Modular packaging container and method of packaging

Abstract

A modular packaging container for a pump (30), abatement system or components thereof is disclosed that is formed of modular components including: a base member (12); side walls (14); a cover; and at least two longitudinal support members (8) affixed to the base member and configured to support the base member at a raised level, the longitudinal support members being spaced apart from each other and providing a space therebetween for receiving a lifting mechanism. The longitudinal support members (8) comprise a plurality of rolls of a paper-based material arranged within and reinforcing an outer cardboard sheet folded to form a rectangular prism.

Description

[0001] M23D718 / JM - 1 -

[0002] PACKAGING PUMPS, ABATEMENT SYSTEMS AND PARTS THEREOF

[0003] FIELD OF THE INVENTION

[0004] The field of the invention relates to packaging containers and a method of packaging pumps, abatement systems and parts thereof.

[0005] BACKGROUND

[0006] The packaging of devices such as pumps, abatement systems and components, such as spare parts for them has conventionally been done using plastics and natural wood for support and protection. However, the carbon dioxide equivalent C02e for such materials is high, and the overall weight may also be high. These all impact the ability to stack the packaging and the packaged items, the cost of manufacturing the packaging, the cost of shipping and the end of life disposal and recycling costs.

[0007] SUMMARY

[0008] According to one aspect there is provided a modular packaging container for a pump, abatement system or components thereof, said modular packaging container comprising a plurality of modular components, said modular components forming: a base member; side walls; a cover; and at least two longitudinal support members affixed to said base member and configured to support said base member at a raised level, said longitudinal support members being spaced apart from each other and providing a space therebetween for receiving a lifting mechanism; wherein said longitudinal support members comprise a plurality of rolls of a paper-based material arranged within and reinforcing an outer cardboard sheet folded around said rolls, in some embodiments, forming a rectangular prism.

[0009] Traditional packaging for pumps, abatement systems and spare parts or components for these systems use wooden crate packaging which comes in set sizes, has a relatively high carbon footprint, adds additional weight, is not easily recyclable and is bulky to store ready for use. An aspect provides an alternativeM23D718 / JM - 2 -

[0010] to this that forms the packaging in a modular manner, allowing different sized packaging to be built from modular components and also providing easier storage of the packaging prior to use. The longitudinal support members that allow a lifting mechanism such as the forks of a fork- lift truck to be placed under the base member, are formed from a paper-based material, that can be cut to size and affixed to different sized bases as required, allowing for flexibility in the size and source of the packaging.

[0011] In some embodiments the rectangular prism forming the outer surface of the longitudinal support member comprises holes at different points along its length for receiving straps for holding at least some of said modular packaging components together.

[0012] In some embodiments, at least some of said modular components are formed from sheets of paper-based products that can be at least one of: cut, folded or rolled to form said modular components. In some embodiments said straps are formed of paper.

[0013] In addition to the longitudinal support members, other of the modular components may be formed from paper-based products, and be cut, folded and / or rolled to form the desired size and shape. All of the components may be made entirely of paper-based products, or in some cases there may be a minority of the modular components, generally those configured to provide support, formed of another stronger material such as wood. The modular components themselves may be formed entirely of paper-based products, or there may be some of them, such as the base member that is mostly made from a paper-based product, but has a reinforcing section formed of another material. A majority of the components may be made entirely of paper-based products, in some cases over 80% of the packaging by volume is formed of paper-based products.

[0014] Forming the modular components in this way allows the majority of the modular components to be stored as stacked flat sheets, that can then be cut, deformedM23D718 / JM - 3 -

[0015] and / or glued to form the required shape. This considerably reduces the amount of storage space required for the packaging components and also reduces the number of components that need to be stored, in order to provide different sized packaging, as such packaging is formed from the same basic units, cut to size.

[0016] In some embodiments, said modular components are held together with soybased glue.

[0017] The modular components may be recyclable, biodegradable, and have a low carbon footprint.

[0018] In some embodiments, said base member and side walls are formed from one or more sheets of corrugated cardboard. In some embodiments, said corrugated cardboard comprises multiple layer corrugated cardboard. In some cases, seven layer corrugated cardboard.

[0019] In some embodiments, three of said side walls are formed from a single sheet of corrugated cardboard folded to form three adjacent side walls that are configured to be attached to said base member.

[0020] Forming the side walls from a single sheet of cardboard folded appropriately, allows them to be cut to size as desired, and allows the material that is to be used to form the side walls to be conveniently stored. Furthermore, different side walls for different sized containers are not required to be sourced separately, as only one supply of cardboard is required and this can then be cut to size for any size of container.

[0021] In some embodiments, said base member is formed of a sheet of corrugated carboard forming a support surface and with three edges pieces folded to be substantially perpendicular to said support surface and configured to enclose and attach to a lower portion of three of said side walls.M23D718 / JM - 4 -

[0022] In some embodiments, said base member is formed of a sheet of corrugated carboard forming a support surface and with three edges pieces folded to be substantially perpendicular to said support surface and configured to attach to a lower portion of three of said side walls.

[0023] In some embodiments, one of said side walls is pivotable about an end adjacent to said base member between an upright position and a ramp position where said side wall forms a sloped surface linking said base member to a surface on which said longitudinal support members are mounted.

[0024] One of the side walls may be mounted such that it can pivot between an upright position where it acts as a side wall and a sloped position where it acts as a ramp for loading the pump, abatement system or component thereof. This provides for a self-contained system, which allows a dual use of a side wall and avoids the need for a separate loading ramp.

[0025] The base and one of the side walls may be formed from a single sheet of corrugated carboard. The corrugated cardboard may have a fold between the side wall and base member, allowing the side wall to pivot along the fold between a ramp position and an upright side wall position.

[0026] The base member and the pivotable side wall may comprise reinforcing strips. Where pumps, abatement systems or components thereof are mounted on wheels or feet, then reinforcing strips may be arranged to provide support for the wheels or feet during loading and storage. The reinforcing strips may be wood such as plywood to provide additional strength and support and inhibit sagging.

[0027] In some embodiments, said packaging further comprises corner supports, extending from said base member to said cover. In some embodiments, said corner supports are formed from strengthened carboard, while in others they are formed from wood. The corner supports act to improve the strength of theM23D718 / JM - 5 -

[0028] container allowing containers to be stacked on top of other. They may also protect the box from external objects hitting the comers and damaging them.

[0029] In some embodiments, said cover comprises a lid formed of corrugated cardboard.

[0030] In some embodiments, said cover comprises a support plate. In some embodiments said support plate is configured to be mounted on a lower surface of said cover and to extend over said corner supports when in position.

[0031] In some embodiments, said support plate is made of wood such as plywood. The use of a support plate allows modular packaging components to be stacked, and the load from the upper containers to be distributed through this plate and corner supports to the base.

[0032] In some embodiments, the packaging container comprises further modular components, said further modular components comprising at least one of the following: side supports for holding said pump, abatement system or components thereof in position; and at least one top pad for mounting between said pump, abatement system or components thereof and said cover.

[0033] In some embodiments, said side supports are formed of corrugated carboard folded to form a rectangular prism. These side supports can be cut and formed as per the required dimensions form sheets to support different sized and shaped products.

[0034] In some embodiments, two of said top pads comprise two triangular prisms configured to fit between a surface on which said longitudinal support members are mounted and said ramp when said ramp is down, and to provide a support for said ramp. It may be advantageous to provide some support for the ramp and in particular for the portion of the ramp up which the wheels of a device to be packaged will run, which may be the portion with reinforcing strips. TriangularM23D718 / JM - 6 -

[0035] shaped prisms with a sloped surface length that is similar to the length of the ramp and with a maximum height similar to that of the longitudinal support members, will fit snugly under the ramp and provide the desired support. They may be placed with sloping sides facing each other within the container to form a top pad between the device being packaged and the top cover. In this way they can provide a dual function and be available to support the ramp when the device is being loaded or unloaded.

[0036] In some embodiments, said pump, abatement system or components thereof weigh between 20 and 120Kg. The modular packaging container of embodiments may be suitable for loads of between 20 and 120 Kg, preferably between 40 and 100Kg.

[0037] A further aspect provides a method of packaging a pump, abatement system or components thereof within a packaging container according to an aspect, said method comprising: cutting at least two lengths of a rectangular prism formed from an outer carboard sheet folded around a plurality of rolls of a paper-based material to form two longitudinal supports for a base member; attaching said two longitudinal supports to a lower surface of said base member parallel to and at a distance from each other; mounting said pump, abatement system or components thereof on said base portion; mounting side walls on said base member; and placing a cover on a top of said side walls.

[0038] The method of packaging according to an embodiment reduces the routing or cycle time to assemble the container and pack the item. The weight and shipping volumes are also reduced as compared with traditional methods of packaging and the whole provides a more environmentally friendly and sustainable packaging.

[0039] In some embodiments, said step of mounting said pump, abatement system or components thereof on said base portion comprises sliding said pump,M23D718 / JM - 7 -

[0040] abatement system or components thereof up said ramp and then pivoting said ramp to form one of said side walls.

[0041] In some embodiments, said step of mounting side walls on said base member, comprises folding a sheet of carboard to form three side walls and mounting these to the base member.

[0042] In some embodiments, said method further comprises: attaching corner supports to each corner; attaching a support plate to a lower surface of said cover and mounting said cover such that said support plate is supported by said corner supports.

[0043] In some embodiments said method further comprises stacking two or more of the containers on top of each other. Having corner supports and a top support plate reinforces the containers allowing the finished containers to be stacked one on top of the other, thereby saving space on shop floors, and during transport.

[0044] Further particular and preferred aspects are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with features of the independent claims as appropriate, and in combinations other than those explicitly set out in the claims.

[0045] Where an apparatus feature is described as being operable to provide a function, it will be appreciated that this includes an apparatus feature which provides that function or which is adapted or configured to provide that function.

[0046] BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Embodiments of the present invention will now be described further, with reference to the accompanying drawings, in which:

[0048] Figure 1 shows the modular components of the modular packaging container; Figure 2 shows the base and ramp of the packaging container;M23D718 / JM - 8 -

[0049] Figure 3A and 3B show the sheet forming the base and ramp of the packaging container of an embodiment;

[0050] Figure 4 show the longitudinal supports;

[0051] Figure 5 shows the packaging container;

[0052] Figure 6 shows the loading and initial assembly of the packaging container of an embodiment;

[0053] Figure 7 shows the ramp supports;

[0054] Figure 8 shows the assembled packaging container with no cover of an embodiment;

[0055] Figure 9 shows the steps performed when packaging a pump; and

[0056] Figure 10 shows a flow diagram illustrating steps in a method of packaging a pump, abatement system or components thereof according to an embodiment.

[0057] DESCRIPTION OF THE EMBODIMENTS

[0058] Before discussing the embodiments in any more detail, first an overview will be provided.

[0059] Embodiments seek to provide a sustainable, modular and cost effective packaging container and method of packaging for pumps, abatement systems, or spare parts thereof. Biodegradable mostly paper-based products are used, many of which can be stored flat, cut to size, and rolled or folded into an appropriate shape.

[0060] This has the following advantages over traditional wooden crate packaging-Environmentally friendly materials which are degradable are used such as cardboard, paper straps, paper pallet, paper ramp for loading and unloading the device inside the packaging;

[0061] C02e (carbon dioxide equivalent) footprints are very low.

[0062] Standardized design.

[0063] Modular Design easy to adopt and modify for different variations just by changing the part dimensions.M23D718 / JM - 9 -

[0064] The standard C- shaped manufacturing layout and standard equipment can reduce the manufacturing cost.

[0065] The modular foldable parts reduce the part storage space required in warehouse and manufacturing lines.

[0066] The possibility of stacking is possible with the packaging design which reduces the space at shop floors and during transportation.

[0067] The overall weight, volume and cost is reduced, in some cases by about 15 % on average when compared with traditional packaging methods.

[0068] Due to the reduction in weight and volume the overall shipping cost for finished good packaging will be reduced.

[0069] Paper cardboards and paper straps are generally 100 % degradable and recyclable and do not add and create any microplastic pollution.

[0070] The modular design allows multiple different pumps, abatement systems and spare part variants to be packaged with only minor changes required.

[0071] Figure 1 shows a modular packaging container 10 according to an embodiment. The different modular components that form the modular packaging container are shown in this figure. Most of them are made from paper-based products, many of them from corrugated cardboard. There is a base 12 that is formed as a single component with ramp 12a which doubles as a sidewall. The base 12 is mounted on two longitudinal support members 8. These longitudinal support members 8 allow the base 12 to be raised from the surface on which the container is mounted, providing a space for a lifting mechanism to pass underneath the base and lift the container.

[0072] There are side walls 14 made from a single sheet of carboard that is folded to form a C-shape and provides three sidewalls. The sheet may be corrugated cardboard in some cases multiple ply, perhaps seven-ply corrugated cardboard. There are corner supports 16 that strengthen the comers and provide additional protection from damage and these may be formed from strengthened card or wood. There are then side support means 18 which are formed from folded cardM23D718 / JM - 10-

[0073] that is folded to form a rectangular cross section prism and that are mounted around the device to be transported, in this case a pump 30, and act to hold it in position and protect it from damage. There are top pads 20, 22 which are configured to protect the top of the pump 30 and there is a further top pad that doubles as ramp supports 24. This is formed of two triangular cross section prisms which when forming the top support are mounted with sloped surfaces facing each other to form a cuboid structure. These components when assembled can be held in place using straps 26a which may be formed from a paper-based product. A box top cover or lid 28 may then be placed on top of the sidewalls of the container to hold everything together and in place. In some embodiments there may be a plywood support plate 29 placed on top of the top pads and under the cover to provide additional support. This plate 29 may rest on corner supports 16 and this provides additional strength allowing multiple assembled containers 10 to be stacked. There are then external straps 26b mounted around the assembled container to hold the whole container together.

[0074] Figure 2 shows base member 12 with ramp sidewall 12a in more detail. As can be seen, there are low sidewalls formed by folding the edge of the base portion and this allows the sidewalls 14 of Figure 1 to be attached to the base by in some cases glue. There are, in this embodiment, additional support strips 13 on the ramp 12a and base 12 that are configured to align with the wheels or feet of any device to be packaged, these provide additional support as the device is slid up the ramp and when it is contained in the container.

[0075] Figures 3a and 3b show base member 12 as a single modular component prior to being folded. Figure 3b shows the base member 12 and ramp 12a, with support strips 13. These support strips 13 may be formed of word such as plywood.

[0076] Figure 4 shows the longitudinal support members 8 or sticky feet in more detail. These are formed from rolls of paper 8a mounted within an outer cardboard sheet 8b that is folded around them to form rectangular prism. There are holes 8c in the sidewalls which are adapted to receive the straps that hold the packagingM23D718 / JM - 11 -

[0077] together. The rolls of paper 8a are arranged at different positions along the length of the longitudinal support and are surrounded by the corrugated cardboard rectangular prism 8b. These longitudinal support members may be formed in any length and may be cut to size as required. This allows different length longitudinal support members to be provided according to the size of the container. They may be glued or stapled in position, generally parallel to one side of the container and at a distance from each other to allow a lifting mechanism to move underneath the base of the container.

[0078] Figure 5 shows the container in an assembled form with the top cover 28 ready to be placed in position. The lid or top cover 28 has a plywood support plate 29 that rests on the corner supports 16 and provides sufficient strength for one or more containers to be mounted on top of this one in a stack.

[0079] Figure 6 shows how the base member component 12 can receive a pump 30 and how the ramp 12a can be supported with the ramp supports 24 allowing the pump 30 to be wheeled up the ramp into position on the base 12 of the container. The sidewalls 14 may then be mounted on the base member 12 and affixed thereto. The base member is supported on longitudinal support members 8.

[0080] Figure 7 shows in more detail the two ramp support members 24 that are configured to rest under the ramp 12a aligned with any support strengthening member 13 on ramp 12a which in turn are aligned with the feet or wheels of the pump, pump component or abatement system that is to be mounted within the container.

[0081] Figure 8 shows the packaging container 10 without the lid on with the ramp members placed with sloping surfaces facing each other to form a rectangular cuboid on top of the pump and keep it in position. The side supports 18 can be seen in position. The corner supports 16 are mounted around the edge of the sidewalls and help hold the ramp 12a in position and also help support the cover when it is placed on top.M23D718 / JM - 12 -

[0082] Figure 9 schematically shows a pump 30 being loaded onto a base 12 up ramp 12a supported by ramp support members 24. When it is in position the side walls 14 are mounted around it and then the side supports put in position and the ramp is folded up to form a sidewall. The corner supports 16 are then glued in position and straps 26a are placed around to hold things in position. The cover 28 and in some cases a plywood plate are placed on top and this is held in position with further straps 26b. The container 10 may then be stacked and in some cases mounted on its own pallet ready to be transported as a stack of three in this embodiment.

[0083] Figure 10 shows a flow diagram illustrating steps in a method according to an embodiment. In a first step S10 two lengths of a rectangular prism are cut to form two longitudinal supports for a base member. The rectangular prism is formed by folding corrugated carboard around rolls of paper that may be fixed to the cardboard at different positions along the length of the longitudinal support means by glue. At step S20 these two longitudinal supports are attached to a lower surface of a base member parallel to each other and parallel to a side of the base member and at a distance from each other.

[0084] The base member has a pivotable side wall extending from one side of it, the side wall being pivotable to form a ramp, or a side wall of the container and at step S30 the side wall is pivoted to rest on the ground and form a ramp from the ground to the upper surface of the base member. In some cases, ramp support members in the form of triangular prisms are placed under the ramp. At step S40 the pump, abatement system or components thereof, are mounted on the base portion and where they have wheels this is done by wheeling them up the ramp. At step S50 the sidewalls are bent to form a 3- sided C shape and are mounted on the base member and stuck thereto and the ramp is pivoted to form a fourth side wall. In some cases side supports are placed around the packaged device and corner supports are added to support the comers of the container.M23D718 / JM - 13-

[0085] The ramp supports if used, are then placed on top of the load, straps are placed around it and at step S60 a cover is placed on top of the sidewalls. In some cases the cover has a plywood support that rests on the corner supports. At step S70 straps are placed around the cover, sides and base to hold it all in position. The straps may be made of a paper- based material.

[0086] In summary embodiments may provide:

[0087] • packaging made from environmentally friendly materials that are biodegradable.

[0088] • low C02e footprint.

[0089] • standardized design.

[0090] • modular design that is easy to adopt & modify for different variations. • standard manufacturing layout

[0091] • reduction in manufacturing and assembly cost.

[0092] • the modular foldable parts reduce part storage space in warehouse and manufacturing lines.

[0093] • stacking of multiple, in some cases 3, containers which reduces the space at storage, shop floor and during transportation.

[0094] • reduction in overall weight, volume and cost

[0095] • due to the reduction in weight and volume the overall shipping cost for finished good packaging will be reduced.

[0096] • reduced end-of-life expenses since all or nearly all materials used for packaging are recyclable and degradable.

[0097] • significant assembly time reduction.

[0098] Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiment and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents.M23D718 / JM - 14-

[0099] REFERENCE SIGNS

[0100] 8 longitudinal support members

[0101] 8a paper rolls

[0102] 8b corrugated cardboard surround 8C holes

[0103] 10 packaging container

[0104] 12 base member

[0105] 12a ramp

[0106] 13 support strips

[0107] 14 side walls

[0108] 16 corner supports

[0109] 18 side supports

[0110] 20, 22 top pad

[0111] 24 ramp supports

[0112] 26A inner straps

[0113] 26B outer straps

[0114] 28 box top cover

[0115] 29 support plate

[0116] 30 pump

Claims

M23D718 / JM - 15-CLAIMS1. A modular packaging container for a pump, abatement system or components thereof, said modular packaging container comprising a plurality of modular components, said modular components forming:a base member;side walls;a cover; andat least two longitudinal support members affixed to said base member and configured to support said base member at a raised level, said longitudinal support members being spaced apart from each other and providing a space therebetween for receiving a lifting mechanism; whereinsaid longitudinal support members comprise a plurality of rolls of a paperbased material arranged within and reinforcing an outer cardboard sheet folded around said plurality of rolls.

2. A modular packaging container according to claim 1 , wherein at least some of said modular components are formed from sheets of paper-based products that can be at least one of: cut, folded or rolled to form said modular components.

3. A modular packaging container according to claim 2, wherein three of said side walls are formed from a single sheet of corrugated cardboard folded to form three adjacent side walls and configured to be attached to said base member.

4. A modular packaging container according to any preceding claim, wherein one of said side walls is pivotable about an end adjacent to said base member between an upright position and a ramp position where said side wall forms a sloped surface linking said base member to a surface on which said longitudinal support members are mounted.M23D718 / JM - 16-5. A modular packaging container according to claim 4, wherein said base member and said one of said side walls are formed from a single piece of corrugated cardboard.

6. A modular packaging container according to claim 4 or 5, wherein said base member and said pivotable side wall comprise reinforcing strips.

7. A modular packaging container according to any preceding claim, further comprising corner supports, extending from said base member to said cover.

8. A modular packaging container according to any preceding claim, wherein said cover comprises a lid formed of corrugated cardboard.

9. A modular packaging container according to claim 8 when dependent on claim 7, wherein said cover comprises a support plate configured to be mounted on a lower surface of said cover and to extend over said corner supports.

10. A modular packaging container according to any preceding claim, comprising further modular components, said further modular components comprising at least one of the following: side supports for holding said pump, abatement system or components thereof in position; and at least one top pad for mounting between said pump, abatement system or components thereof and said cover.

11. A modular packaging container according to claim 10, wherein two of said top pads comprise two triangular prisms configured to fit between a surface on which said longitudinal support members are mounted and said ramp when said ramp is down, and to provide a support for said ramp.

12. A method of packaging a pump, abatement system or components thereof within a packaging container according to any preceding claim, said method comprising:M23D718 / JM - 17-cutting at least two lengths of a rectangular prism formed from an outer carboard sheet folded around a plurality of rolls of a paper-based material to form two longitudinal supports for a base member;attaching said two longitudinal supports to a lower surface of said base member parallel to and at a distance from each other;mounting said pump, abatement system or components thereof on said base portion;mounting side walls on said base member; andplacing a cover on a top of said side walls.

13. A method according to claim 12, wherein said packaging container is one according to claim 4 or 5, wherein said step ofmounting said pump, abatement system or components thereof on said base portion comprises sliding said pump, abatement system or components thereof up said ramp and then pivoting said ramp to form one of said side walls.

14. A method according to claim 13, wherein said step of mounting side walls on said base member, comprises folding a sheet of carboard to form three side walls and mounting these to the base member.

15. A method according to any one of claims 12 to 14, comprising:attaching corner supports to each corner;attaching a support plate to a lower surface of said cover and mounting said cover such that said support plate is supported by said corner supports.

Images