Parts Packaging
A packaging product and method of packaging items by using a flat stiff board having the general shape of each part to be bundled cut into the board. Preferably the board is joined with another backing board, the parts are placed within the cutouts, transparent tape may be optionally applied over one or more of the parts and a transparent wrap is placed over the board.
This application claims the benefit of U.S. Provisional Application No. 61/718,704, filed Oct. 25, 2012.
BACKGROUNDOften small parts are needed to be bundled in desired quantities and assortments as “kits” for use at a later time, such as when needed for installation, assembly or repair of a device, including engines and turbochargers and may include small engine parts, rubber and metal gaskets, o-rings of all sizes, bolts, washers, and screws. When the end user is performing a given task upon the device, the appropriate kit, with the bundled parts needed, may be obtained and used, ensuring the proper parts are removed and replaced.
The parts are often bundled in a convenient container, such as a bag or envelope. Frustration can result, however, when the end user of the bundled package finds that a part was inadvertently left out or lost during bundling of the parts or storage. Even with clear plastic bags or envelopes, it is difficult for a person to quickly assess whether all parts intended to be bundled in the container are present. Bags or containers also present storage and inventory difficulties in that they generally do not stack well when placed upon a shelf or within another container and making it difficult for a person to quickly count the number of bundled parts containers present in a given location. A need exists for an inexpensive packaging product and method of packaging small parts whereby the parts are easily packaged, compactly stored, easily viewed for inspection and identification, and easily removed for use when needed.
The invention is illustrated by the accompanying drawings, which exemplify the invention but do not limit the invention's scope, in which:
Disclosed is a packaging container designed to remedy the problems with traditional bundled parts containers. In one embodiment a flat stiff board is disclosed having the general shape of each part to be bundled cut into the board. In another embodiment the board is joined with another backing board, providing additional stiffness and preventing parts from falling through the back side. The parts are placed within the cutouts and a transparent wrap is placed over the board.
In another embodiment the board is folded over once for single panel and glued together to form a compartment or special shape recess for each part to fit in. The board may be folded twice for double panel thickness to form a deeper compartment or a special shape recess for thicker parts. When the boards are assembled and glued, the parts, such as a bolt or o-ring, may be placed in the custom shaped recess in the board.
The board may be made from corrugated paperboard material, folding carton materials or plastic core materials. The board is then customized by creating apertures, such as by die-cutting, with the desired part-fitting shapes. A transparent covering, such as a shrink-wrap film, may be placed over the board.
Each kit can be custom die cut and designed according to the parts needed. In an embodiment each die cut board is cut to fit each part such that the part has an interference fit with cut-out shape of that particular part. Some finger sized portions, or interconnecting spaces between each part may be cut-out of the board to allow easier removal of each part. Each kit then may be wrapped with a clear shrink wrap film. The thickness of the film can vary depending upon number and weight of parts on kit die cut board, but usually between 75 mil.-100 mil. The resulting bundled kit packaging enables inspectors, assembly line workers, or end users to identify any wrong or missing parts. The easily viewable kit contents enables the assembly line to visually have a 100% quality check system in place to stop bad or incomplete kits from leaving the plants, reducing end-user and customer frustration, down time and costs.
DESCRIPTION OF THE DRAWINGSOnce the layers of the board are bonded to one another, the parts may be placed within the cut out recesses of the board. Transparent tape, such as a clear polyethylene protection tape, may be placed over the part and recess. The tape acts to secure the part in place, preventing it from pushing through the clear wrap. The additional layer tape is an optional step, and can allow the use of thinner shrink wrap to contain lighter parts, while supporting the heavier parts with the additional layer of tape. The tape may be placed over the part after any previous step of placing a part within the respective recess, but before the board is wrapped with a transparent or translucent wrap.
The board may then be wrapped with a plastic shrink wrap. The shrink wrapped board may be placed into a warm oven to allow the shrink wrap to tighten.
The result is a parts package that is easy to visually verify the presence or absence of a part, aiding in efficiency of the quality control.
Claims
1. A flat package having a plurality of recesses for a plurality of parts contained therein comprising:
- a board having a first layer and a second layer;
- a transparent plastic wrap;
- said first layer having a plurality of apertures, each said plurality of apertures having a shape matching the general outline of each said part;
- said second layer bonded to said first layer; wherein said parts are placed within each aperture and said board is wrapped with a transparent plastic.
2. The packaging of claim 1 wherein each said aperture forms an interference fit with each part.
3. The packaging of claim 1 wherein said first layer and said second layer are joined at a folded edge.
4. The packaging of claim 1 wherein said first layer and said second layer's folded edge possesses a scored portion and a hinge portion, each said hinge portion being between two hinge cuts, each hinge cut made perpendicular to the folded edge.
5. The packaging of claim 1 further comprising a third layer, said third layer bonded to said second layer.
6. The packaging of claim 1 further comprising clear tape placed over at least one said part and under said transparent wrap.
7. The packaging of claim 1 wherein said board is corrugated paperboard.
8. The packaging of claim 1 wherein said board is plastic core material.
9. The packaging of claim 1 wherein said board is folding carton material.
10. A method of packaging a plurality of parts in a flat package having a recess provided for each part contained therein, the method comprising:
- selecting a board of a desired thickness;
- partially cutting said board where said board is to be folded forming a cut fold line;
- cutting at least one shape outline, said shape outline being cut in the general shape of the outline of at least one said plurality of parts;
- folding said board over said cut fold line;
- placing said each part within each respective shape outline;
- placing transparent tape over said each said part; and
- wrapping said board with a transparent plastic.
11. The packaging of claim 10 wherein each said shape outline forms an aperture having an interference fit with each part.
12. The packaging of claim 10 wherein said board is corrugated paperboard.
13. The packaging of claim 10 wherein said board is plastic core material.
14. The packaging of claim 10 wherein said board is folding carton material.
15. The packaging of claim 10 wherein at least a portion of material adjacent to one said shape outline is removed forming an enlarged shape outline, allowing for a finger of a user to extend down into said enlarged shape shape outline and alongside said part.
16. A method of packaging parts in a flat package having a recess provided for each part contained therein, the method comprising:
- selecting a board of a desired thickness;
- partially cutting said board where said board is to be folded;
- cutting at least one shape outline, said shape outline being cut in the general shape of the outline of said each part;
- a portion of material adjacent to one said shape outline is removed forming an enlarged shape outline, allowing for a finger of a user to extend down into said enlarged shape outline and alongside said part;
- folding said board along said fold line;
- placing said each part within each respective cut-out;
- placing transparent tape over said each said part; and
- wrapping said board with a transparent plastic.
17. The packaging of claim 16 wherein said board is corrugated paperboard.
18. The packaging of claim 16 wherein said board is plastic core material.
19. The packaging of claim 16 wherein said board is folding carton material.
Type: Application
Filed: Oct 25, 2013
Publication Date: Jul 31, 2014
Inventors: Ronald Martin (Memphis, TN), Charles R. Dixon (Memphis, TN)
Application Number: 14/064,107
International Classification: B65D 25/54 (20060101); B65B 5/06 (20060101); B65B 5/02 (20060101); B65D 73/00 (20060101); B65D 75/00 (20060101);