TIER SHEET SYSTEM AND METHOD

Abstract

A system for palletizing containers with tier sheets is disclosed. In embodiments, a system includes a pallet; at least two layers of containers, each layer including a plurality spouted containers; and a tier sheet provided between the at least two layers of containers. In embodiments, the tier sheet includes a top portion and a plurality of projections.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/421,628, filed Nov. 2, 2022, the entire disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure generally relates to packaging, bulk palletizing, and/or transport for articles, including bottles and containers with an extended portion or spout, along with related systems and methods.

BACKGROUND

In the container industry, empty containers of various sizes and configurations are typically transported on pallets. Such containers are commonly arranged by layers on a pallet, and the layers (or tiers) typically include rows of containers with the pallet having different layers being separated by tier sheets.

However, additional challenges are often associated with the stacking or palletization of bottles or containers that include an extended portion or spout. With previous concepts, spouted containers are commonly case or box packed. Although, case or box packing can be cost and/or labor intensive, particularly in connection with the re-use of cases/boxes. Among other things, used boxes or cases associated with conventional packing may not always be re-erected by machines, for example, due to damage or wear and tear of such cases or boxes. That can lead to the need for added manual labor. Additionally, cases or boxes are often universal in design, and such universal cases or boxes may not be configured to best accommodate different types of spouted bottles or containers. Such cases or boxes may not provide good or optimized use of space so as to eliminate or avoid voids or wasted space—which consequently can reduce packing density for shipping or transportation.

Among other things, it is desirable to provide improved systems and methods for bulk handling and palletization of spouted articles. It can be further desirable to provide a system for bulk palletization that will work with a wide variety of different sized spouted bottles or containers.

SUMMARY

A system for palletizing containers with tier sheets is disclosed. In embodiments, a system includes a pallet; at least two layers of containers, each layer including a plurality spouted containers; and a tier sheet provided between the at least two layers of containers. In embodiments, the tier sheet includes a top portion and a plurality of projections.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will now be described, by way of example, with reference to the accompanying drawings, wherein:

FIG. 1 generally illustrates a rear view of an embodiment of a container.

FIG. 2 generally illustrates a side view of an embodiment of spout for a container.

FIG. 3 generally illustrates a side view of an embodiment of container with a spout.

FIG. 4 generally illustrates a front view of an embodiment of palletized articles with a plurality of rows of spouted containers provided on a pallet in accordance with aspects or teachings of the present concept.

FIG. 5 generally illustrates an enlarged view of a portion of FIG. 4.

FIG. 6 generally illustrates a side view of an embodiment of palletized articles such as generally shown in FIG. 4.

FIG. 7 generally illustrates an enlarged view of a portion of FIG. 6.

FIG. 8 generally illustrates a side view of an embodiment of a tier sheet in accordance with aspects or teachings of the present disclosure.

FIG. 9 generally illustrates an enlarged view of a portion of FIG. 8.

FIG. 10 generally illustrates a side view of another embodiment of a tier sheet in accordance with aspects or teachings of the present disclosure.

FIG. 11 generally illustrates an enlarged view of a portion of FIG. 10.

FIG. 12 generally illustrates a front view of an embodiment of a plurality of rows of spouted articles provided on a pallet.

FIG. 13 generally illustrates an enlarged view of a portion of FIG. 12, which inter alia, shows exemplary dimensions associated with a tier sheet and an associated pallet.

FIGS. 14, 15, and 16 generally illustrate top, side, and front views of an embodiment of a pallet in accordance with aspects or teachings of the present disclosure.

DETAILED DESCRIPTION

An embodiment of an article, in the form of a container 10, is generally illustrated in FIG. 1. The container may be comprised of various materials and may have various shapes and sizes. In embodiments, a container 10 may be comprised of plastic, glass, or other materials. For example and without limitation, in embodiments a container 10 may be comprised of polyethylene (PE), polypropylene (PP), high-density polyethylene (HDPE), low-density polyethylene (LDPE), and/or polyethylene terephthalate (PET).

An embodiment of a spout 20 is generally illustrated in FIG. 2. In embodiments, a spout may be comprised of plastic that may, for example and without limitation, be injection or compression molded. An embodiment of a spouted container 30 (or container assembly) including a container 10 and spout 20 is generally illustrated in FIG. 3. Embodiments of spouts can vary in shape and size, depending on the specific function and design of a container.

FIG. 4 generally illustrates a front view of an embodiment of palletized articles (spouted containers 30) with a plurality of rows (or tiers) provided on a pallet 40 in accordance with aspects or teachings of the present concept. As generally illustrated, the rows of spouted containers 30 are separated by a tier sheet 50. A tier sheet 50 may include a top portion 52, which may be flat or substantially flat, and a plurality of projections 54 that extend (e.g., downwardly) from the top portion 52. In embodiments of a tier sheet 50, the top portion 52 and the plurality of projections 54 are integrally formed as a single or unitary component. However, with other embodiments, the top portion 52 and plurality of projections 54 may be provided (or assembled) as two separate assembled or connected components.

In embodiments, a tier sheet 50 may be comprised of a polymer or plastic. For example and without limitation, a tier sheet may be comprised of high-density polyethylene (HDPE), polycarbonate (PC), or acrylonitrile butadiene styrene (ABS). With embodiment, a tier sheet may be molded, such as thermoformed.

As generally illustrated in FIG. 5, the spouted container 30 includes a neck portion 12, and the spout 20 extends upwardly from the neck (or finish) portion 12. In embodiments, the projections 54 may extend substantially in columns along the tier sheet 50 and may straddle, or are separated and spaced, from, the spout 20. That is, the plurality of projections 54 may be configured, for example, as spaced rails (e.g., forming channels) provided about and along opposing sides of the spouts 20 of the palletized spouted containers 30. As such the projections 54 may provide a space or gap between or over an uppermost portion of a spout 20 relative to a tier sheet 50 (e.g., a top portion 52 of a tier sheet 50). With embodiments a vertical space or gap is provided vertically above the spout 20 of a container 30. For example and without limitation, with embodiments, when a tier sheet 50 is in position with palletized spouted containers 30, all of the portions of the tier sheet 50 may be at a minimum distance of 0.25 inches (6.35 mm) from the spout 20. As such, the tier sheet 50 may protect the spots by providing a safety channel or recess into which the spout extends without contact with the tier sheet 50. The non-contact of the spout 20 with the tier sheet 50 can remain as such even when one or more rows of containers are stacked upon and/or above the tier sheet 50.

Further, as generally illustrated in the figures (including FIG. 5), channels formed by or associated with the projections 54 may be configured such that the weight from stacking and/or forces directed downwardly may be borne by or shouldered by the neck portion (or finish portion) 12 of the spouted container 30 without distributing any substantial force associated with the stacking of such containers upon the spout 20. Such a configuration can provide good weight support and distribution, as well as protection for the spouts 20, as the neck or finish portion 12 of the spouted containers 30 are generally the strongest upper portion of a container for carrying or bearing weight. Embodiments of the present concept may, among other things, also eliminate transfer top load from shoulder portions of the associated containers or other articles. Moreover, providing a channel configuration with the plurality of projections 54 can provide for or permit the inclusion of containers in particular or desired orientations (e.g., by row or row centers), which can make such a system compatible with conventional palletizing apparatus.

FIG. 6 generally illustrates a side view of an embodiment of palletized articles—i.e., spouted containers 30. As generally shown in this view, which is effectively perpendicular to the view shown in FIG. 4, the tier sheets 50 appear in the form of rails (or portions of channels) that extending along a length adjacent to a plurality of spouts 20 (which, while shown, would be on the other side of, and not touching, the illustrated tier sheets 50). The enlarged portion of FIG. 6 that is shown in FIG. 7 generally illustrates portions (i.e., projections 54) of tier sheets 50 that extend substantially linearly or horizontally across a plurality of neck or finish portions 12 of a plurality of spouted containers 30. As the spouted containers 30 are substantially identical in size and shape, the weight of the tier sheet 50, as well as any additional weight from above the tier sheet, will generally be distributed fairly evenly over a plurality of neck portions 12 along the various columns of projections 54.

With reference to FIG. 8, a side view of an embodiment of a tier sheet 50 in accordance with aspects or teachings of the present disclosure is generally illustrated. As further illustrated in FIG. 9, the projections 54 may each have a length L that extend vertically downwardly from a top or upper surface of a top portion 52. For example and without limitation, in an embodiment the length L may be about 1.3125 inches. In embodiments, projections 54 that are disposed on a column ends of a tier sheet 50 may have a substantially vertical side VS and a tapered side TS. Among other things, tapered sides of the plurality of projections 54 can avoid damage and/or assist with locating and positioning of a tier sheet 50 over a plurality of spouts, which can typically be accomplished by dropping or placing/nesting a tier sheet 50 down over or upon a plurality of columns of spouted containers. In embodiments, the vertical side VS may be substantially vertical, and the tapered side TS may have a taper of 10 degrees or less (e.g., T1=6.0 degrees). As generally illustrated in FIG. 9, the projections 54 may be evenly spaced apart from one another (e.g., spaced apart at a portion of the projection at or about where the projection meets the top portion) by a spaced distance SD. In an embodiment, SD may be about 1.4060 inches. Also as generally shown, non-end projections of the tier sheet 50 may each have two tapered sides TS, with each tapered side intended to “face” a different spout in a different column of spouted containers. The projections 54 may have the same or different widths at their ends. As generally shown in the illustrated embodiment of FIG. 9, an end projection may have an end width W1, and a non-end projection may have an end width W2. While W1 may be the same as W2, in embodiments, W2 may be greater than W1. For example and without limitation, W2 may be about 0.2052 inches and W1 may be about 0.1250 inches.

FIG. 10 generally illustrates a side view of another embodiment of a tier sheet 50 in accordance with aspects or teachings of the present disclosure. As generally illustrated in the view of the enlarged portion shown in FIG. 11, distal or end portions of the projections may include tapered side and may further include end portions with a radius. Such a radius may provide a lower profile that is more rounded or one that is “flatter.” That is, the more curved a radius is, the blunter the edges may be, which may, inter alia, improve loading of the tier sheet and may help protect portions of the spouted container, including the spout. Moreover, the inclusion of a radius with the projections may simplify or improve the manufacturing thereof. By way of example and without limitation, the radius may be about 0.0625 or about 0.0938.

FIG. 12 generally illustrates a front view of an embodiment of a plurality of rows (in this instance, eight rows are shown) of spouted articles provided on a pallet. With embodiments, the area associated with a tier sheet 50 (e.g., length times width), and the associated dimensions (length and width) may be less than a corresponding area and length and width dimensions of a pallet. Such a comparative reduced sizing can, among other things, prevent a tier sheet from having portions that extend over or beyond the edges of an associated pallet.

FIG. 13 generally illustrates an enlarged view of a portion of FIG. 12, which illustrates several dimensions associated with a tier sheet and an associated pallet. For example and without limitation, in an embodiment a pallet may have a corresponding length LP of 56.00 inches and a width WP of 44.00 inches, and an associated tier sheet 50 may have a length LTS of less than 56.00 inches and a width WTS of less than 44.00 inches (e.g., 42.8535 inches).

Additionally, as generally illustrated in FIGS. 12 and 13, embodiments of the disclosed system may include a top frame 60. With embodiments, a top frame 60—which may be of the type commonly associated with top frames commonly used with palletizing. In embodiments, the top frame 60 may be provided on top of the uppermost (or top) tier sheet, may be flat or substantially flat, may be configured to protect tier sheets and palletized articles (such as from strapping and/or wrapping), and/or may be comprised of wood or plastic.

FIGS. 14, 15, and 16 generally illustrate top, side, and front views of an embodiment of a pallet 40 in accordance with aspects or teachings of the present disclosure.

Embodiments of the disclosed system with tier sheets may work with existing palletizers, including robot palletizers and/or palletizers that clamp/side grip tier sheets, as well as vacuum tier sheet picking palletizers. As such, the method of palletizing articles, such as spouted containers, in accordance with aspects and teachings of the present disclosure may involve similar steps as conventionally used for palletizing with the substitution of tier sheets as disclosed herein for other conventional tier sheets or separators.

Moreover, as tier sheets may be comprised of a polymer, such tier sheets may be recycled, and potentially re-used. For example, if damaged or otherwise at the end of its useful life, a tier sheet may be recycled and the material may be reused, whether to form new tier sheets or other articles.

Various embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to “various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope thereof.

It should be understood that references to a single element are not necessarily so limited and may include one or more of such elements. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of embodiments.

Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. The use of “e.g.” in the specification is to be construed broadly and is used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. Uses of “and” and “or” are to be construed broadly (e.g., to be treated as “and/or”). For example and without limitation, uses of “and” do not necessarily require all elements or features listed, and uses of “or” are intended to be inclusive unless such a construction would be illogical.

While examples of dimensions of certain components may be described herein, such dimensions are provided as non-limiting examples and the components may have other dimensions.

While processes, systems, and methods may be described herein in connection with one or more steps in a particular sequence, it should be understood that such methods may be practiced with the steps in a different order, with certain steps performed simultaneously, with additional steps, and/or with certain described steps omitted.

It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the present disclosure.

Claims

1. A system for palletizing containers, comprising:

a pallet;

at least two layers, each layer including a plurality of containers having a spout; and

a tier sheet disposed between the layers of plastic containers;

wherein the tier sheet includes a top portion and a plurality of projections that extend downwardly from the top portion of the tier sheet; the projections of the plurality of projections are configured to straddle the spouts of the plurality of containers in a layer below the tier sheet; and a space or gap is provided between an uppermost portion of the spouts and the top portion of the tier sheet provided above the spouts.

2. The system of claim 1, wherein the tier sheet is comprised of a polymer.

3. The system of claim 1, wherein the top portion and the plurality of projections are integrally formed as a single or unitary component.

4. The system of claim 1, wherein, when the tier sheet is in position with palletized spouted containers, all portions of the tier sheet are a minimum distance of 0.25 inches (6.35 mm) from the spout.

5. The system of claim 1, wherein the projections extend along the tier sheet in separated rows and/or columns.

6. The system of claim 1, wherein more than one layer of a plurality of containers is provided above the tier sheet.

7. The system of claim 6, wherein an additional tier sheet is provided between each of the more than one layer of the plurality of containers provided above the tier sheet.

8. A tier sheet for dividing tiers of containers, comprising:

a top portion; and

a plurality of projections that extend downwardly from the top portion;

wherein the tier sheet is comprised of a polymer.

9. The tier sheet of claim 8, wherein the polymer comprises high-density polyethylene (HDPE), polycarbonate (PC), or acrylonitrile butadiene styrene (ABS).

10. The tier sheet of claim 8, wherein the tier sheet is molded.

11. The tier sheet of claim 8, wherein the top portion is substantially flat.

12. The tier sheet of claim 8, wherein the top portion and the plurality of projections are integrally formed as a single or unitary component.

13. The tier sheet of claim 8, wherein the top portion and the plurality of projections are two separate assembled or connected components.

14. The tier sheet of claim 8, the projections extend along the tier sheet in separated rows and/or columns.

15. The tier sheet of claim 8, wherein the projections include substantially vertical sides.

16. The tier sheet of claim 8, wherein one or more projections include at least one tapered side.

17. The tier sheet of claim 8, wherein the at least one tapered side has a taper of 10 degrees or less.

18. The tier sheet of claim 8, wherein a plurality of non-end projections each have two tapered sides.

19. The tier sheet of claim 8, wherein an end projection and a non-end projection have different end widths.

20. The tier sheet of claim 8, wherein one or more projections include end portions having a radius.