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Description  |
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TECHNICAL FIELD
The present invention relates generally to wood reinforced corrugated boxes
and, more particularly, to a wood reinforced corrugated paperboard
shipping container for packing, shipping and storing heavy equipment.
BACKGROUND OF THE INVENTION
Packaging heavy, bulky machinery such as lawn and garden tractors, lawn
mowers, snowmobiles, boat motors, engines, air compressors, air
conditioners and the like presents many unique considerations. Because
such machinery is by its nature difficult to handle and store,
conventional double-wall or triple-wall laminated corrugated paperboard
containers have long been recognized as being unsuitable for packing heavy
equipment. As a result, wood reinforced boxes with mating bases and top
frames have been developed. These shipping containers are often referred
to as wood cleated boxes.
The conventional wood cleated box consists of a wood reinforce corrugated
paperborad body, a wooden top frame and a wooden base. At least one
interior wall of the corrugated paperboard body is provided with a wood
reinforcement vertically aligned to provide stacking strength. The
corrugated paperboard body gives the container definition and maintains
the position of the vertical wood reinforcements. The base member, often
referred to as a skid board, supports the container and the product packed
therein. The top frame closes off the container and provides a constant
surface upon which another container may be stacked. This arrangement
seeks to prevent collapse of the container even when shipped and stored in
two to four unit stacks.
Conventional packaging of heavy equipment in a typical wood cleated box
calls for the product to be packed by first being fastened to the base.
The wood reinforced corrugated paperboard body is then placed over the
product and slid down over the base. The corrugated paperboard body is
stapled to the wood base in a conventional manner by a compressed
air-driven staple gun. The top frame is inserted into the upper portion of
the corrugated paperboard body and supported by the wood reinforcements of
the corrugated paperboard body. Once the top flaps of the box are folded
and secured in place, steel or plastic banding is often provided to grid
the completed package.
While conventional wood reinforced shipping containers have proven
adequately effective for packaging heavy equipment, several problems
exist. These containers are often handled by fork lifts. Forklifts require
that the shipping container include an external skid board below the
container base to provide clearance for the fork blades. Thus, not only is
an extra component part required, but the product is stored at a
significantly greater height. Such additional height is compounded in a
three or four high stack of unit containers. The additional component (the
skid board, pallet, etc.) renders stacking a more difficult task because
the container can slide thereabout. Yet another problem with forklifts is
operator error. Even when acting with due care, a forklift operator may
misdirect the fork blades and pierce the container, thereby causing damage
not only to the container but the product packaged therein.
For these and other reasons, clamp trucks are often preferred over fork
lifts for handling packaged heavy machinery. Clamp trucks provide a pair
of hydraulically activated arms that squeeze the container in order to
lift and transport it. In preferred use, the arms of the clamp truck are
placed about the base of the conventional wood cleated box so as to exert
the squeezing action against a solid, rigid member. Thus, there is no need
for an external skid board, pallet or like member when using a clamp
truck. Clamp trucks have been found to provide superior handling
capability, resulting in less damage to the package and contents.
Additionally, clamp trucks can be used to stack unit packages to a greater
height and, once stacked, to straighten the individual containers within
any particular stack.
The conventional wood cleated box is unsuited for handling by a clamp
truck. A principal problem is separation of the base and the corrugated
paperboard body. While it is recommended that the clamp truck arms be
placed about and squeezed against the rigid base of the conventional wood
cleated box, the arms are often clamped about the corrugated paperboard
body. Because the packaged product is extremely heavy, a tremendous
downward force is exerted against the base of the conventional box. As a
result, the staples that secure the base to the corrugated paperborad body
often work through the paperboard and are pulled loose. As a result, the
base and the packaged product secured thereto fall from the corrugated box
body, causing irreparable damage to the container, significant damage to
the product and potential harm to bystanders.
Furthermore, those skilled in the art will recognize that twisting, lateral
forces are exerted on all containers during shipment. When three or four
containers are stacked one on top of the other in a truck, rail car or the
like, the jostling action resulting from typical transport will cause the
staples to work through the corrugated paperboard body wall. This, of
course, can result in separation of the base and the corrugated paperboard
body upon handling by either a forklift or a clamp truck.
Thus, there is a need in the prior art for a wood reinforced shipping
container that addresses the problems of base and body separation so that
the container's integrity is assured during packing, shipping and storage.
SUMMARY OF THE INVENTION
The present invention solves the above-described problems in the prior art
by providing a wood reinforced corrugated paperboard shipping container
that insures against separation of the component parts of the container.
More particularly, the present invention provides separate, specifically
configured attaching strips on the lowermost portion of the corrugated
paperboard body. The attaching strips, in combination with the vertical
wood reinforcements, facilitate a wood-to-wood connection between the base
and the corrugated paperboard body. This wood-to-wood connection insures
the base will stay attached to the corrugated paperboard body during
shipment and handling.
Generally described, a wood reinforced corrugated paperboard shipping
container constructed in accordance with the present invention comprises a
rigid base that supports the article to be packed, a reinforced corrugated
paperboard body including a plurality of substantially vertically aligned
reinforcing members and a plurality of attaching strips fixedly secured at
the lowermost portion of the corrugated paperboard body and a top frame
set across the uppermost end of the corrugated paperboard body to close
off the container. The container is assembled by securing the article to
be packaged to the base and placing the corrugated paperboard body over
the article onto the base. The attaching strips are aligned with the sides
of the base and fixedly secured thereto The top frame is placed into the
uppermost portion of the corrugated paperboard body and depends from the
substantially vertically aligned reinforcing members to close off the
container. The securing of the attaching strips to the base provides a
wood-to-wood connection that assures that the integrity of the container
will be maintained.
Thus, it is an object of the present invention to provide an improved wood
reinforced corrugated paperboard shipping container.
It is a further object of the present invention to provide a wood
reinforced corrugated paperboard shipping container that insures against
component part separation.
It is a further object of the present invention to provide a wood
reinforced corrugated paperboard shipping container that providss a
wood-to-wood connection between the base frame and the reinforced
corrugated paperboard body of the container so as to insure against
separation thereof.
It is a further object of the present invention to provide a wood
reinforced corrugated paperboard shipping container that can be handled by
clamp trucks and forklifts.
It is a further object of the present invention to provide a wood
reinforced corrugated paperboard shipping container that not only insures
against component separation, but that can be shipped in a knocked-down
fashion.
It is a further object of the present invention to provide a wood
reinforced corrugated paperboard shipping container that permits the
vertical reinforcing members to be secured directly to the base.
It is a further object of the present invention to provide a wood
reinforced corrugated paperboard shipping container that protects the
packaged product even when the container is mishandled or dropped.
These and other objects, features and advantages will become apparent from
a reading of the following detailed description of the invention and
claims in view of the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a preferred embodiment of a container
constructed in accordance with the present invention, with certain key
portions of the embodiment shown in phantom.
FIG. 2 is a top plan view of the corrugated paperboard blank for forming
the body portion of the container shown in FIG. 1.
FIG. 3 is a perspective view of a corner wood cleat of the embodiment shown
in FIG. 1.
FIG. 4 is a section view of the embodiment shown in FIG. 1.
FIG. 4A is a partial view of the embodiment shown in FIG. 4, with a portion
cut away to show the vertical support.
DETAILED DESCRIPTION
Referring now in more detail to the drawings, in which like numerals
indicate like parts throughout the several views, FIG. 1 shows a preferred
embodiment of a reinforced corrugated paperboard shipping container with
attaching strips according to the present invention generally at 10. The
container 10 includes a top frame 12 positioned immediately above a
corrugated paperboard body 14. Immediately below the corrugated paperboard
body 14 is the bottom frame 16. Each of these component parts of the
present invention are described in detail hereinbelow.
The top frame 12 consists of two wood pieces 20 and 22 that run lengthwise
of the box. Secured to the top of the two lengthwise pieces 20 and 22 are
three wood pieces 25, 27 and 29. These elements 20, 22, 25, 27 and 29 may
be secured in this arrangement by nails, staples or any suitable
connector. As shown best in FIG. 1 and FIG. 4, the top frame 12 is
dimensioned to sit in the uppermost portion of the corrugated paperboard
body 14. It is to be noted that the lengthwise elements 20 and 22 are each
formed with notches 30, 31 and 32, 33, respectively. The notches 30, 31,
and 32, 33 facilitate mating receipt of the top frame 12 by the corrugated
paperboard body 14 as described below.
The corrugated paperboard body 14 of the present invention is formed by a
blank of corrugated paperboard material. FIG. 2 shows a typical blank 40
of such material. The blank 40 includes four main panels 42, 44, 46 and 48
foldably connected along three score lines 51, 52 and 53. The four main
panels 42, 44 46 and 48 form the four walls of the container 10 as shown
in FIG. 1. A manufacturer's crush tab 54 is foldably connected to the main
panel 42 along a score line 55. The function of the crush tab 54 is well
known to those skilled in the art and is otherwise outside the scope of
the present invention. A series of four top flaps 62, 64, 66 and 68 are
foldably connected to the main panels 42, 44, 46 and 48, respectively,
along score lines 71, 73, 75 and 77. It will be noted that additional
folding scores are provided on the blank 40. An additional folding score
81 is provided on main panel 42 and top flap 62. A second additional
folding score 83 is provided on main panel 46 and top flap 66. The
function of these additional scores is described in detail below.
Each main panel 42, 44, 46 and 48 is provided with an attaching strip 92,
94, 96 and 98, respectively, at their lowermost portion. The attaching
strips 92, 94, 96 and 98 are preferably made of a dense hardwood and
extend substantially the length of their respective main panels 42, 44, 46
and 48. The attaching strips 92 and 96 extend up to but do not cross the
fold lines 81 and 83, respectively. The attaching strips 92, 94, 96 and 98
are fixedly secured in these positions preferably by both staples and
adhesive. However, any suitable means of attachment is acceptable.
The main panels 44 and 48 of the blank 40 are each provided with vertical
corner reinforcements. Main panel 44 is provided with vertical corner
reinforcements 100 and 102. Main panel 48 is provided with corner
reinforcements 104 and 106. The vertical reinforcements 100, 102, 104 and
106 are preferably made of a dense hardwood and extend substantially the
height of their respective main panels 44 and 48. The lowermost edge of
the vertical reinforcements 100, 102, 104 and 106 sit near the very bottom
of their respective main panels 44 and 48. The bottom portion of each
vertical reinforcement 100, 102, 104 and 106 is notched; the notch being
generally indicated at 107. FIG. 3 shows vertical corner reinforcement 100
in isolation. The lowermost portion of corner vertical reinforcement 100,
as indicated generally at 107 is cut away to provide an indent a recessed
wall 108. The uppermost portion of each corner vertical reinforcement 100,
102, 104 and 106, as illustrated in FIG. 3 by vertical corner
reinforcement 100, is beveled such that the outer portion of the
reinforcement is of greater height than the innermost portion of the
reinforcement. The beveled surface 109 is preferably angled at a
24.degree. angle.
Main panels 42 and 46 are provided with reinforcing members 110 and 112,
respectively. Reinforcing members 110 and 112 are preferably made of dense
hardwood and extend substantially the height of their respective main
panels 42 and 46. However, as opposed to the vertical corner
reinforcements 100, 102, 104 and 106, the center reinforcements 100 and
112 extend no lower than the attaching strips 92 and 96, respectively. In
addition, the center reinforcements 110 and 112 extend no higher than the
inner most edge of the top surface 109 of the vertical corner
reinforcements 100, 102, 104 and 106.
The base 16 of the container 10 consists of four floorboards 120, 121, 122
and 123 that extend the entire width of the base 16. Secured to the
floorboards 120-124 are wood strips 127, 128 129 and 130 that form a
rectangular base member collectively referred to as the base crown. The
strips 127-130 are preferably made of a dense hardwood and may be fastened
or otherwise secured to the floor boards 120-123 by nails, wood screws,
glue or any other suitable means. The frame 16 further consists of a
center reinforcing strip 132 that extends between strips 128 and 130 to
give stability to the frame 16. It will be noted that the wood strips 127,
128, 129 and 130 are set off from the corner of the floor boards 120 and
123. The purpose of this set off is described in detail hereinbelow.
In practice of the present invention, the blank of corrugated paperboard 40
is laid flat as shown in FIG. 2. The attaching strips 92, 94, 96 and 98
are fully glued and stapled to the main panels 42, 44, 46 and 48,
respectively. A preferred adhesive is polyvinyl alcohol (PVA), but any
suitable adhesive may be used. The preferred staples are 3/4" to 1" crown,
having a leg length equal to approximately the thickness of the attaching
strips 92, 94, 96 and 98 plus the thickness of the blank 40. It is
furthermore preferred that the staples be spaced apart a distance of
approximately 4" and angled at 45.degree. to achieve maximum contact of
the corrugated paperboard main panels 42, 44, 46 and 48 to their
respective attaching wood strips 92, 94, 96 and 98. While it is preferred
that the attaching strips 92, 94, 96 and 98 be located along the bottom
edges of the interior of the main panels 42, 44, 46 and 48, respectively,
the attaching strips may be secured to the exterior surfaces of the main
panels.
In a similar manner, the vertical corner reinforcements 100, 102, 104 and
106 are attached to their respective main panels 44 and 48. It is to be
noted that the notches 107 in each corner vertical reinforcement 100, 102,
104 and 106 are aligned with their respective attaching strips 94 and 98
on main panels 44 and 48, respectively. Additionally, the center
reinforcements 110 and 112 are glued and stapled to their respective main
panels 42 and 46. Once the corrugated paperboard body 14 is formed, it is
placed over the base 16. As shown best in FIG. 1 and FIG. 4, the notch 107
in the bottom portion of the vertical corner reinforcements 100, 102, 104
and 106 is positioned such that the notch surface 108 sits flush against
the base crown and in particular against the wood strips 128 and 130,
respectively. Similarly, the attaching strips 92, 94, 96 and 98 sit flush
against the wood strips 127, 130, 129 and 128, respectively. It will be
appreciated that the thickness of the wood strips 92, 94, 96 and 98 must
be not greater than half the thickness of the vertical corner
reinforcements 100, 102, 104 and 106. The outermost portion of the
attaching strips 92, 94, 96 and 98 is to be in alignment with the
outermost portion of the notched surface in the vertical reinforcements
100, 102, 104 and 106. When the corrugated paperboard body 14 is thus fit
about the crown of the base 16 formed by the strips 127-130, the strips
127-130 may be joined to the attaching strips 92, 94, 96 and 98 and the
notched portion 107 of the vertical corner reinforcements 100, 102, 104
and 106. Thus, the present invention provides a wood-to-wood connection at
the location of the base 16.
The top frame 12 is configured to fit inside the upper dimensions of the
corrugated paperboard body 14. The notches 30, 31 and 32, 33 of the
respective lengthwise wood pieces 20 and 22 are positioned to fit over the
beveled surfaces 109 at the top of the corner vertical reinforcements 100,
106 and 102, 104, respectively. This arrangement serves to lock the top
frame 12 into the corner vertical reinforcements 100, 102, 104 and 106.
The cross pieces 25, 27 and 29 are positioned to clear and to protect any
heavy packaged machinery.
In order for the finished wood reinforced corrugated paperboard shipping
container of the present invention to knock down into a flat condition for
shipment, the additional scores 81 and 83 are provided in diagonally
opposite corners of the set-up container 10. These scores are of a
sufficient distance from the main panel scores 51 and 53, respectively, to
allow the box 10 to fold around the corner vertical reinforcements 100,
102, 104 and 106. In addition, slits 150 and 151 may be cut along the top
flap score line 71 and 75 to allow the box to knock down without tearing
the flap.
It will be appreciated that the above-described invention provides a
significant advantage over prior art containers in that a wood-to-wood
arrangement is provided at the intesection and joining of the base 16 and
the corrugated paperboard body 14. This wood-to-wood arrangement insures
connection of the respective component parts and prevents separation of
the base 16 from the rest of the container 10 under normal conditions of
packing, shipping, handling and storing. The notches 107 are critical to
the present invention because they maintain a constant attaching surface
along the interior portion of the container 10 at the location of the
attaching strips 92, 94, 96 and 98. In addition, the notches 107 in the
vertical corner reinforcements 100, 102, 104 and 106 provide for the
vertical corner reinforcements themselves to be connected directly to the
base. This arrangement helps to secure the entire corrugated paperboard
body 14 to the base 16 and provides additional racking resistance for
stacking purposes. Furthermore, the notch 107 in each of the corner
vertical reinforcements 100, 102, 104 and 106 provides clamp truck
resistance. When the clamp truck arms squeeze the corner vertical
reinforcements 100, 102, 104 and 106, their attachment to the crown of the
base 16 greatly improves resistance to racking or sideways collapsing of
the entire container 10 under such stress.
This specification has thus described a preferred embodiment of the present
invention, including the steps necessary for fabricating this preferred
embodiment. It is to be understood, however, that numerous changes and
variations may be made in the construction of the present container within
the spirit of the present invention. It should therefore be further
understood that the foregoing specification relates only to a preferred
embodiment of the present invention and that modifications may be made
therein without departing from the scope thereof as set forth in the
appended claims.
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