EP0231727A2

EP0231727A2 - A composite packaging structure for the protection of domestic appliances in transit, and method of making same

Info

Publication number: EP0231727A2
Application number: EP86830062A
Authority: EP
Inventors: Alvise A.M.D. Di Dellai E Miramondi S.N.C. Dellai
Original assignee: Amd Di Dellai E Miramondi SNC
Current assignee: Amd Di Dellai E Miramondi SNC
Priority date: 1985-12-27
Filing date: 1986-03-14
Publication date: 1987-08-12
Also published as: YU68986A; IT1186512B; EP0231727A3; ES553777A0; IT8523394A0; ES297049U; ES297049Y; ES8802124A1

Abstract

A composite packaging structure comprises a frame-like member (21) of expanded polystyrene with a peripheral step shaped to receive one end of a domestic electrical appliance to be packaged thereby, and a sheet or film of rigid impermeable material (6) shaped as a tray and peripherally bonded to the frame-like member.

A process for the production of the composite packaging structure of the invention comprises hot moulding the frame-like member (2) in a mould cavity comprising two dies (7,8) opening the mould by displacement of a movable one of the dies (8), stretching the film over the fixed die (7), reclosing the mould and subjecting the contents to a second heating under pressure to heat-form the film to a tray-like shape and at the same time bond it to the frame member (2).

Description

The present invention relates to a composite packaging structure for the protection of the upper and lower ends of domestic appliances in transit, in particular for the protection of domestic electrical appliances of significant weight, such as refrigerators, washing machines, dish washers (known as "white" goods because they are conventionally made with a white enamel casing), which need for their transport, a packaging of adequate rigidity able to protect the surfaces thereof, and in particular the corners, from damage.
Known packaging structures for this purpose comprise a base element and a similar or identical upper element which are fitted over the upper and lower ends of the domestic electrical appliance to be protected and held together by bands of strapping material. These two packaging elements are conventionally made of an expanded polystyrene structure generally in the form of a frame able to protect the corresponding base and upper surface portions of domestic electrical appliances in general. However, the strapping bands by which the said packaging elements are fixed to the domestic electrical appliance have to be tensioned tightly to retain the packaging in position and this often causes unwanted splitting of the structure of the elements themselves thereby weakening them significantly.
In order to try and overcome this disadvantage it has been proposed to incorporate the protective frame structures into box-like cardboard bodies to provide protection for the expanded polystyrene structure, but unfortunately cardboard does not have any degree of resistance to liquids and it is often the case that liquids escape from packaged domestic electrical appliances because there are residues of liquid left in them following testing operations effected on the appliances themselves before packaging.
The present invention seeks therefore to eliminate the above-discussed disadvantages of the prior art packaging structures by providing a composite structure for the protection of the surfaces of domestic electrical appliances in transit which is able to resist the effects of the tension exerted by the strapping bands which secure the various parts of the packaging together. In particular, the present invention also seeks to provide a composite packaging structure for the protection of the upper and lower ends of domestic electrical appliances which is water impermeable and therefore able to maintain its appearance even in the presence of a loss of liquids from the packaged appliance.
The present invention also comprehends a method of making a packaging structure using simple techniques and extremely simple apparatus.
According to one aspect of the present invention, there is provided a composite packaging structure for the protection of surfaces and corners of domestic electrical appliances, comprising a frame-like member of mouldable material such as expanded polystyrene, characterised by the fact that the said frame-like member of mouldable material is provided with a covering layer of rigid impermeable material bonded thereto and extending in the form of a tray over the space defined by the frame.
In another aspect, the present invention provides a process for the production of a composite packaging structure, characterised by the fact that it comprises the steps of moulding a frame-like member of mouldable plastics material in a mould cavity comprising a fixed die and a movable die, and subsequently opening the mould cavity and stretching a sheet or film of impermeable plastics material between one of the dies and the preliminarily formed frame-like member, closing the mould and subjecting the contents thereof to a second heating under pressure.
Embodiments of the present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is an exploded view showing two elements which, when coupled together, form the composite packaging structure of the invention;
Figure 2 is a perspective view of the composite packaging structure formed by combining the two elements shown in Figure 1;
Figure 3 is a plan view from above of the structure shown in Figure 2;
Figures 4,5,6 and 7 are schematic diagrams illustrating the manufacturing process for the composite structure of the present invention.

Referring now to the various Figures of the attached drawings, there is shown a composite structure 1 for packaging domestic electrical appliances, which is substantially constitutted by a frame-like element 2, provided with a perimetral step 3 able to receive one of the ends of an unspecified domestic electrical appliance (not shown) and made of suitable expanded plastics material, preferably polystyrene in granules or "beads".
This frame or framework has convenient perimetral seats 4 in which are housed the ends of suitable struts (not shown) which serve to interconnect a pair of such frames forming the package as a whole. These struts also act as protection elements for the corners of the lateral walls of the packaged domestic electrical appliance. To the peripheral outer edges of the frame 2 there are fixed the peripheral portions 5 of a sheet or film 6 of rigid plastics, such as polystyrene, able to constitute, with the frame itself, an element substantially similar to a tray which is capable of retaining liquids, provided it remains in a substantially horizontal position. By means of this constructional arrangement the possible loss of liquids from a packaged domestic electrical appliance consequent on the testing operations performed thereon do no therefore damage the packaging, even aesthetically.
The production process for the present structure involves the use of a pair of dies, namely a fixed die 7 and a movable die 8. Centrally of the fixed die there is formed a hole which serves for the passage of an injection nozzle 9 constituting the end of an injection unit generally indicated 10 and provided with a hopper 11 for supply of the material to be moulded. This material is constituted by polystyrene in granules or "beads" and is injected into the die cavity after closure thereof by displacing the movable die 8 into contact with the fixed die 7. The polystyrene is then subjected to a first heating (Figure 4). After this first heating operation, the movable die 8 is removed to open the mould cavity and the workpiece 2, now shaped as a frame, remains adherent to it. After the opening of the mould, a film of rigid polystyrene 6 is stretched over the fixed die 7, being supplied from a suitable coil 12. Instead of polystyrene, the film 6 may be constituted by a polypropylene-aluminium laminate, or a PVC-aluminium laminate or the like.
Subsequently, as shown in Figure 6, the two moulds are closed and a second heating of the materials therein is effected in such a way as to obtain a stable connection of the expanded polystyrene frame and the rigid polystyrene or laminated film. Finally, (Figure 7) the mould is opened and the formed workpiece, 1 is removed.
From what has been explained hereinabove, and from observation of the various Figures of the attached drawings, the great functionality and practicality in use which characterises the composite packaging structure for the protection of the surfaces and corners of white domestic electrical goods in general will be appreciated.

Claims

1. A composite packaging structure for the protection of the surfaces and corners of domestic electrical appliances, comprising a frame-like member (2) of mouldable material such as expanded polystyrene, characterised by the fact that the said frame-like member of mouldable material is provided with a covering layer (6) of rigid impermeable material bonded thereto and extending in the form of a tray over the space defined by the frame.

2. A composite packaging structure according to Claim 1, characterised by the fact the said frame-like member (2) is provided with a perimetral step (3) defining a recess for receiving one end of a domestic electrical appliance, the frame-like member (2) being made of a suitable expanded plastics material such as expanded polystyrene.

3. A composite packaging structure according to Claim 1 or Claim 2, characterised by the fact that the said frame-like member (2) has a plurality of perimetral seats (4) for receiving the ends of substantialy rigid struts for connecting together a pair of frame-like members to complete a package, the struts also servicing as protection elements for the corners of the lateral walls of the packaged appliance

4. A composite packaging structure according to any of the preceding Claims, characterised by the fact that the said sheet of rigid impermeable material (6) is bonded at its peripheral edges to the edges of the said frame-like member (2).

5. A composite packaging structure according to any preceding Claim, characterised in that the sheet of rigid impermeable material (6) is composed of rigid plastics material such as rigid polystyrene, or a laminate of plastics materials, or a plastics and a metal, such as aluminium and polypropylene.

6. A process for the production of a composite packaging structure according to any of the preceding Claims, characterised by the fact that it comprises the steps of moulding a frame-like member of mouldable plastics material in a mould cavity comprising a fixed die (7) and a movable die (9), and subsequently opening the mould cavity and stretching a sheet or film of impermeable plastics material (6) between one of the dies (7) and the preliminarily formed frame-like member (2), closing the mould and subjecting the contents thereof to a second heating under pressure.

7. A process according to Claim 6, characterised by the fact that upon opening of the said mould by displacement of the movable die (8) the preliminarily moulded frame-like member (2) remains adherent thereto and the said sheet or film of rigid plastics such as polystyrene, supplied from a coil is stretched over the fixed die (7) prior to reclosure of the mould for the second heating operation.

8. A process according to Claim 6 or Claim7, characterised by the fact that during the second heating within the mould cavity the impermeable plastics sheet or film (6) is bonded at its periphery to the said frame-like member (2) to form a permanent and stable union of the frame-like member (2) and the sheet or film of rigid impermeable material whilst at the same time this latter is heat-formed to the shape of a tray.