Stock material or miscellaneous articles – Structurally defined web or sheet – Fold at edge
Reexamination Certificate
1999-05-26
2001-05-29
Loney, Donald J. (Department: 1772)
Stock material or miscellaneous articles
Structurally defined web or sheet
Fold at edge
C428S126000, C428S155000, C428S181000
Reexamination Certificate
active
06238770
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to tier sheets used to separate a layered and stacked arrangement of packages to be shipped, such as layers of soda bottles or canned goods, and also relates to methods of manufacturing such tier sheets.
Bottling companies and other companies in the food industry often ship products in multiple layers on pallets, with each layer separated by a tier sheet that adds stability to the stack. At least in the bottling industry, cardboard is used because it is low cost and lightweight, and further it is easily disposed of. However, cardboard suffers from short life, such that it must be thrown away after only a limited number of cycles of use, such as about five-trip cycles. Further, cardboard can generate dust as edges of the cardboard become worn. Further, the edges of cardboard can collect debris and unsanitary particles or provide a place for insects to hide. Also, cardboard is sensitive to water and moisture, both in terms of degrading strength of the cardboard and also in terms of the cardboard soaking up the water and holding it while molds and germs grow.
Cardboard tier sheets commonly include folded edges that are glued in place to form a lipped edge that helps retain individual packages on the tier sheets. However, the glue adds expense to the tier sheet, and further glue is a separate material that requires separate application to the cardboard, as well as time to dry. Also, the glue can break off, adding to the debris. Still further, unless the glue is continuously applied along the edges, the edges may form gaps, which gaps can collect debris, unsanitary materials, and insects.
Accordingly, a tier sheet solving the aforementioned problems and having the aforementioned advantages is desired.
SUMMARY OF THE PRESENT INVENTION
In one aspect of the present invention, a plastic tier sheet is provided for use in layered and stacked arrangements of bottles and similar packages to assist in shipping and handling the bottles and similar packages. The plastic tier sheet includes a tier sheet made from a plastic sheet with linear edges and score lines spaced from but parallel the linear edges. The score lines divide the plastic sheet into a center panel and edge flanges around the center panel, and are deep enough into the plastic sheet to allow the edge flanges to uniformly fold, but to leave material forming integral hinges connecting the edge flanges to the center panel. The edge flanges are folded back onto the center panel and include material of the edge flanges bonded to material of the center panel. The edge flanges characteristically lie flat against the center panel. Thus, there are substantially no gaps between the edge flanges and the center panel, thus minimizing collection of debris, unsanitary matter, and insects.
In another aspect of the present invention, a method of manufacturing plastic tier sheets is provided for use in layered and stacked arrangements of bottles and similar packages to assist in shipping and handling. The method comprises steps of providing a flat plastic sheet with linear edges, the plastic sheet having a stiffness sufficient to act as a separator to separate layers of packaged materials and to stabilize a stack of such layers. The method further includes scoring lines into the plastic sheet at locations spaced from but parallel the linear edges, the score lines dividing the plastic sheet into a center panel and edge flanges around the center panel, with the score lines being relatively deep into the plastic sheet, but leaving material forming integral hinges connecting the edge flanges to the center panel. The method still further includes folding the edge flanges back onto the center panel and bonding the edge flanges to the center panel, with the edge flanges characteristically lying flat against the center panel to form a tier sheet with substantially no gaps between the edge flanges and the center panel.
In yet another aspect of the present invention, a method includes steps of providing a plastic sheet having edges forming a rectangular perimeter, notching corners in the sheet, and forming the sheet parallel the edges of the sheet to form integral hinges and edge flanges connected to a center panel of the sheet by the integral hinges. The method further includes folding the edge flanges against the center panel and bonding the edge flanges to the center panel. In a narrower form, the step of forming includes scoring the sheet along the edge flanges to form the integral hinges.
These and other features, objects, and advantages of the present invention will become apparent to a person of ordinary skill upon reading the following description and claims together with reference to the accompanying drawings.
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Loney Donald J.
Plastic Tier Sheet, Inc.
Price Heneveld Cooper DeWitt & Litton
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