not expected to be its primary use. Any object with a bottom that will rest on the upward-facing surfaces 26 and 34 of the bottom edge pieces 24 and corner pieces 22, without projecting downwards too far in the middle, may be packed in the shipping frame. Even if the object does not engage the top and side edge and corner pieces, they can provide useful protection for an object within them, and can enable soft, crushable, or awkwardly shaped objects to be stacked as easily as if they were rectangular boxes. When the object is visible within the frame and is not enclosed within an inner box, or when the inner box has ornamental or informative printing on it, then wrapping the frame in clear film so that the object or inner box within is still visible may be advantageous.
Further or in the alternative, an object with a generally rectangular base could be placed and handled in a bottom frame of four corner pieces and four edge pieces, and the upright and top pieces could be added at a later stage for shipping. Indeed, depending on the particular object, less than the whole cuboidal frame may be used. For example, an object, especially an object with a flat bottom and an irregularly shaped top, may simply be secured to a rectangular frame with transparent wrapping film. For example, one or more upright edge pieces, optionally with top corner pieces and optionally with top edge pieces forming less than the full cuboidal frame, may be used. [0047]
It will be appreciated that a supply of the packing frames shown in FIG. 1 may be stored in the form of a stock of [0048] edge pieces 24 and a stock of corner pieces 22. These will take up far less room than the actual packing frames, because they do not include the large empty central space of the assembled frame. Further, if it is desired to store packing frames of several different sizes, it is merely necessary to stock a range of lengths of edge piece 24. Indeed, if it is found that, for example, the length of one standard size of shipping box corresponds to the width of another, there is a further economy of stocking, because only one supply of the corresponding length of edge piece 24 is required. Alternatively, long stock lengths of the tubing for the edge pieces 24 may be kept, and may be cut to length as desired to create custom sized frames.
Alternatively, the pieces could be supplied partly assembled. For example, each of the edge pieces forming a rectangular frame could be supplied with a corner piece attached to one end, say, the counter-clockwise end of each edge piece as seen in FIG. 2. For example, if it was desired to make the length of the frame adjustable, but not the width, then the edge pieces extending across the ends of the frame could each have two corner pieces attached, allowing them to be assembled by inserting plain side edge pieces of the desired length. These alternatives will be quicker to assemble into frames on the production line, because there are fewer connections between edge and corner pieces to be made. On the other hand, they are slightly less compact to store and ship than the fully disassembled versions, and there may be some reduction in versatility of assembly. [0049]
It will be understood that, where this description refers to an edge piece of a length corresponding to the dimension of the box or packing frame, the edge piece is in fact shorter than the inside dimension of the frame by an amount equal to twice the width of the [0050] square face 34 of a corner piece 22. For any given stock of corner pieces 22, this will be a constant and easily-determined dimension, so that converting the size of a box into the lengths of the edge pieces 24 will be trivial. Indeed, stock edge pieces could be identified by a “nominal” length that is in fact the length of the edge of the box that is to be enclosed.
Except in the special case where edge pieces need to be cut to length, the frame can be quickly and easily assembled without requiring any tools. It can almost as easily be disassembled, and the pieces stored compactly for future use, or shipped back in compact form to the point of origin. [0051]
Referring now to FIGS. 7 and 8, a second form of packing frame indicated generally by the reference numeral [0052] 78 consists of edge pieces 24, substantially identical to those of the first form of packing frame, and corner pieces 80. The corner pieces 80 are similar to the corner pieces 22 described above, except that they do not have pins 40, and do not have the flat surface 38 from which the pins 40 in the first form of corner piece 22 arose. Instead, there are rounded upper surfaces 82 that continue the lines of the rounded portions 28 along the tops of a pair of edge pieces 24 fitted onto the projections 50. There is thus formed a rectangular frame, onto and into which a rectangular box can be placed, but with a continuous, rounded top edge without provision for attaching upright edge pieces or a top frame.
Referring now to FIGS. [0053] 9 to 11, a third form of packing frame indicated generally by the reference numeral 90 is similar to the second form shown in FIGS. 7 and 8, except that it comprises corner pieces 92 that consist essentially of two triangular halves 94, joined together by a vertical hinge 96 along the outside angle between the two flat faces 76. A suitable arrangement of lugs 98 and sockets 100 is provided on the diagonal faces 102 where the two halves 94 meet. These lugs 98 and sockets 100 prevent the hinge 96 from being subjected to torsion or shear loads in use of the frame, and may snap together to hold the corner piece 92 in an assembled configuration. The hinge 96 may be of any desired form. Preferably, the two halves 94 of a corner piece 92 are molded as a single piece, and the hinge 96 is a strip of material joining the two halves that is thin enough to be flexible. Alternatively, the two halves 94 may be separate moldings with hinge parts that fit together, with or without a separate hinge pin.
When the diagonal faces [0054] 102 are separated, the halves 94 of the corner piece 92 may be hinged apart until a pair of edge pieces 24 mounted on the projections 50 lie substantially in the same straight line. Thus, a frame 90 consisting of four edge pieces 24 and four corner pieces 92 can be folded out into a long, straight shape that can be stored very economically because it does not enclose the large empty space that the assembled, rectangular frame encloses. In order to assemble the frame, it is merely necessary to fold it, insert the projection 50 of the last corner piece 92 at one end into the open end of the last edge piece 24 at the other end, and snap the projections 98 into the sockets 100. This can be done quickly, easily, and without requiring any tools. This will be appreciably quicker than assembling the frame shown in FIG. 10 from four edge pieces and four corner pieces, with four push-fit connections. On the other hand, the frame 90 must be pre-assembled in a specific size, so there is some loss of versatility. However, where a large number of frames of a specific size are required, it may be advantageous.
Referring now to FIG. 12, a fourth form of packing frame comprises a flat base [0055] 110, which may be essentially a standard-sized pallet, if the size of the objects to be shipped is appropriate. The flat base 110 includes four corner pieces 112 which, instead of being separate components as in the forms of packing frame described above, are integrated into the corners of the base 110. Each corner piece 112 comprises three upstanding pins 114, which may be identical in shape, size, and relative position to the pins 40 shown in FIGS. 2, 3, and 5. Each group of three pins 114 can receive an edge piece 24, which then stands up vertically from the base 110. The top of the frame may then be formed by edge pieces 24 and corner pieces 22, as shown in FIG. 1, or by another flat piece 110, which may be the flat base 110 of another layer of packing frame stacked on top of the first.
Referring now to FIGS. [0056] 13 to 15, an alternative form of corner piece 122 is substantially identical to the corner piece 22 shown in FIGS. 1 to 6 except that the L-shaped side 38 on which the three pins 40 are mounted is recessed into the corner piece 122, so that the L-shaped side 38 is the upper surface of a wall forming part of the bottom of the corner piece 122. The other L-shaped sides 36, the square faces 34, and the outer faces 76 all extend to the same height as in FIGS. 1 to 6, and the insides of the walls defining those sides and faces thus define an L-shaped socket with the pins 40 at the bottom of the socket. By choosing the corner piece 122 and the edge piece 24 so that the inside dimensions of the socket match the outside dimensions of the edge piece, a secure fit, with substantial resistance to tilting of the edge pieces 24, is possible. Preferably, the edge piece 24 is of a slightly compressible and slightly flexible material, and is a tight fit. As explained above, for ease of molding the socket is preferably tapered by a few degrees, and this taper can be used to provide a wedge action as the edge piece 24 is inserted into the socket.
Referring now to FIGS. 16 and 17, a modified form of the [0057] corner piece 122 is the same as that shown in FIGS. 14 and 15 except that the three pins 40 are replaced by a single L-shaped raised portion 140. As shown in FIG. 16 the arms of the L-shaped raised portion 140 have straight sides. However, to accommodate edge pieces 24 as shown in FIGS. 1 to 6, with concave portions 32, recesses may be provided in the outer sides 142 of the raised portion 140. Alternatively, edge pieces 24 without the concave portions 32, or with much smaller concave portions 32, may be used.
The dimensions of the edge and corner pieces will depend on the size and weight of the object to be packed. For a washing machine, [0058] edge pieces 24 about 3 or 4 inches (7 to 10 cm) wide made of {fraction (1/16)} inch (1.5 mm) thick, 3 or 4 ply laminated paperboard may be suitable. One such material is the tubes sold by Sonoco Products Company under the trade marks SONOPOST® 180 and SONOPOST® 190. However, it is contemplated that the frame 20 may be used for products as small as a microwave oven or as large as a rider mower, and the dimensions of the pieces making up the packing frame will vary accordingly.
Throughout this specification, terms such as “top”, “bottom,” and “vertical” are used in the interest of clarity with reference to an orientation of the frame in a typical use with an object positioned upon or within the frame. If the base does not wholly enclose the object it is not required that the frame be provided below the appliance or that the frame be maintained exactly in this orientation. If the frame does wholly enclose the appliance, it is not required that any specific side be downwards, or that the sides be in any specific orientation. In some variations of the structure, the whole or portions of the frame may be oriented obliquely with respect to horizontal. Also, when separated from the object, the frame may be stored and transported in any convenient orientation. [0059]
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. For example, although the [0060] corner piece 22 has been shown with projections 50 on two sides 36, and pins 40 on the third side 38, other permutations are, of course, possible. Although the hinged corner piece 90 of FIG. 11 has been shown in the context of a flat frame, hinged corner pieces could also be used with pins 40 for upright edge pieces 24.
As shown in the drawings, the edge and corner pieces have a generally L-shaped profile facing towards the inside of the frame. This is the preferred shape, because it is easy to produce, and fits a rectangular object, which is a very common shape of object. However, to fit objects of a particular shape, other profiles could be produced if the quantity required is sufficient. [0061]
Although a [0062] cuboidal frame 20 is shown in FIGS. 1-9, it will be appreciated that other shapes may be formed if the corner pieces 22 hold the edge pieces 24 at angles other than 90° to one another. In particular, a prism, with a flat top and bottom and a number of upright sides other than four, or some other form of polyhedron, may be desirable in some cases.
Although the invention has been described and illustrated with respect to the exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. [0063]

Claims

What is claimed is:

1. A frame for shipping and supporting goods, comprising:

a plurality of elongated, hollow edge pieces; and

a plurality of corner pieces engaging ends of said edge pieces together to form said frame,

each corner piece having projections comprising at least one plurality of pins extending into said end of at least one said hollow edge pieces.

2. A frame according to claim 1, comprising a base, with a plurality of said corner pieces disposed at corners of said base.

3. A frame according to claim 1, wherein said plurality of corner pieces are separate pieces joining adjacent ends of said edge pieces together to form said frame,

each corner piece having projections extending into said adjacent ends of at least two said hollow edge pieces, and

said projections comprising at least one said plurality of pins.

4. A frame according to claim 3, wherein each said corner piece is arranged to join together three said edge pieces.

5 A frame according to claim 3, wherein each said corner piece is arranged to join together two said edge pieces.

6. A frame according to claim 3, wherein said corner pieces comprise two parts hinged together in such a manner that two said edge pieces connected by a said corner piece can be hinged into an orientation in which they lie substantially in the same straight line.

7. A frame according to claim 1, wherein each said corner piece comprises a socket receiving an end of a said edge piece.

8. A frame according to claim 7, wherein said at least one plurality of pins is disposed within said socket.

9. A frame according to claim 1, wherein said edge pieces are of generally L-shaped profile, and said corner pieces hold said edge pieces in an orientation with the concave side of the L facing the middle of the frame.

10. A frame according to claim 9, wherein said at least one plurality of pins comprises three pins arranged in an L shape aligned with the L-shaped profile of the associated edge member.

11. A frame according to claim 10, wherein a plurality of said edge pieces are joined in a ring by said corner pieces, and wherein the concave sides of the L-shaped profiles thereof define a common plane and sides upstanding from that plane.

12. A frame according to claim 11, wherein said edge pieces are joined in a polyhedral frame, and wherein the concave sides of the L-shaped profiles thereof define the faces of the polyhedron.

13. A frame according to claim 1, wherein said pins are round.

14. A frame for shipping and supporting goods, comprising:

a plurality of elongated, hollow edge pieces; and

a plurality of corner pieces joining adjacent ends of said edge pieces together to form said frame;

wherein each corner piece has projections extending into said adjacent ends of at least two said hollow edge pieces; and

wherein said corner pieces comprise two parts hinged together in such a manner that two said edge pieces connected by a said corner piece can be hinged into an orientation in which they lie substantially in the same straight line.

15 A frame according to claim 14, wherein each said corner piece is arranged to join together two said edge pieces.

16. A frame according to claim 15, comprising four said edge pieces joined end-to-end by three said corner pieces and defining two free ends; and

further comprising a fourth said corner piece having a said projection extending into one said free end, and having a said projection arranged to be inserted into the other said free end.

17. A frame according to claim 14, wherein said edge pieces are of generally L-shaped profile, and said corner pieces hold said edge pieces in an orientation with the concave side of the L facing the middle of the frame.

18. A frame according to claim 17, wherein a plurality of said edge pieces are joined in a ring by said corner pieces, and wherein the concave sides of the L-shaped profiles thereof define a common plane and sides upstanding from that plane.

19. A system for shipping and supporting goods, comprising:

a plurality of elongated, hollow edge pieces; and

a plurality of corner pieces arranged to join adjacent ends of said edge pieces together to form a frame;

wherein each corner piece has projecting formations arranged to extend into said adjacent ends of at least two said hollow edge pieces; and

wherein at least one said projecting formation comprises a plurality of pins arranged to extend into one of said adjacent ends.

20. A system according to claim 19, wherein each said corner piece is arranged to join together three said edge pieces.

21 A system according to claim 19, wherein each said corner piece is arranged to join together two said edge pieces.

22. A system according to claim 19, wherein each said corner piece comprises a recess for receiving said adjacent end of one of said hollow edge pieces, and a said projecting formation positioned in said recess and arranged to extend into said adjacent end of said one hollow edge piece.

23. A system according to claim 19, wherein said edge pieces are of generally L-shaped profile, and said corner pieces are arranged to hold said edge pieces in an orientation to form said frame with the concave side of the L facing the middle of the frame.

24. A system according to claim 23, wherein said at least one plurality of pins comprises three pins arranged in an L shape arranged to be aligned with the L-shaped profile of an edge member into which said pins extend.

25. A system according to claim 23, wherein said corner pieces are arranged to join a plurality of said edge pieces in a ring in such a manner that wherein the concave sides of the L-shaped profiles thereof define a common plane and sides upstanding from that plane.

26. A system according to claim 23, wherein said corner pieces are arranged to join said edge pieces in a polyhedral frame in such a manner that the concave sides of the L-shaped profiles thereof define the faces of the polyhedron.

27. A system according to claim 19, wherein each said corner piece has a said projection inserted into one edge piece.

28. A system according to claim 19, wherein said corner pieces comprise two parts hinged together in such a manner that two said edge pieces connected by a said corner piece can be hinged into an orientation in which they lie substantially in the same straight line.

29. A system according to claim 19, wherein said pins are round.

30. A system for shipping and supporting goods, comprising:

a plurality of elongated, hollow edge pieces; and

wherein each corner piece has projections arranged to extend into said adjacent ends of at least two said hollow edge pieces; and

31 A system according to claim 30, wherein each said corner piece is arranged to join together two said edge pieces.

32. A system according to claim 30, wherein said edge pieces are of generally L-shaped profile, and said corner pieces are arranged to hold said edge pieces in an orientation with the concave side of the L facing the middle of the frame.

33. A system according to claim 32, wherein said corner pieces are arranged join a plurality of said edge pieces in a ring in such a manner that the concave sides of the L-shaped profiles thereof define a common plane and sides upstanding from that plane.

34. A system for shipping and supporting goods, comprising:

a plurality of elongated, hollow edge pieces; and

wherein each edge piece has a generally L-shaped cross section defined by two generally flat, perpendicular surfaces on the inside of the L, by two outwardly convex surfaces at the ends, by an outwardly convex surface at the outside of the angle of the L, and two outwardly concave surfaces on the outsides of the arms joining the outwardly convex surface at the angle to the outwardly convex surfaces at the ends; and

wherein each corner piece has projecting formations arranged to extend into said adjacent ends of at least two said hollow edge pieces.

35. A system according to claim 31, wherein said projecting formations comprise rounded parts dimensioned and positioned to fit within said outwardly convex surfaces of said edge pieces.

36. A system according to claim 32, wherein at least one said projecting formation comprises a plurality of round pins forming said rounded parts.

37 A system for shipping and supporting goods, comprising:

a plurality of elongated, hollow edge pieces; and

a plurality of corner pieces arranged to engaging ends of said edge pieces to form a frame,

each corner piece having a socket for receiving said end of at least one said hollow edge piece, and a projection within said socket arranged to extend into said end.

38. A system according to claim 37, comprising a base, with a plurality of said corner pieces disposed at corners of said base.

39. A system according to claim 37, wherein said plurality of corner pieces are separate pieces joining adjacent ends of said edge pieces together to form said frame,

each corner piece having projections extending into said adjacent ends of at least two said hollow edge pieces.

40. A system according to claim 39, wherein each said corner piece is arranged to join together three said edge pieces.

41. A system according to claim 39, wherein each said corner piece is arranged to join together two said edge pieces.

42. A system according to claim 39, wherein said corner pieces comprise two parts hinged together in such a manner that two said edge pieces connected by a said corner piece can be hinged into an orientation in which they lie substantially in the same straight line.

43. A system according to claim 37, wherein each said corner piece comprises at least one plurality of pins constituting said projection within said socket.

44. A system according to claim 43, wherein said at least one plurality of pins comprises three pins arranged in an L shape.

45. A system according to claim 44, wherein said pins are round.

46. A system according to claim 37, wherein each said corner piece comprises an L-shaped projection within said socket.

47. A system according to claim 37, wherein said socket is L-shaped.

48. A system according to claim 47, wherein said edge pieces are of generally L-shaped profile, and are shaped and dimensioned to mate with said L-shaped socket.

49. A system according to claim 37, wherein said edge pieces are of generally L-shaped profile, and said corner pieces are arranged to hold said edge pieces in an orientation with the concave side of the L facing the middle of the frame.

50. A system according to claim 49, wherein said corner pieces are arranged to join a plurality of said edge pieces in a ring wherein the concave sides of the L-shaped profiles of said edge pieces define a common plane and sides upstanding from that plane.

51. A system according to claim 50, wherein said corner pieces are arranged to join said edge pieces into a polyhedral frame, and wherein the concave sides of the L-shaped profiles of said edge pieces then define the faces of the polyhedron.