Note: Descriptions are shown in the official language in which they were submitted.
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STRETCH-WRAPPED MODULAR MASTERPACKAGE
AND METHOD OF MAKING SAME
FIELD OF THE INVENTION
This invention relates to a stretch-wrapped
modular masterpackage and, more particularly, to such a
masterpackage compr:ising palletized modular units each
of which comprises a plurality of articles such as
bundles of builder's shims.
BACKGROUND OF THE INVENTION
Builder's shims are a standard product used by
builders to shim door and window assemblies and the
like. Typically, they are shipped to builders supply
stores on pallets, where they are purchased by building
contractors and professional window installers, as well
as by homeowners themselves. The builders supply store
likes to display the shims on the pallets on which they
are shipped.
Builders shims are typically made from green
wood; that is, wood that is not completely dry. It is
very advantageous to group the shims in bundles and wrap
each bundle around its vertical outer periphery to
permit the moisture to escape. The wrapping is
essential, because otherwise the bundle would fall apart
as the individual shims dry out.
It is also commercially advantageous to ship a
group of pallets banded together to form what is known
as a masterpackage. The builders supply store can then
separate the individual pallets from the masterpackage
and distribute such individual pallets as desired
throughout the store.
Builders supply stores also desire to eliminate
handling of the product by store personnel. This is
advantageous in that it minimizes the risk of injury to
the product, but it also minimizes any disruption in the
relationship between the ultimate consumer and the
manufacturer, thereby to leave unaffected the
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manufacturer's ultimate liability and responsibility for
its product.
Stretch-wrapping of palletized articles is a
common way to prepare such articles for shipment to an
ultimate destination. An example of this technique is
disclosed in Dreher U.S. Patent No. 3, 986,611. Examples
of stretch-wrapping of multiple stacked non-palletized
articles are disclosed in Gombos et al., U.S. Patent
No. 5,090,177, Lancaster et al., U.S. Patent
10No. 5,195,297 and Lashyro U.S. Patent No. 5,450,708.
The ' 297 patent discloses machinery suitable for the
purpose. The machinery is made and sold by Lantech,
Inc., Louisville, Kentucky, assignee of the Lashyro
patent.
15Accordingly, it is a principal object of the
present invention to provide a tension film-wrapped
modular masterpackage of palletized modular units which
can be safely and eI-ficiently transported to an ultimate
destination, whence the individual modular palletized
units can be distributed as desired by the recipient.
It is a furt:her object of the present invention
to provide a method of unitizing for shipment a
plurality of such modular palletized units to reduce
handling to a minimum at the ultimate retail
distribution site.
It is a still further object of the present
invention to provide a method of shipping a plurality of
unitized modular masterpackages to provide the most cost
effective system for delivering a product from the
manufacturer to the ultimate consumer.
It is a still further object of the present
invention to provide a masterpackage as above set forth
wherein bundles of builders shims, shipped in a "green"
condition, are themselves shrink wrapped to insure
bundle integrity right to the point of ultimate purchase
by the consumer.
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SU~MARY OF THE INVENTION
The invention provides a tension film-wrapped
masterpackage for shipment to a destination. The
masterpackage comprises a plurality of pallets each of
which supports a pll~rality of articles in a
predetermined array. The articles form a column having
a superimposed outer tension wrap of a flexible cling
film which envelops the vertical outer periphery of the
column. The column and the pallet form a modular unit.
The pallets comprise means such that they can be handled
in any of the four sides by the tines of a forklift
truck.
The palletized modular units are disposed in a
horizontal side-by-side relationship to form the
masterpackage. The masterpackage also has a
superimposed outer t:ension wrap of a flexible cling film
which envelops the outer periphery of the group of
individually wrappecl palletized modular units. Thus,
removal of the outer tension wrap from the masterpackage
2C following shipment t:o the destination permits the
individually outer wrapped palletized modular units to
be distributed as desired by the consignee.
Preferably, the articles in the column comprise
individual bundles of builder's shims. Each bundle of
shims may optionally have a superimposed tension wrap of
a flexible cling film enveloping its own vertical outer
periphery, and this wrap may desirably comprise a shrink
wrapped film.
The pallets utilized in the invention have been
3 0 configured in such a way that permits a truck trailer to
be loaded to its maximum capacity, thereby to achieve
maximum efficiency in shipment.
The invention also provides a method of
unitizing a masterpackage for shipment to a destination.
The method comprises loading a plurality of articles in
a predetermined array on a pallet to form a column of
articles. The pallet is capable of being lifted from
any direction using the tines of a forklift truck. The
method then comprises wrapping a flexible cling film
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under tension around the vertical outer periphery of the
column to form a vertically wrapped palletized modular
unit.
The method further comprises placing a plurality
of the palletized film-wrapped modular units in a
horizontal side-by-side relationship. A flexible cling
-film under tension is then wrapped around the vertical
outer periphery of the plurality of palletized film-
wrapped modular units to form a masterpackage. Removal
of the film from around the vertical periphery of the
masterpackage after arrival at the destination permits
the plurality of in,~ividually wrapped modular units to
be distributed as desired at the destination.
Preferably, the articles forming the column
comprise individual bundles of builder's shims.
Optionally, the method comprises wrapping the bundles of
builder's shims comprising the articles of the column
each with a flexible cling film around the vertical
outer periphery thereof. Wrapping of each bundle may
comprise shrink wrapping the bundle.
The invention also provides a method of shipping
unitized masterpackaLges in a cost effective manner to a
selected destination in a truck trailer having a defined
interior width.
The method comprises loading a plurality of
articles in a predet:ermined array on a rectangular
pallet to form a column of articles having sides having
dimensions substantially in the ratio of x:y, wherein x
is less than y, and x and y are integers. The side
corresponding to the integer x is the short side of the
column, and the side corresponding to the integer y is
the long side of the~column. The pallet is capable of
being lifted from any of the four sides using the tines
of a forklift truck.
The method further comprises wrapping a flexible
cling film under tension around the vertical outer
periphery of the column to form a vertically wrapped
palletized modular unit.
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Four of the palletized tension film-wrapped
modular units are then placed in a horizontal two-by-two
relationship. A flexible cling film under tension is
then wrapped around the vertical outer periphery of the
palletized tension film-wrapped modular units in the
horizontal two-by-two relationship to form a unitized
-masterpackage having sides substantially in the ratio of
x:y. The side corresponding to x is the short side of
the masterpackage, and the side corresponding to y is
the long side of the masterpackage.
The unitized masterpackages are then loaded in
the truck trailer in a pattern such that x of the
masterpackages (x being an integer) are placed in a
first line with their short sides adjacent each other,
and y of the masterpackages (again, y is an integer) are
placed in a second :Line adjacent the first line with
their long sides adjacent each other. The
masterpackages thus form a group of x + y masterpackages
having a rectangular exterior boundary which
substantially extends across the full width of the
interior of the truck trailer.
Preferably, the column has dimensions at least
equal to the dimensions of the pallet. For a standard
sized truck trailer, x:y = 3:4.
Preferably, the articles comprising the columns
comprise bundles of builder's shims. Optionally, the
method comprises shrink wrapping the bundle of builders
shims comprising each of the articles with a flexible
cling film around the vertical outer periphery thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a tension film
wrapped modular masterpackage according to the
invention, after the masterpackage has been shipped to a
destination, and wherein the superimposed outer tension
film wrap around the masterpackage has been cut to
permit the individually outer wrapped palletized modular
units to be distributed as desired by the store owner.
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Fig. 2 is a perspective view of one of the
palletized modular units, particularly illustrating the
pallet, wherein the column of articles is wrapped with a
superimposed outer tension wrap of a flexible cling
film.
Fig. 3 is a perspective view of a bundle of
-builders shims itself shrink wrapped with a superimposed
tension wrap of a flexible cling film.
Fig. 4 is a top plan view of the pallet of
Fig. 2.
Fig. 5 is a view of one (the short) side of the
pallet.
Fig. 6 iS a view of the other (the iong) side of
the pallet.
Fig. 7 is a plan view of the interior of a truck
trailer loaded with one layer of unitized masterpackages
according to the method of the invention.
Description of a Preferred Embodiment
Referring to the drawings, builders shims 10 are
typically sold in bundles 12 comprising 48 shims. Such
a bundle 12 is designed to satisfy the needs of both
homeowners and contractors. Shims may also be bundled
in bundles comprising 24 shims for an end user having a
single job (such a bundle not being shown), or in
bundles comprising 80 pieces for the professional
installer of windows and doors (such a bundle also not
being shown).
Each indiviclual bundle 12 can be wrapped with a
superimposed tension wrap 14 of a flexible cling film 16
around its side edges 18, deemed the vertical outer
periphery of the bundle 12. The side edges 18 are the
only surfaces wrapped, because the shims 10 are
typically prepared in the wet or pre-dried condition.
Leaving the tops anc! bottoms of the bundles open,
permits the shims to dry out prior to actual use. See
Fig. 3.
Wrapping each bundle 12 is preferably
accomplished by what is known as "overbanding"; that is,
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shrink banding the bundle 12, to let the moisture out,
with a non-tacky polyvinyl chloride (pvc) film using a
Seal-A-TronTM shrink tunnel, Model TST-2410-LR15VSA. The
film 16 preferably extends slightly below the bundle and
slightly above the upper surface thereof (see Fig. 3),
thereby to secure the individual shims 10 together.
- The bundles 12 of shims 10 are typically shipped
to builders supply .,tores on pallets loaded with fifty
bundles 12. The stores prefer to receive them on
pallets, because a pallet loaded with fifty bundles 12
can be placed wherever the store manager desires.
Shipping individual pallets loaded with shims, however,
is an inefficient and impractical way to transport them.
Thus, fifty of the bundles 12 are loaded in a
predetermined array, for example, stacked on a pallet 20
such that the bundles 12 all have their shims 10
disposed in the same direction. The fifty bundles 12
form what is called a column 21. See Fig. 2.
The pallet 20 is preferably constructed as a
rectangular frame 22, having a short side 24 (the side
parallel to the longitudinal direction of the shims 10)
twenty inches long, and a long side 26 (its other
horizontal dimension) twenty-seven inches long. A
rectangular pallet is preferable because of the inherent
rectangular nature of the bundles 12 themselves. The
rectangular nature of the pallets also greatly
facilitates the ultimate loading of a truck trailer as
will be more fully explained hereinafter.
The stacked or loaded bundles 12 preferably
extend slightly outwardly of the sides 24, 26 of the
pallet 20, such that the column 21 has sides 28, 30
slightly larger than the sides 24, 26 of the pallet.
The sides 28, 30 of the column 21 typically may have
dimensions of about 20-1/2 inches by 27-1/2 inches. It
will be noted that the ratio of the length of the
side 28 to the length of the side 30; i.e.,
20-1/2:27-1/2, iS about 3:4, and the significance of
this ratio will be hereinafter more fully explained.
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The pallet frame 22 iS preferably constructed of
two "two-by-four" pieces 32 forming its long sides 26
joined by two "two-by-three" pieces 34 extending
interiorly of the pieces 32 and flush with their upper
5 surfaces 36 and two more "two-by-three'~ pieces 38
extending exteriorly of the pieces 32, positioned below
the lower surfaces 40 thereof and extending to the outer
side surfaces 42 of the pieces 32, as shown in Fig. 2.
By this means the tines of a forklift truck (not shown)
facing either long side 26 of the pallet 20 can be
inserted in the space 44 formed below the long side
pieces 32 (between the pieces 38) to handle the
pallet 20 and associated column 21 from the direction of
the long side 26. Similarly the tines of a forklift
truck facing either short side 24 of the pallet 20 can
be inserted in the space 46 formed between the cross
pieces 34 and 38 to handle the pallet 20 and associated
column 21 from the direction of the short side 24.
Thus, the pallets 20 are capable of being lifted from
any of the four sides using the tines of a forklift
truck, and this greatly facilitates the loading of a
truck trailer as wi:ll be hereinafter further described.
Each of the columns 21 is then vertically banded
using a single vertically oriented steel or plastic
strap 47. The strap 47 passes through the space 46
between the cross pieces 34 and 38, around the
bundles 12 comprising the column 21, thereby tying the
bundles 12 to the pallet 20. See Figs. 1 and 2.
The column 21 and pallet 20 are then wrapped by
another tension wrap 48, using a flexible cling (tacky)
film 50, to form a vertically wrapped palletized modular
unit 52. This is ac:complished using a LantechT~ machine,
sold by Lantech, Inc:., Louisville, Kentucky, preferably
a LantechTU Model STE'SD, using LLDPE stretch film. The
film 50 preferably extends slightly above the upper
surface of the column 21, slightly over the bundles 12
as shown in Fig. l; also slightly below the upper
surfaces 36 of the "two-by-four" side pieces 32, and
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slightly below the upper surfaces of the two "two-by-
three" cross pieces 34. The wrapping, together with the
banding provided by the strap 47, insures that the
pallet 20 is secureLy incorporated within the modular
5 unit 52 and that it remains with the column 21 when the
unit 52 is moved.
- After each modular unit 52 is wrapped, it is
taken off the Lantec;hTM machine and put aside until a
desired number of such units 52 have been wrapped,
typically groups of four such units. Four wrapped
modular units 52 are then placed in a horizontal side-
by-side, two-by-two relationship on the LantechT~
machine, where they are again wrapped to form the
masterpackage 54 shown in Fig. 1. As in the case of the
15 modular units 52, wrapping of the masterpackage 54 is
preferably accomplished on a LantechTM Model STPSD
machine using LLDPE stretch film.
Because the ratio of the lengths of the
sides 28, 30 of the columns 21 is approximately 3 :4, the
20 ratio of the length of the short side 56 of the
masterpackage 54 to the length of the long side 58
thereof is also approximately 3: 4.
The masterpackage of four outer wrapped
palletized modular units 52 is wrapped with a tension
25 wrap 60 of a flexible cling film 62. The four wrapped
units 52 stay together very well, without the necessity
of using another strap, because the tension wrap 60
forces them into a close relationship. This takes
advantage of the inherent tackiness of the film 50
30 surrounding each modular unit 52 and the tendency of the
edges of the shims 10 to protrude through the film.
Thus, it has been found that no pallet is needed below
the masterpackage 54 itself for support. The finished
masterpackage 54 has side dimensions of about 41 inches
35 by 54 inches, i.e., twice that of the modular units 52
themselves, and also approximately in the ratio of 3 :4.
Upon arrivin~ at the ultimate destination,
typically the builders supply store, the wrap 60 around
the masterpackage 54 can be cut, as shown in Fig. 1,
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such that the individually wrapped modular units 52,
which include the pa:llets 20, can be placed in the store
as desired.
The assembly as above described permits
efficient usage of e~isting truck trailers to ship the
product. As shown in Fig. 7, the interior of a truck
~railer 64 is loaded in the following manner. Three
masterpackages 54 are placed in a first line 66 with
their short sides 56 adjacent each other and their long
sides 58 adjacent the interior sidewall of the trailer.
Loading in this manner is facilitated because the tines
of a forklift truck can engage each masterpackage 54
using the spaces 46 :in the two side-by-side pallets 20.
Four masterpackages 54 are then placed in a
second line 68 adjacent the first line 66, the four
masterpackages 54 being placed with their long sides 58
adjacent each other and their short sides 56 adjacent
the opposite interior sidewall of the truck trailer 64.
In loading these four masterpackages 54, the forks of
the forklift truck engage the-two pallets 20 using the
spaces 44 formed in the long sides 26 thereof.
Because the outer dimensions of the
masterpackages 54 are substantially in the ratio of 3:4,
seven masterpackages 54 loaded as aforesaid, form a
group 70 which has a rectangular boundary. The 54 inch
long side 58 of the masterpackages 54 in the second
line 68, placed adjac~ent the 41 inch short side 56 of
the masterpackages 54 in the first line 66, provide the
group 70 with a tota] width of 95 inches, thereby
efficiently filling t:he 98-inch standard interior width
of the trailer 64.
An additiona] two groups 70 plus two more
individual masterpackages 54 are usually loaded into the
truck trailer 64 as shown in Fig. 7, preferably
alternating short sicles and long sides of the
masterpackages 54, as shown, thereby substantially fully
loading the interior with twenty-three
masterpackages 54, each consisting of four modular
units 52, each unit ',2 containing fifty bundles 12, each
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bundle 12 containing forty-eight shims 10. Typically,
the truck trailer 64 is loaded with two layers of
groups 70, thus to accommodate a total of forty-six such
masterpackages 54. There is enough interior height in a
typical truck trailer 64 to add a third layer, providing
existing weight lim:itations are not exceeded.
- A trailer could be loaded with more groups 70 in
each layer if the truck trailer is long enough to
accommodate them, which would also depend on the
particular dimensions of the masterpackage 54 concerned.
Also if a particular truck trailer is slightly longer
than, for example, t:he trailer described herein that
accommodates the forty-six masterpackages 54 shown,
additional masterpac:kages 54, not necessarily the seven
that form a complete group 70, can be loaded at the end
of the trailer and maintained in position during transit
with airbags (not shown).
Although an example has been selected wherein
the dimensions of the masterpackage optimizes truck
trailer loading using a group of seven masterpackages,
in two lines of three and four masterpackages,
respectively, the loading method would be analogous for
any assembly of modular units and masterpackages having
short sides and long sides in the ratio of x:y. The
truck trailer would merely be loaded in a pattern
wherein x of the masterpackages are placed in the first
line and y of the masterpackages are placed in the
second adjacent line, thereby to form a group of x + y
masterpackages having a rectangular exterior boundary.
The present invention may be embodied in other
specific forms without departing from the spirit and
essential characteristics thereof. The present
embodiments are presented merely as illustrative and not
restrictive, with the scope of the invention being
indicated only by the attached claims. All changes
coming within the meaning and equivalency of the claims
are, therefore, intended to be embraced thereby.
