Corrugated corner post

Abstract

A comer post (32, 34) for a plastic film wrapped package (10) include a first comer post leg (40, 130) and a second comer post leg (44, 134) that intersect at a post comer (64, 154). The outer wall (48, 138) of the first comer post leg (40, 130) includes a plurality of recessed areas (50, 140) extending inward from an outer surface of the outer wall (48, 138) and are longitudinally spaced to define a plurality of ribs (58, 148) along the outer wall (48, 138). The recessed areas (50, 140) and ribs (58, 148) are spaced so that the ribs (58, 148) of comer posts (32, 34) of adjacent packages (10) mesh to prevent relative vertical movement of the packages (10). The post comer (64, 154) of the comer post (32, 34) may include longitudinally spaced recessed edge contours (62, 152) extending inward that grab plastic film (30) as it is stretched or heat shrunk around the package (10) to prevent the plastic film (30) from sliding along the comer post (32, 34).

Description

DescriptionCorrugated Comer PostTechnical Field

[0001] The present disclosure relates generally to packaging for appliances and other large products and, more particularly, to a corrugated comer post for appliance and large item packaging configured to prevent slippage of packaging film and relative vertical slippage of adjacent packages.Background

[0002] Major home appliances and other large products are packaged for storage and shipping in one of two ways. The outer packaging material is either a fiberboard carton or a plastic film wrapped around the product. In either type of packaging, comer protection for the product is typically provided by hollow tube comer posts, honeycomb paper, cormgated fiberboard, expanded polystyrene (EPS) foam cushions, or other similar cushioning structures. When plastic film is used to contain the product, comer cushioning structures are applied at the four comers of the product to protect the comers against damage from impacts. These comer structures may also assist in supporting package stacking in the distribution environment. The plastic film is wrapped around the product and the cushioning structure to hold the product closed and to hold the cushioning structures against the vertical comers of the product. The plastic film is typically either a shrink wrap film or a stretch wrap film. Shrink wrap film is loosely applied around the product and heat is applied to shrink the film tightly against the sides of the product and partially capturing the bottom and top of the product to prevent the film and cushioning structures from sliding along the comers of the product.Stretch wrap film is stretchable and is wrapped around the product and cushioning structures tightly so that tension in the film holds the cushioning structures against the comers of the product.

[0003] Currently-known paper-based cushioning structures and hollow cushioning structures can present issues in storage and transport of the products. Because paper-based cushioning structures are linear and smooth, plastic films used as the packaging tend to slip when the packaging is handled through the distribution network. The slippage can cause the bottom capture to be compromised and allow the product to fall out the bottom. The smoothness also allows slipping between packages during multiple product handling. Hollow cushioning structures can potentially yield under the forces applied by the film wrap and collapse. The horizontal tension applied by stretch wraps can tend to roll and collapse the hollow structures around the comers. As the geometry of the hollow structures changes during distribution, the film wraps loosen, thereby allowing slippage between the product and the cushioning structures.Summary of the Disclosure

[0004] In one aspect of the present disclosure, a comer post for a plastic film wrapped package for a product is disclosed. The comer post may be fabricated from a paperboard blank and may include a first comer post leg having a first leg inner wall and a first leg outer wall, and a second comer post leg having a second leg inner wall and a second leg outer wall, wherein the first comer post leg and the second comer post leg intersect at a post comer. The first leg outer wall may include a plurality of recessed areas extending inward from an outer surface of the first leg outer wall, wherein the plurality of recessed areas may be spaced in a longitudinal direction of the comer post to define a plurality of ribs spaced in the longitudinal direction along the first leg outer wall, and the plurality of recessed areas may extend to a first post leg edge that is opposite the post comer.

[0005] In another aspect of the present disclosure, a comer post for a plastic film wrapped package for a products is disclosed. The comer post may include a comer post blank fabricated from a paperboard sheet and having a longitudinal direction and a transverse direction that is perpendicular to the longitudinal direction, a plurality of fold lines in the longitudinal direction dividing the comer post blank into a plurality of walls of the comer post, and a row of recessed area cutoutportions through the comer post blank in a first leg outer wall that are spaced in the longitudinal direction to define a plurality of ribs of the first leg outer wall. When the comer post blank is folded about the plurality of fold lines to form the comer post having a first comer post leg and a second comer post leg intersecting at a post comer, the recessed area cutout portions may define a plurality of recessed areas extending inward from an outer surface of the first leg outer wall and separated by the plurality of ribs.

[0006] In a further aspect of the present disclosure, a comer post for a plastic film wrapped package for a product is disclosed. The comer post may be fabricated from a paperboard blank and may include a first comer post leg having a first leg inner wall and a first leg outer wall, a second comer post leg having a second leg inner wall and a second leg outer wall, wherein the first comer post leg and the second comer post leg intersect at a post comer, and a plurality of recessed edge contours disposed at the post comer and extending inward from an outer surface of the first leg outer wall and an outer surface of the second leg outer wall. The plurality of recessed edge contours may be spaced in the longitudinal direction of the comer post.

[0007] Additional aspects are defined by the claims of this patent.Brief Description of the Drawings

[0008] Fig. 1 is an isometric view of a plastic film wrapped package for a large product having comer posts in accordance with the present disclosure;

[0009] Fig. 2 is an isometric view of a front comer post in accordance with the present disclosure of the plastic film wrapped package of Fig. 1;

[0010] Fig. 3 is a side view of an adjacent pair of the front comer posts of Fig. 2;

[0011] Fig. 4 is a plan view of a front comer post blank in accordance with the present disclosure from which the front comer post of Fig. 2 may be formed;

[0012] Fig. 5 is an end view of the front comer post of Fig. 2 formed from the front comer post blank of Fig. 4;

[0013] Fig. 6 is an isometric view of a rear comer post in accordance with the present disclosure of the plastic film wrapped package of Fig. 1;

[0014] Fig. 7 is a side view of an adjacent pair of the rear comer posts of Fig. 6;

[0015] Fig. 8 is a plan view of a rear comer post blank in accordance with the present disclosure from which the rear comer post of Fig. 6 may be formed;

[0016] Fig. 9 is an end view of the rear comer post of Fig. 6 formed from the rear comer post blank of Fig. 8; and

[0017] Fig. 10 is an isometric view of a clamp forklift engaging three adjacent plastic film wrapped packages of Fig. 1.Detailed Description

[0018] Fig. 1 illustrates an exemplary package 10 for a large item or product 12 such as a large appliance. In this example, the product 12 is a refrigerator having upper doors 14 with vertical handles 16 and a pull-out freezer door 18 with a horizontal handle 20 with ends proximate side walls 22 of the refrigerator 12. A rear wall 24 of the refrigerator 12 may be flat or have components such as power cords, water lines, radiator assemblies, screw heads and the like disposed rearward of the rear wall 24.

[0019] The package 10 for the product 12 is formed by a plastic film 30, a pair of front comer posts 32, and a pair of rear comer posts 34. The plastic film 30 may be a shrink wrap film or a stretch film that tightly wraps around the product 12 and the comer posts 32, 34 to tightly hold the comer posts 32, 34 against the corresponding vertical comers of the product 12. The plastic film 30 may be extended above the top edges of the comer posts 32, 34 to partially iuIK capture the top wall 36 of the product 12 and / or below bottom edges of the comer posts 32, 34 to partially capture a bottom wall 38 of the product 12, and thereby prevent the plastic film 30 and the comer posts 32, 34 from sliding along the comers of the product 12.

[0020] Fig. 2 illustrates an embodiment of the front comer post 32 in accordance with the present disclosure configured to prevent slippage of the plastic film 30 along the front comer post 32 and slippage of adjacent packages 10 during transport. The front comer post 32 may be generally L-shaped to fit around the corresponding front comer of the product 12. A first comer post leg 40 of the frontcomer post 32 may have a first leg inner wall 42 that faces and engages the corresponding side wall 22 of the product 12 and sides of the doors 14, 18. A second comer post leg 44 of the front comer post 32 may have a second leg inner wall 46 that faces and engages the front walls of the doors 14, 18 when the front comer post 32 is installed. The leg inner walls 42, 46 may intersect at a comer post comer 64 and form an inner comer angle therebetween that is complimentary to an angle at the corresponding comer of the product 12 so that the leg inner walls 42, 46 are pressed against the surfaces of the product 12 when the plastic film 30 is applied.

[0021] The first comer post leg 40 may have a first leg outer wall 48 opposite the first leg inner wall 42 and facing away from the side wall 22 of the product 12. The first leg outer wall 48 may include cut-out or recessed areas 50 spaced along the first leg outer wall 48 in a longitudinal direction indicated by an arrow 52 from a first post end edge 54 to a second post end edge 56. The recessed areas 50 extend inward from an outer surface of the first leg outer wall 48. The alternating recessed areas 50 in the first leg outer wall 48 define a plurality of alternating ribs 58 of the first leg outer wall 48 that may extend to a first post leg edge 60. In alternative embodiments, the recessed areas 50 may also extend to the comer post comer 64

[0022] As shown in Fig. 3, the ribs 58 may be staggered so that a common front comer post 32 may be used on both sides of the product 12. The front comer posts 32 may be flipped or rotated 180° relative to each other about an axis perpendicular to the longitudinal direction 52 so that the ribs 58 of a left front comer post 32 of one package 10 align with the recessed areas 50 of the right front comer post 32, and vice versa, when the first post end edge 54 of one front comer post 32 is longitudinally aligned with the second post end edge 56 of the other front comer post 32. The ribs 58 may have a rib width WR that is equal to or slightly less than a recessed area width WRA of the recessed areas 50. With this arrangement, the ribs 58 of the adjacent front comer posts 32 can mesh and engage to prevent the adjacent packages 10 from sliding vertically relative to each other when pressed together and lifted by a clamp forklift.

[0023] The first leg outer wall 48 may further include recessed edge contours 62 at the comer post comer 64 where the first leg outer wall 48 intersects a second leg outer wall 66. The recessed edge contours 62 may extend around the comer post comer 64 to the second leg outer wall 66, and may be longitudinally spaced along the comer post comer 64. The recessed edge contours 62 may be shaped in terms of length and depth to grab the plastic film 30 as it is stretched or heat shrunk around the package 10 to prevent the plastic film 30 from sliding along the front comer posts 32.

[0024] The front comer post 32 may be further configured to accommodate the forward extension of the door handles 16, 20 from the doors 14, 18. The second leg outer wall 66 may be spaced forward of the second leg inner wall 46 by a distance so that the door handles 16, 20 to not extend forward beyond the second leg outer wall 66. A second leg intermediate wall 68 may extend between edges of the second leg inner wall 46 and the second leg outer wall 66 opposite the second comer post leg 44 and define a second leg cavity 70. To prevent the second leg cavity 70 from collapsing under the tension of the plastic film 30, a second leg support wall 72 may be provided within the second leg cavity 70 and extend between opposite comers of the second leg cavity 70 to bisect the second leg cavity 70 into two triangles. The size of the second leg cavity 70 may vary based on the size of the structures extending from the product 12.

[0025] Fig. 4 illustrates an embodiment of a front comer post blank 80 from which the front comer post 32 may be formed. The front comer post blank 80 may be a standard corrugated cardboard sheet having at least one fluted sheet between two liner sheets. In alternative embodiments, the front comer post blank 80 may be formed from other types of paperboard sheets that may be folded into the front comer post 32 in accordance with the present disclosure. The front comer post blank 80 is subdivided by longitudinal fold lines or creases 82-98 that separate the blank 80 into the walls 42, 46, 48, 66, 68, 72 as well as first leg interior walls 100, 102 of the front comer post 32. Adjacent walls 42, 46, 48, 66, 68, 72, 100, 102 will be folded around the corresponding fold lines 82-98 to form the front comer post 32 as discussed further below. In this embodiment, the fold lines 82, 94 areshown as dashed lines to indicate that the blank 80 will be folded about the fold lines 82, 94 in the opposite direction as the remaining fold lines 84-92, 96, 98 when the front comer post 32 is formed.

[0026] The blank 80 is fabricated with cutout portions removed by die cuts or other forms of cutting to form the recessed areas 50 and ribs 58, the recessed edge contours 62 and other features of the front comer post 32. A first set of recessed area cutout portions 104 form the recessed areas 50 in the first leg outer wall 48. The recessed area cutout portions 104 begin within the first leg outer wall 48 and extend in a transverse direction (arrow 106) that is perpendicular to the longitudinal direction 52. The recessed area cutout portions 104 extend past the fold lines 96, 98 that separate the walls 42, 48 and define the rear edge 60 of the front comer post 32. Extending the recessed area cutout portions 104 across the fold lines 96, 98 extends the recessed areas 50 and the ribs 58 to the rear edge 60 so that the recessed areas 50 can receive the ribs 58 of the front comer post 32 of an adjacent package 10 and the ribs 58 of the front comer posts 32 can mesh and interlock as discussed above.

[0027] To align the recessed areas 50 of the left front comer post 32 of one package 10 with the ribs 58 of the right front comer post 32 of an adjacent package 10, and vice versa, the recessed area cutout portions 104 are not arranged symmetrically relative to a longitudinal centerline 108 of the front comer post blank 80 and, correspondingly, the front comer post 32. As shown in Fig. 4, the recessed area cutout portions 104 may be offset in one direction by approximately one-half the recessed area width WRA. With this offset, the recessed areas 50 and the ribs 58 align as shown in Fig. 3 when one front comer post 32 is rotated 180° relative to the other front comer post 32.

[0028] The recessed edge contours 62 may be formed through multiple walls of the front comer post 32 to provide depth to firmly engage and grab the plastic film 30 to prevent slippage. A series of partial contour cutout portions 110 may be made along a comer edge 112 of the front comer post blank 80 at the first leg outer wall 48. The partial contour cutout portions 110 are longitudinally spaced and may have a depth inward from the comer edge 112 in the transverse direction 106 thatis approximately half a transverse depth of contour cutout portions 114, 116 made along the fold lines 82, 88, respectively. The contour cutout portions 108, 114, 116 are longitudinally spaced so that contour cutout portions 108, 114, 116 at the same longitudinal position along the front comer post blank 80 are stacked to form each of the recessed edge contours 62.

[0029] Additional cutout portions may be provided in the front comer post blank 80 to accommodate product features extending forward from the front surface of the product 12 proximate the comers at which the front comer posts 32 are located. For example, handle cutout portions 118 may be made in the second leg inner wall 46 and the second leg intermediate wall 68, and across the fold line 92, to form handle openings 120 in the second comer post leg 44. As shown in Fig. 1, a lower one of the handle openings 120 of the left front comer post 32 may receive a left end of the horizontal handle 20 of the freezer door 18. On the right front comer post 32, which has been flipped 180° relative to the left front comer post 32, the other handle opening 120 is the lower one that receives the right end of the horizontal handle 20.

[0030] Fig. 5 illustrates the front comer post blank 80 folded along the fold lines 82-98 to form the front comer post 32. From the perspective shown in the drawing figure, formation of the front comer post 32 from the front comer post blank 80 may begin by folding the first leg interior wall 102 about the fold line 82 toward the second leg support wall 72 in the counterclockwise direction. Subsequently, the adjacent walls at the fold lines 84-92 may be folded clockwise about the fold lines 84-92 to form the interior of the first comer post leg 40 from first leg interior walls 100, 102 and the second comer post leg 44 from walls 46, 66, 68 with the second leg support wall 72 positioned within the second leg cavity 70. The first leg inner wall 42 is folded counterclockwise about the fold line 94 toward the second leg inner wall 46, and clockwise folds are made about the fold lines 96, 98 to form the first post leg edge 60 and dispose the first leg interior walls 100, 102 between the first leg inner wall 42 and the first leg outer wall 48.

[0031] The front comer post blank 80 is configured so that the front comer post 32 has a complimentary shape to the corresponding front comer of the product 12.The walls 42, 46, 48, 66, 68, 72, 100, 102 are dimensioned so that an inner comer angle 0c matches the outer comer angle of the product 12 so that the leg inner walls 42, 46 engage the surfaces of the product 12 when the plastic film 30 applies tension to the front comer posts 32. Additionally, hidden lines on the second leg inner wall 46 and the second leg intermediate wall 68 indicate the locations of the handle cutout portions 118 forming the handle openings 120 for receiving the ends of the horizontal handle 20. If necessary cutouts may be formed in the second leg support wall 72 at the longitudinal positions of the handle cutout portions 118 to allow insertion of the horizontal handle 20 while allowing the second leg support wall 72 to support the second comer post leg 44 at the fold line 92.

[0032] The front comer post blank 80 is further configured to form the exterior features preventing slippage between adjacent packages 10 and between the plastic film 30 and the front comer posts 32. Hidden lines on the first leg outer wall 48 indicate the location of the recessed area cutout portions 104 to form the recessed areas 50 and the ribs 58 and extension thereof through the first post leg edge 60. Additional hidden lines in the walls 48, 66, 72, 100, 102 indicate the partial contour cutout portion 110 and the contour cutout portions 114, 116 that align at the post comer 64 to form the recessed edge contours 62 of the front comer post 32 that will grab the plastic film 30.

[0033] The rear comer posts 34 may have similar features as the front comer posts 32 to prevent slippage of the plastic film 30 and adjacent packages 10 during transport. Fig. 6 illustrates an embodiment of the rear comer post 34. The rear comer post 34 may be generally L-shaped to fit around the corresponding rear comer of the product 12. A first comer post leg 130 of the rear comer post 34 may have a first leg inner wall 132 that faces and engages the corresponding side wall 22 of the product 12. A second comer post leg 134 of the rear front comer post 34 may have a second leg inner wall 136 that faces and engages the rear wall 24 of the product 12 when the rear comer post 34 is installed. The leg inner walls 132, 136 may intersect and form an inner comer angle that is complimentary to an angle at the corresponding comer of the product 12 so that the leg inner walls 132, 136 are pressed against the surfaces of the product 12 when the plastic film 30 is applied.

[0034] The first comer post leg 130 may have a first leg outer wall 138 opposite the first leg inner wall 42 and facing away from the side wall 22 of the product 12. The first leg outer wall 138 may include cut-out or recessed areas 140 similar to the recessed areas 50 spaced along the first leg outer wall 138 in the longitudinal direction 52 from a first post end edge 144 to a second post end edge 146. The alternating recessed areas 140 in the first leg outer wall 138 define a plurality of alternating ribs 148 of the first leg outer wall 138 that may extend to a first post leg edge 150. As shown in Fig. 7, the ribs 148 may be staggered so that two rear comer posts 34 may be flipped 180° relative to each other so that the recessed areas 140 and the ribs 148 of the rear comer post 34 of adjacent packages 10 align as described above, and the ribs 148 of the adjacent rear comer posts 34 can mesh and engage to prevent the adjacent packages 10 from sliding vertically relative to each other when pressed together and lifted by a clamp forklift.

[0035] The first leg outer wall 138 may further include recessed edge contours 152 at a comer post comer 154 where the first leg outer wall 138 intersects a second leg outer wall 156. The recessed edge contours 152 may extend around the comer post comer 154 to the second leg outer wall 156, and may be longitudinally spaced along the rear comer post comer 154. The recessed edge contours 152 may be shaped in terms of length and depth to grab the plastic film 30 as it is stretched or heat shrunk around the package 10 to prevent the plastic film 30 from sliding along the rear comer posts 34.

[0036] In the illustrated embodiment, the product 12 does not have components extending a substantial distance rearward from the rear wall 24. Consequently, the second comer post leg 134 may not need to be constructed in a similar manner as the second comer post leg 44 by having the second leg outer wall 156 spaced from the second leg inner wall 136. However, if necessary, embodiments of the rear comer post 34 may have the second leg walls 136, 156 spaced and additional structures similar to the walls 68, 72 may be provided to provide spacing while resisting collapsing under the tension of the plastic film 30.

[0037] Fig. 8 illustrates an embodiment of a rear comer post blank 160 from which the rear comer post 34 may be formed. The rear comer post blank 160 maybe a standard corrugated cardboard sheet having at least on fluted sheet between two liner sheets. In alternative embodiments, the rear comer post blank 160 may be formed from other types of paperboard sheets that may be folded into the rear comer post 34 in accordance with the present disclosure. The rear comer post blank 160 is subdivided by longitudinal fold lines or creases 162-178 that separate the blank 160 into the walls 132, 136, 138, 156 as well as first leg intenor walls 180, 182 and second leg interior walls 184, 186 of the rear comer post 34. Adjacent walls 132, 136, 138, 156, 180-186 will be folded around the corresponding fold lines 162-178 to form the rear comer post 34 as discussed further below. The fold lines 162, 172 are shown as dashed lines to indicate that the blank 160 will be folded about the fold lines 162, 172 in the opposite direction as the remaining fold lines 164-170, 174-178 when the rear comer post 34 is formed.

[0038] The rear comer post blank 160 is fabricated with cutout portions removed by die cuts or other forms of cutting to form the recessed areas 140 and the ribs 148, the recessed edge contours 152 and other features of the rear comer post 34. A first set of recessed area cutout portions 188 form the recessed areas 140 in the first leg outer wall 138. The recessed area cutout portions 188 begin within the first leg outer wall 138 and extend in the transverse direction 106. The recessed area cutout portions 188 extend past the fold lines 174, 176 that separate the walls 132, 138 and define the front edge 150 of the rear comer post 34. Extending the recessed area cutout portions 188 across the fold lines 174, 176 extends the recessed areas 140 and the ribs 148 to the first post leg edge 150 so that the recessed areas 140 can receive the ribs 148 of the rear comer post 34 of an adjacent package 10 and the ribs 148 of the rear comer posts 34 can mesh and interlock as discussed above.

[0039] To align the recessed areas 140 of the left rear comer post 34 of one package 10 with the ribs 148 of the right rear comer post 34 of an adjacent package 10, and vice versa, the recessed area cutout portions 188 are not arranged symmetrically relative to a longitudinal centerline 190 of the rear comer post blank 160 and, correspondingly, the rear comer post 34. As shown in Fig. 8, the recessedarea cutout portions 188 are offset in one direction by approximately one-half the recessed area width WRA. With this offset, the recessed areas 140 and the ribs 148 align as shown in Fig. 7 when one rear comer post 34 is rotated 180° relative to the other rear comer post 34.

[0040] The recessed edge contours 152 may be formed through multiple walls of the rear comer post 34 to provide depth to firmly engage and grab the plastic film 30 to prevent slippage. A series of contour cutout portions 192, 194 may be made along the fold lines 166, 178, respectively, and are longitudinally spaced across the blank 160. The contour cutout portions 192, 194 are longitudinally spaced so that contour cutout portions 192, 194 at the same longitudinal position along the rear comer post blank 160 are stacked to form each of the recessed edge contours 152. Additional cutout portions may be provided in the rear comer post blank 160 to accommodate product features extending rearward from the rear surface of the product 12 proximate the edges at which the rear comer posts 34 are located. For example, screw head cutout portions 196 may be made in the second leg inner wall 136 and the second leg interior wall 184 to form screw head openings 198 in the second comer post leg 134 (Fig. 6). The screw head openings 198 of the rear comer posts 34 may receive screw heads of screws (not shown) that fasten the rear wall 24 to a frame of the product 12 to enclose internal components.

[0041] Fig. 9 illustrates the rear comer post blank 160 folded along the fold lines 162-178 to form the rear comer post 34. As shown in the drawing figure, formation of the rear comer post 34 from the rear comer post blank 160 may begin by folding the first leg interior wall 180 about the fold line 162 toward the second leg interior wall 184 in the clockwise direction. Subsequently, the adjacent walls at the fold lines 164-168 may be folded counterclockwise about the fold lines 164- 168 to form the intenor of the side leg 130 from first leg interior walls 180, 182 and the interior of the rear leg 134 from the second leg interior walls 184, 186. Folding the second leg inner wall 136 counterclockwise about the fold line 170 forms a second post leg edge 200 of the rear comer post 34. The first leg inner wall 132 is folded clockwise about the fold line 172 to form the inner comer angle 0c that is complimentary to the outer comer angle of the rear comers of the product12 so that the leg inner walls 132, 136 engage the surfaces of the walls 22, 24, respectively. Counterclockwise folds are made about the fold lines 174-178 to form the first post leg edge 150 and dispose the first leg interior walls 180, 182 between the first leg inner wall 132 and the first leg outer wall 138 and the second leg interior walls 184, 186 between the second leg inner wall 136 and the second leg outer wall 156.

[0042] Hidden lines on the first leg outer wall 138 indicate the location of the recessed area cutout portions 188 to form the recessed areas 140 and the ribs 148 and extension thereof through the first post leg edge 150. Hidden lines in the walls 138, 156, 182, 186 indicate the contour cutout portions 192, 194 that align at the comer post comer 154 to form the recessed edge contours 152 of the rear comer post 34 that will grab the plastic film 30. Additional hidden lines on the second leg inner wall 136 and the second leg interior wall 184 indicate the locations of the screw head cutout portions 196 forming the screw head openings 198 for receiving the screw head on the rear wall 24.Industrial Appli cabi 1 i tv

[0043] The comer posts 32, 34 in accordance with the present disclosure may provide improved reliability in plastic film wrapped packaging for large appliances and other products. The recessed edge contours 62, 152 provide discontinuity along the comer post comers 64, 154 that disrupts the smoothness found in previous comer posts. When the plastic film 30 is stretched or shrunk around the package 10, the plastic film 30 sinks into and is grabbed by the recessed edge contours 62, 152. The tension in the plastic film 30 may prevent the portions disposed within the recessed edge contours 62, 152 from being easily pulled out of the recessed edge contours 62, 152 during storage and transport so that the plastic film 30 does not slide in the longitudinal direction 52 along the comer posts 32, 34.

[0044] The comer posts 32, 34 in accordance with the present disclosure also may prevent slippage between adjacent packages 10 during transport by material handling equipment. To increase productivity on loading docks and in warehouses, multiple packages 10 may be handled by the material handlingequipment at the same time. Due to the size of the products 12, it may be most efficient to handle the packages 10 when they are side-by-side. Fig. 10 illustrates an example of a clamp forklift 210 that may include right and left clamp plates 212 to grab and lift the packages 10 so that the clamp forklift 210 can drive the packages 10 to another location. In previous plastic film wrapped packages, the center package may tend to slip relative to the other packages when the clamp forklift 210 lifts the packages due to the smooth sides of the comer posts, the packages may drop, and the products 12 may be damaged. Conversely, in packages 10 with the comer posts 32, 34, the ribs 58, 148 of adjacent comer posts 32, 34 mesh to prevent slippage of the adjacent packages 10.

[0045] The comer posts 32, 34 in accordance with the present disclosure are also resistant to collapsing or rolling under the tension from the plastic film 30 as can happen with previous hollow comer posts. The comer post legs 40, 130, 134 are formed by stacked cardboard plies with no gaps to collapse upon. Hollow legs such as the second comer post leg 44 may have separation between inner and outer walls 46, 66 and form the second leg cavity 70. However, structure such as the second leg support wall 72 reinforce the second comer post leg 44 to prevent collapse from tension in the direction of the product 12 and from horizontal tension tending to roll the comer post 32 around the comer of the product 12.

[0046] The comer posts 32, 34 in accordance with the present disclosure may provide benefits in addition to the structural benefits when used in the package 10. The paperboard from which the comer posts 32, 34 are fabricated may be a sustainable material that can be recycled and reused in other products.Additionally, the design of the comer posts 32, 34 may facilitate manufacturing and inventory management. As discussed, pairs of identical front comer posts 32 and rear comer posts 34 can be used on the left and right sides of the package 10 by flipping one of each pair 180°. The recessed areas 50 and the ribs 58 are positioned to align and mesh when adjacent packages 10 are pressed together. With this design, only a single blank, part number and fabrication process are required to make the front comer posts 32 or rear comer posts 34 for both sides of the package 10.

[0047] While the preceding text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of protection is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the scope of protection.

[0048] It should also be understood that, unless a term was expressly defined herein, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to herein in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term be limited, by implication or otherwise, to that single meaning.

Claims

ClaimsWhat is claimed is:

1. A comer post (32, 34) for a plastic film wrapped package (10) for a product (12), wherein the comer post (32, 34) is fabricated from a paperboard blank (80, 160), the comer post (32, 34) comprising: a first comer post leg (40, 130) having a first leg inner wall (42, 132) and a first leg outer wall (48, 138); and a second comer post leg (44, 134) having a second leg inner wall (46, 136) and a second leg outer wall (66, 156), wherein the first comer post leg (40, 130) and the second comer post leg (44, 134) intersect at a post comer (64, 154), wherein the first leg outer wall (48, 138) comprises a plurality of recessed areas (50, 140) extending inward from an outer surface of the first leg outer wall (48, 138), wherein the plurality of recessed areas (50, 140) are spaced in a longitudinal direction (52) of the comer post (32, 34) to define a plurality of ribs (58, 148) spaced in the longitudinal direction (52) along the first leg outer wall (48, 138), and wherein the plurality of recessed areas (50, 140) extend to a first post leg edge (60, 150) that is opposite the post comer (64, 154).

2. The comer post (32, 34) of claim 1, comprising: a first post end edge (54, 144) at a first longitudinal end of the comer post (32, 34); and a second post end edge (56, 146) at a second longitudinal end of the comer post (32, 34) that is longitudinally opposite the first longitudinal end, where the plurality of recessed areas (50, 150) and the plurality of ribs 58, 148) are positioned along the first leg outer wall (48, 138) such that, for a first comer post (32, 34) and a second comer post (32, 34) rotated 180° relative to thefirst comer post (32, 34) about an axis perpendicular to the longitudinal axis (52) and having the first post end edge (54, 144) of the first comer post (32, 34) longitudinally aligned with the second post end edge (56, 146) of the second comer post (32, 34) and the second post end edge (56, 146) of the first comer post (32, 34) longitudinally aligned with the first post end edge (54, 144) of the second comer post (32, 34), the plurality of recessed areas (50, 140) of the first comer post (32, 34) are longitudinally aligned with the plurality of ribs (58, 148) of the second comer post (32, 34) and the plurality of ribs (58, 148) of the first comer post (32, 34) are longitudinally aligned with the plurality of recessed areas (50, 140) of the second comer post (32, 34).

3. The comer post (32, 34) of claim 1, wherein each of the plurality of recessed areas (50, 140) has a recessed area width (wRA) and each of the plurality of ribs (58, 148) has a rib width (wR) that is less than or equal to the recessed area width (wRA).

4. The comer post (32, 34) of claim 1, wherein the first comer post leg (40, 130) comprises a first leg interior wall (100, 102, 182) disposed between the first leg inner wall (46, 136) and the first leg outer wall (48, 138).

5. The comer post (32, 34) of claim 1, comprising a plurality of recessed edge contours (62, 152) disposed at the post comer (64, 154) and extending inward from the outer surface of the first leg outer wall (48, 138) and an outer surface of the second leg outer wall (66, 156), wherein the plurality of recessed edge contours (62, 152) are spaced in the longitudinal direction (52) of the comer post (32, 34).

6. The comer post (32, 34) of claim 5, wherein the first comer post leg (40, 130) comprises a first leg interior wall (100, 102, 182) disposed between the first leg inner wall (46, 136) and the first leg outer wall (48, 138), wherein the second comer post leg (44, 134) comprises a second leg interior wall (186) disposed between the second leg inner wall (136) and the second leg outer wall (156), and wherein the plurality of recessed edge contours (62, 152) extend inward through the first leg interior wall (100, 102, 182) and the second leg interior wall (186).

7. The comer post (32, 34) of claim 1, wherein the second leg outer wall (66) is spaced from the second leg inner wall (46), wherein the second comer post leg (44) comprises a second leg intermediate wall (68) extending between an inner wall edge of the second leg inner wall (46) opposite the post comer (64) and an outer wall edge of the second leg outer wall (66) opposite the post comer (64) to define a second leg cavity (70).

8. The comer post (32, 34) of claim 7, wherein the second comer post leg (44) comprises a second leg support wall (72) extending from the post comer (64) to an intersection of the second leg inner wall (46) and the second leg intermediate wall (68).

9. A comer post (32, 34) for a plastic film wrapped package (10) for a product (12), comprising: a comer post blank (80, 160) fabricated from a paperboard sheet and having a longitudinal direction (52) and a transverse direction (106) that is perpendicular to the longitudinal direction (52);a plurality of fold lines (82-98, 162-178) in the longitudinal direction (52) dividing the comer post blank (80, 160) into a plurality of walls of the comer post (32, 34); and a row of recessed area cutout portions (104, 188) through the comer post blank (80, 160) in a first leg outer wall (48, 138) that are spaced in the longitudinal direction (52) to define a plurality of ribs (58, 148) of the first leg outer wall (48, 138), wherein, when the comer post blank (80,160) is folded about the plurality of fold lines (82-98, 162-178) to form the comer post (32, 34) having a first comer post leg (40, 130) and a second comer post leg (44, 134) intersecting at a post comer (64, 154), the recessed area cutout portions (104, 188) define a plurality of recessed areas (50, 140) extending inward from an outer surface of the first leg outer wall (48, 138) and separated by the plurality of ribs (58, 148).

10. The comer post (32, 34) of claim 9, wherein the recessed area cutout portions (104, 188) extend across a fold line (98, 176) defining an edge of the first leg outer wall (48, 138) such that the plurality of recessed areas (50, 140) extend to a first post leg edge (60, 150) that is opposite the post comer (64, 154).

11. The comer post (32, 34) of claim 9, wherein, when the comer post blank (80, 160) is folded about the plurality of fold lines 82-98, 162-178) for form the comer post (32, 34), the first comer post leg (40, 130) includes a first leg interior wall (100, 102, 182) disposed between the first leg outer wall (48, 138) and a first leg inner wall (42, 132) that does not include recessed area cutout portions (104, 188).

12. The comer post (32, 34) of claim 9, comprising:a first post end edge (54, 144) at a first longitudinal end of the comer post (32, 34); and a second post end edge (56, 146) at a second longitudinal end of the comer post (32, 34) that is longitudinally opposite the first longitudinal end, where the plurality of recessed area cutout portions (104, 188) are positioned along the first leg outer wall (48, 138) such that, for a first comer post (32, 34) and a second comer post (32, 34) rotated 180° relative to the first comer post (32, 34) about an axis perpendicular to the longitudinal axis (52) and having the first post end edge (54, 144) of the first comer post (32, 34) longitudinally aligned with the second post end edge (56, 146) of the second comer post (32, 34) and the second post end edge (56, 146) of the first comer post (32, 34) longitudinally aligned with the first post end edge (54, 144) of the second comer post (32, 34), the plurality of recessed areas (50, 140) of the first comer post (32, 34) are longitudinally aligned with the plurality of ribs (58, 148) of the second comer post (32, 34) and the plurality of ribs (58, 148) of the first comer post (32, 34) are longitudinally aligned with the plurality of recessed areas (50, 140) of the second comer post (32, 34).

13. The comer post (32, 34) of claim 9, comprising a row of first contour cutout portions (114, 194) through the comer post blank (80, 160) that extend across a first fold line (88, 178) between a first leg first wall (100, 138) of the first comer post leg (40, 130) and a second leg first wall (66, 156) of the second comer post leg (44, 134), wherein the first contour cutout portions (114, 194) are spaced in the longitudinal direction (52) along the first fold line (88, 178), and wherein, when the comer post blank (80,160) is folded about the plurality of fold lines (82-98, 162-178) to form the comer post (32, 34), the first contour cutout portions (114, 194) define a plurality of recessed edge contours (62, 152) disposed at the post comer (64, 154) and extending inward from the outer surface of the first comer post leg (40, 130) and an outer surface of the second comer post leg (44,14. The comer post (32, 34) of claim 13, comprising a row of second contour cutout portions (116, 192) through the comer post blank (80, 1 0) that extend across a second fold line (82, 166) between a first leg second wall (102, 182) of the first comer post leg (40, 130) and a second leg second wall (72, 186) of the second comer post leg (44, 134), wherein the second contour cutout portions (116, 192) are spaced in the longitudinal direction (52) along the second fold line (82, 166), and wherein, when the comer post blank (80,160) is folded about the plurality of fold lines (82-98, 162-178) to form the comer post (32, 34), the second contour cutout portions (116, 192) align with the first contour cutout portions (114, 194) to define the plurality of recessed edge contours (62, 152) extending inward from the outer surface of the first comer post leg (40, 130) and the outer surface of the second comer post leg (44, 134) and through the first leg second wall (102, 182) and the second leg second wall (72, 186). wherein the first comer post leg (40, 130) comprises a first leg interior wall (100, 102, 182) disposed between the first leg inner wall (46, 136) and the first leg outer wall (48, 138), wherein the second comer post leg (44, 134) comprises a second leg interior wall (186) disposed between the second leg inner wall (136) and the second leg outer wall (156), and wherein the plurality of recessed edge contours (62, 152) extend inward through the first leg interior wall (100, 102, 182) and the second leg interior wall (186).

15. A comer post (32, 34) for a plastic film wrapped package (10) for a product (12), wherein the comer post (32, 34) is fabricated from a paperboard blank (80, 160), the comer post (32, 34) comprising: a first comer post leg (40, 130) having a first leg inner wall (42, 132) and a first leg outer wall (48, 138);a second comer post leg (44, 134) having a second leg inner wall (46, 136) and a second leg outer wall (66, 156), wherein the first comer post leg (40, 130) and the second comer post leg (44, 134) intersect at a post comer (64, 154); and a plurality of recessed edge contours (62, 152) disposed at the post comer (64, 154) and extending inward from an outer surface of the first leg outer wall (48, 138) and an outer surface of the second leg outer wall (66, 156), wherein the plurality of recessed edge contours (62, 152) are spaced in the longitudinal direction (52) of the comer post (32, 34).

16. The comer post (32, 34) of claim 15, wherein the first comer post leg (40, 130) comprises a first leg interior wall (100, 102, 182) disposed between the first leg inner wall (46, 136) and the first leg outer wall (48, 138), wherein the second comer post leg (44, 134) comprises a second leg interior wall (186) disposed between the second leg inner wall (136) and the second leg outer wall (156), and wherein the plurality of recessed edge contours (62, 152) extend inward through the first leg interior wall (100, 102, 182) and the second leg interior wall (186).

17. The comer post (32, 34) of claim 15, wherein the second leg outer wall (66) is spaced from the second leg inner wall (46), wherein the second comer post leg (44) comprises a second leg intermediate wall (68) extending between an inner wall edge of the second leg inner wall (46) opposite the post comer (64) and an outer wall edge of the second leg outer wall (66) opposite the post comer (64) to define a second leg cavity (70).

18. The comer post (32, 34) of claim 17, wherein the second comer post leg (44) comprises a second leg support wall (72) extending from the post comer (64) to an intersection of the second leg inner wall (46) and the second leg intermediate wall (68).

19. The comer post (32, 34) of claim 15, comprising a plurality of recessed areas (50, 140) extending inward from the outer surface of the first leg outer wall (48, 138), wherein the plurality of recessed areas (50, 140) are spaced in a longitudinal direction (52) of the comer post (32, 34) to define a plurality of ribs (58, 148) spaced in the longitudinal direction (52) along the first leg outer wall (48, 138).

20. The comer post (32, 34) of claim 19, comprising: a first post end edge (54, 144) at a first longitudinal end of the comer post (32, 34); and a second post end edge (56, 146) at a second longitudinal end of the comer post (32, 34) that is longitudinally opposite the first longitudinal end, where the plurality of recessed areas (50, 150) and the plurality of ribs 58, 148) are positioned along the first leg outer wall (48, 138) such that, for a first comer post (32, 34) and a second comer post (32, 34) rotated 180° relative to the first comer post (32, 34) about an axis perpendicular to the longitudinal axis (52) and having the first post end edge (54, 144) of the first comer post (32, 34) longitudinally aligned with the second post end edge (56, 146) of the second comer post (32, 34) and the second post end edge (56, 146) of the first comer post (32, 34) longitudinally aligned with the first post end edge (54, 144) of the second comer post (32, 34), the plurality of recessed areas (50, 140) of the first comer post (32, 34) are longitudinally aligned with the plurality of ribs (58, 148) of the second comer post (32, 34) and the plurality of ribs (58, 148) of the first comer post (32, 34) are longitudinally aligned with the plurality of recessed areas (50, 140) of the second comer post (32, 34).

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