VEHICLE PART PACKAGING SYSTEM, PACKAGE, JIG, AND METHOD
A part packaging system and method includes a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The system further includes a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The jig includes contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
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This application claims priority to U.S. Provisional Application Ser. No. 61/805,145 filed on Mar. 25, 2013, which is expressly incorporated herein by reference.
BACKGROUNDVehicle manufacturers are increasingly manufacturing larger, more aesthetically appealing headlights on their vehicles. Due to the more sophisticated design for the headlight, more fragile features are incorporated into the headlight package. For example, mounting tabs and plastic edges tend to be more fragile and more prone to damage than previous models. Heretofore, headlight packaging consisted of a box and an internal restraint/cushioning system. The typical restraint was constructed using corrugated inserts and stretch film. This packaging does not always adequately protect more modern headlight designs and/or involves a relatively time consuming process for packaging each headlight.
SUMMARYAccording to one aspect, a part packaging system includes a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The system further includes a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The jig includes contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
According to another aspect, a method for packaging a part includes providing a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The method further includes installing the package blank within a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, positioning a part on the package blank, and folding the package blank into the enclosed package to contain the part therein. The part has a shape that is complementarily fit by the enclosed package.
According to a further aspect, an enclosed package for a part includes a package blank formed from a single sheet of foldable material folded about fold lines disposed thereon with the assistance of a jig into a box shape. The enclosed package further includes a part enclosed by the package blank when folded into the box shape. The part has a shape that is complementarily fit by the enclosed package.
According to yet another aspect, a jig for folding a package blank into an enclosed package to contain a part includes a body structure configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The body structure includes contact portions that correspond to fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
With reference now to the drawings wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting same,
The packaging blank 10 includes an inner side 24 (the side shown in
The part packaging system 10 can further include a cushioning member 28. In the illustrated embodiment, the cushioning member 28 is affixed to the inner side 24 of the package blank 10 for contacting the part 14 and maintaining a position of the part 14 within the enclosed package 22. In an exemplary embodiment, the cushioning member 28 is formed of polypropylene, and in a more specific exemplary embodiment, the cushioning member 28 is formed of microfoam polypropylene. By way of example, the cushioning member 28 can be adhered (e.g., via adhesive) to the inner side 24 of the package blank 10 for contact with the part 14 to inhibit movement of the part 14 within the enclosed package 22. In one embodiment, such as when the cushioning member 28 is polypropylene or microfoam polypropylene, the cushioning member 28 has a coefficient of friction higher than the package blank 10, such as when the package blank 10 is corrugated cardboard for example.
The package blank 10 of the illustrated embodiment includes a base panel 10a to which the cushioning member 28 is affixed, a side panel 10b, another side panel comprised of sections 10c, 10d, and 10e, an inner top panel 10f and an outer top panel 10g. The package blank 10 further includes end flaps 10h, 10i extending from ends of the base panel 10a, end flaps 10j, 10k extending respectively from ends of the side panel 10b, end flaps 10l, 10m extending from ends of the section 10c, and end flaps 10n, 10o extending from ends of the outer top panel 10g. Further fold lines 16 are defined between adjacent panels, sections and flaps.
With reference to
In the illustrated embodiment, the contact portions 36, 38 are laterally spaced apart and extend from a base frame member 44 at a slightly upward oblique angle. The contact portions 40, 42 extend from angled supports 46, 48 at slightly downward oblique angles. As shown in
In the illustrated embodiment, as shown in FIGS. 8 and 10-12, the part 14 is a vehicle part, and is specifically illustrated as a vehicle headlamp or headlight, though this is not required and the part 14 can be any part to be packaged (e.g., a non-vehicle part) or could be some other type of vehicle part (i.e., a vehicle part other than a headlight or headlamp). The illustrated vehicle headlamp 14 includes a body portion 14a and at least one fragile feature extending from the body portion 14a. As will be described in more detail below, one advantage of the vehicle part packaging system disclosed herein is that the at least one fragile feature can be spaced apart from walls of the enclosed package 22 (wherein the walls are the panels and flaps of the package blank 10) and are inhibited from contacting the walls of the enclosed package 22. In the illustrated embodiment, the at least one fragile feature includes a mounting tab 14b extending from approximately an intersection of a bottom side 14c of the body portion 14a and an outer lateral side 14d of the body portion 14a. Additionally, in the illustrated embodiment, the at least one fragile feature includes at least one plastic edge tip extending from a lateral side of the body portion 14a.
Specifically in the illustrated embodiment, the at least one plastic edge tip includes a pair of spaced apart inner plastic edge tips 14e disposed along an inner lateral side 14f of the body portion 14a and an outer plastic edge tip 14g disposed along the outer lateral side 14d of the body portion 14a. As shown, each of the at least one plastic edge tips 14e and 14g can include an aperture size to receive a fastener (not shown) for mounting the vehicle headlamp 14 to an associated vehicle (not shown). Additionally, the vehicle headlamp 14, and particularly the body portion 14a, can include a lens 14h. Advantageously, the cushion member 28 can be interposed between the lens 14h and the enclosed package 22. The cushioning member 28 specifically functions to maintain a spaced apart relation between a portion of the vehicle part 14 (e.g., the lens 14h when the vehicle part 14 is a vehicle headlamp) that the cushioning member 28 contacts and the enclosed package 28.
With reference to
More particularly, installing the package blank 10 within the jig 12 is shown in
The method can further include installing the cushioning member 28 on the package blank 10 prior to positioning the vehicle part 14 on the package blank 10 for contacting the vehicle part 14 and maintaining the position of the vehicle part 14 within the enclosed package 22. More specifically, installing the cushioning member 28 on the package blank 10 can occur prior to the package blank 10 being inserted into the jig 12 or could occur after the package blank 10 is installed in the jig 12. As already mentioned, installing the cushioning member 28 can include affixing or adhering the cushioning member 28 on the package blank 10. With additional reference to
Advantageously, once the package blank 10 is in this position (i.e., partially folded), the jig 12 will hold the package blank 10 in position. This affords an opportunity to position the vehicle part 14 on the package blank 10 in its partially folded position. Specifically, the vehicle part 14 can be positioned on the package blank 10 as shown in
Next, the inner top panel 10f can be folded over the vehicle part 14 as shown in
Advantageously, the vehicle part packaging system, package, jig and method described herein in its various embodiments protects the vehicle part 14 to be packed while using less material and reducing the packaging cycle time. Moreover, any fragile portions of the vehicle part 14 are protected. In particular, the enclosed package 22 secures the vehicle part 14 in a set position and inhibits movement thereof within the enclosed package 22 and simultaneously isolates any fragile areas of the vehicle part 14. An additional advantage is that the package blank 10 provides a single layer. That is, no outer pack is required beyond the package blank 10 when folded into the enclosed package 22.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
Claims
1. A part packaging system, comprising:
- a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package; and
- a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the jig including contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
2. The part packaging system of claim 1 further including:
- a vehicle part received on the package blank and being contained within the enclosed package, the vehicle part having a shape that is complementarily fit by the enclosed package.
3. The part packaging system of claim 2 wherein the package blank is dimensioned so that the enclosed package has dimensions closely conforming to the shape of the vehicle part.
4. The part packaging system of claim 2 wherein the vehicle part is a vehicle headlamp, wherein the vehicle headlamp includes a body portion and at least one fragile feature extending from the from the body portion, and wherein the at least one fragile feature is spaced apart from the walls of the enclosed package and inhibited from contacting the walls of the enclosed package.
5. The part packaging system of claim 4 wherein the vehicle headlamp includes a lens and the vehicle part packaging system further includes a cushion member is interposed between the lens and the enclosed package.
6. The part packaging system of claim 2 further including:
- a cushioning member affixed to an inner side of the package blank for contacting the vehicle part and maintaining a position of the vehicle part within the enclosed package, the cushioning member further maintaining a spaced apart relation between a portion of the vehicle part that the cushioning member contacts and the enclosed package.
7. The part packaging system of claim 1 wherein a cushioning member is adhered to an inner side of the package blank for contact with a part received on the package blank to inhibit movement of the part within the enclosed package.
8. The part packaging system of claim 1 wherein the single sheet is formed of a corrugated material and is die cut to form the package blank.
9. The part packaging system of claim 1 wherein the package blank includes inner side and an opposite outer side, the inner side configured to contact a vehicle part received on the package blank, and the outer side forming an exposed outer side of the enclosed package.
10. A method for packaging a part, comprising:
- providing a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package;
- installing the package blank within a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package;
- positioning a part to be packaged on the package blank; and
- folding the package blank into the enclosed package to contain the part therein, the part having a shape that is complementarily fit by the enclosed package.
11. The method of claim 10 wherein installing the package blank within the jig includes applying pressure to the package blank such that contact portions of the jig corresponding to the fold lines of the package blank force the package blank to fold along the fold lines toward the configuration of the enclosed package, and
- wherein applying pressure to the package blank includes the jig forcing projection portions of the package blank inward to form a shaped cavity within the enclosed package for complementarily fitting the part.
12. The method of claim 10 wherein the package blank includes overlapping sides secured together via a tab of the overlapping sides being received in an aperture of the overlapping sides.
13. The method of claim 10 wherein the package blank includes end flaps defined by the cutout portions, the end flaps overlapping one another during installing of the package blank within the jig and folding the package blank into the enclosed package.
14. The method of claim 10 further including:
- installing a cushioning member on the package blank prior to positioning the part on the package blank for contacting the part and maintaining a position of the part within the enclosed package.
15. The method of claim 14 wherein the part is a vehicle headlamp that includes a lens and the cushion member is interposed between the lens and the enclosed package in contact with the lens.
16. The method of claim 10 wherein installing the package blank within the jig includes moving the package blank into the jig until vertical supports of the jig limit further movement of the package blank into the jig, and
- wherein installing the package blank within the jig further includes, after the step of moving the package blank into the jig until the vertical supports limit further movement, applying pressure at a target location on the package blank such that the package blank folds along the fold lines and jig erects a back wall of the enclosed package and forces projection portions inward toward an interior of the enclosed package.
17. An enclosed package for a part, comprising:
- a package blank formed from a single sheet of foldable material folded about fold lines disposed thereon with the assistance of a jig into a box shape; and
- a part enclosed by the package blank when folded into the box shape, the part having a shape that is complementarily fit by the enclosed package.
18. The enclosed package of claim 17 wherein the part is a vehicle headlamp.
19. The enclosed package of claim 17 in combination with the jig, the jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the jig including contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
20. A jig for folding a package blank into an enclosed package to contain a part, comprising:
- a body structure configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the body structure including contact portions that correspond to fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
Type: Application
Filed: Mar 25, 2014
Publication Date: Sep 25, 2014
Applicant: Honda Motor Co., Ltd. (Tokyo)
Inventors: Michael Van Patten (Troy, OH), Christopher Braun (Beavercreek, OH), Dean Eifert (Englewood, OH)
Application Number: 14/224,396
International Classification: B65D 57/00 (20060101);