NZ578251A

NZ578251A - Gas flow support spacers for cartons stacked in a coolroom

Info

Publication number: NZ578251A
Application number: NZ57825109A
Authority: NZ
Inventors: Royston Douglas Bull
Original assignee: Icon Plastics Pty Ltd
Priority date: 2008-07-11
Filing date: 2009-07-08
Publication date: 2009-11-27
Also published as: AU2009202765A1

Abstract

A support and gas flow panel member 10 for spacing stacked cartons in a coolstore is integrally formed by injection moulding from a plastic material and includes opposed support planes 12, 16 spaced apart by a uniform distance 9. Each support plane has a plurality of support sections 11, 15 spaced from one another in the respective support planes and being defined at least by a perimeter plastic material web 5, 6 with at least one internal gas flow opening 26, 27 within the perimeter web permitting gas flow transversely through the support sections. The support planes are interconnected across the uniform distance by a plurality of separate leg members 17. Each support section in a respective one of the support planes is disposed directly opposite an open zone 7,8 in the other facing plane. The panel can be nested with other similarly formed panels in at least one and conveniently several different relative rotational positions.

Description

578251 1 GAS FLOW SUPPORT SPACERS The present invention relates to improvements in spacer type devices for improving air or gas flow about stored products, particularly where gas or fumes are to be dispersed from the stored products or where cooling or heating gas flow 5 is to be more efficiently supplied to the stored products.

Commonly in food processing such as dairy or similar products, a final step in the processing is to chill or cool the product to a temperature where the processing is complete and the product is capable of being delivered to a retail or wholesale distribution outlet. Such products include yogurts, sour cream and 10 food dips but will also include many other products. Currently these products are packed into final delivery cartons and the cartons are then close packed in a cool room or the like such that the contained products can be chilled to the required temperature. The cartons are close packed to maximize the products being cooled. Such cool rooms commonly develop a flow of cool gas to be blown over 15 the stacked cartons in the cool room such that the outer cartons in the stack cool reasonably quickly, however the cartons in the middle of the stack take a relatively long time to cool down to the desired temperature because the cool air flow to them is obstructed by the carton material itself and the packed cartons stacked around same. To ensure all products are cooled to the required 20 temperature, the cartons can be held in such cool rooms for a long period, for example four days or more. If it were possible to reduce this holding period, the production rate and subsequent delivery rate for a plant producing such products could be substantially improved.

Australian innovation patent specification no. 2007100634 discloses an air 25 or gas flow spacer material panel adapted for positioning between stacked cartons or similar packed items adapted to improve the air or gas flow around such packed items. The spacer material panel is formed by thermoplastic mesh material that is then formed to have spaced upper and lower support planes formed by the strands of the mesh material. This type of gas flow spacer has 30 worked well but the strands forming the mesh material provide some degree of obstruction to the gas flow around the stacked items and towards the stacked items when the mesh has relatively small openings or where the strands forming the mesh are relatively thick. When the mesh openings are large or where the 578251 2 strand material is thin, the formed spacer panel may not have the required strength to store heavy loads.

It is also generally desirable that the gas flow spacer material be stackable and nest into one another without having directional sensitivity, ie that they nest 5 and stack without requiring a particular orientation.

The objective of the present invention is to provide an improved gas flow spacer material panel of the abovementioned type that minimizes any obstruction to air or gas flow about the items stored thereon. A further objective of the present invention is to provide an improved gas flow spacer material panel that 10 will nest into similarly formed panels, preferably in a plurality of relative positions.

Accordingly, in a first aspect of this invention there is provided a support and gas flow panel member for at least one stored object, the support and gas flow pane! member being integrally formed from a plastic material having opposed support planes spaced apart by a uniform first distance, each said 15 support plane having a plurality of support sections spaced from one another in the support plane with each said support section being defined by a perimeter plastic material web with at least one internal gas flow opening within said perimeter plastic material web permitting gas flow transversely through the support section, the support sections in each said support plane being connected 20 to at least one support section in the other said support plane by a plurality of separate leg members, each said support section in one said support plane being disposed directly opposite an open zone in the other said support plane, whereby a first said panel member positioned overlaying a second similar said panel member will nest into the second said panel member.

Preferably the first panel member will nest into said second panel member in at least two different relative rotational positions. Conveniently, the support and gas flow panel member has a square or rectangular perimeter edge region and a pattern of said support sections in each said support plane being divided by a median line between two opposed edges of said perimeter edge region of said 30 panel member.

In a further preferred configuration, the support and gas flow panel member is such that the first panel member will nest into the second panel member in four different relative rotational positions. In this embodiment, the 578251 3 panel member has a square or rectangular perimeter edge region and a pattern of said support sections in each said support plane is divided by four median line sections, each said median line section extending from a centre of the panel member to an edge of the perimeter edge region of said panel member.

Preferably, the perimeter plastic material web of at least some and conveniently most of said support sections define a rectangular perimeter shape in a said support plane having two opposed side edge webs and two opposed end edge webs, at least one intermediate connecting web extending between said side edge webs. Conveniently gas flow in a direction parallel to and between 10 said support planes is obstructed only by said leg members. Preferably, the panel member has a square or rectangular perimeter edge region and when viewed perpendicular to said perimeter edge region parallel to said support planes, the leg members are arranged in aligned rows.

Further preferred features may be as defined in claims 8 to 18 inclusive as 15 annexed hereto, the subject matter of these claims being included in the disclosure of this specification by this reference thereto.

According to a further aspect of the present invention, there is provided a support and gas flow panel member for at least one stored object, the support and gas flow panel member being integrally formed from a plastic material having 20 opposed support planes spaced apart by a uniform first distance, each said support plane having a plurality of support sections spaced from one another in the support plane with each said support section being defined by a perimeter plastic material web with at least one internal gas flow opening within said perimeter plastic material web permitting gas flow transversely through the 25 support section, the support sections in each said support plane being connected to at least one support section in the other said support plane by a plurality of separate leg members each having a thickness and a width, the leg members in a first direction parallel to said support planes being arranged in aligned groups on either side of a respective said support section or a respective group of said 30 support sections extending across said panel member, the leg members in each said aligned group presenting substantially only the thickness of one of said leg members in the aligned group as an obstruction to gas flow in said first direction. 578251 4 Conveniently, the panel member may include a plurality of first said support sections in a first one of said support planes where said first support sections are transversely spaced from one another and extend between opposed edge regions of said panel member. The panel member may further include a 5 plurality of second said support sections in a second one of said support planes where said second support sections are transversely spaced from one another each said second support section being located between a pair of said first support sections.

Preferably, a respective said aligned group of said leg members connect a 10 lateral edge of a said first support section to a lateral edge of a said second support section. Gas flow in a direction perpendicular to the first direction is obstructed by a multiple of the widths of said leg members in a said aligned group of said leg members. Conveniently in said direction perpendicular to said first direction, the leg members in adjacent said groups are respectively aligned. 15 Preferably a flange member extends peripherally around the panel member and may be wider than each said leg member. Conveniently, at least one web member extends across the internal gas flow opening in each said support section. Preferably the web member or members are arranged transverse to the first direction. Conveniently each said web member is aligned 20 with a said leg member. Preferably the support sections and said leg members have a substantially uniform thickness. Preferably adjacent groups of said aligned leg members are splayed outwardly relative to one another, conveniently forming an angle of between 5 and 15° to the vertical (preferably about 8°).

The support and gas flow panel member as described above provides an 25 arrangement that minimizes gas flow obstruction to gas flow about items stacked on or under the panel member, particularly when gas flow is directed substantially in the first direction.

A preferred embodiment will hereafter be described with reference to the accompanying drawings, in which: Fig 1 is a perspective view of a preferred panel member constructed according to the present invention; Fig 2 is an enlarged detail view of a comer region of the panel member shown in Fig 1; 578251 Fig 3 is a schematic plan view of the panel member shown in Fig 1; Fig 4 is a schematic side view of the panel member shown in Fig 1 viewed in a first direction; Fig 5 is a schematic side view of the panel member shown in Fig 1 viewed 5 perpendicular to the first direction; Fig 6 is a perspective view of another preferred embodiment; Fig 7 is a detailed perspective view of the embodiment shown in Fig 6; Fig 8 is a perspective view of yet another preferred embodiment; Fig 9 is a detailed perspective view of the embodiment of Fig 8; 10 Fig 10 is a perspective view of a still further preferred embodiment; Fig 11 is a detailed perspective view of the embodiment of Fig 10; Fig 12 is a schematic elevation view showing the panel member in use stacking a plurality of cartons; and Fig 13 is a schematic illustration of processes utilizing the panel member 15 shown in earlier drawings.

Referring to Figs 1 to 5 of the drawings, a first preferred embodiment of a panel member 10 is illustrated. The panel member 10 has first support sections 11, all located in a first support plane 12 and spaced from one another. Each of the first support sections 11 extend from one edge 13 of the panel member 10 to 20 an opposed edge 14 of the panel member 10. The panel member 10 further has a plurality of second support sections 15 all arranged in a second support plane 16 spaced from but parallel to the first support plane 12. The second support sections 15 also extend between the panel member edges 13 and 14 and are generally located between the first support sections 11. A plurality of aligned 25 upright leg members 17 are positioned spaced from one another between the panel member edges 13 and 14 and connect the first and second support sections 11, 15. The leg members have a thickness facing the edges 13, 14 of the panel member 10 and a width facing the edges 18, 19 of the panel member 10 joining the edges 13, 14. The leg members 17 all have substantially the same 30 length to define a uniform distance 9 between first support plane 12 and the second support plane 16.

Conveniently, the panel member 10 includes a relatively wide flange member 20 along each of the edges 18, 19 generally in the first support plane 12 578251 6 and a widened flange member 21 (Fig 3) along each of the edges 13, 14 of the panel member 10. The flange members 20 and 21 provide stability to the panel member 10, particularly when used as described hereafter.

Each of the first and second support sections 11,15 comprise a perimeter 5 plastic material web 5, 6 formed by bar members 22, 23 and 24, 25 extending generally between the edges 13, 14 of the panel member 10, the bar members 22, 23 and 24, 25 define lateral edge regions of the support sections 11, 15. The perimeter plastic material webs 5, 6 are completed by end connecting webs 28, 29 at the edges 13,14. A generally large open space 26 is provided between the 10 bar members 22, 23 and a similar large open space 27 is provided between the bar members 24, 25 to allow easy air or gas flow in a direction perpendicular to the support planes 12 and/or 16. For stability of the panel member 10 it is desirable that one or more further connecting web members 28, 29 respectively join the bar members 22, 23 and the bar members 24, 25 between the panel 15 edges 13, 14. Conveniently the connecting web members 28, 29 may be equal in number to the leg members 17 and be generally aligned therewith. Each of the support sections 11, 15 are directly opposite an open zone 7, 8 in the respective support planes 12, 16. For greater strength the bar members 22, 23 and 24, 25 may be thickened or chamfered at 5 as best seen in Fig 2. If greater strength is 20 required, the width of the leg members 17 might be increased or alternatively the number of the leg members might be increased to provide a greater compressive strength between the support sections 11 and 15. As can be seen in the drawings, adjacent groups of the leg members 17 are splayed relative to one another defining an angle of about 8° to the vertical to enable panel members of 25 this configuration to be stacked into one another when not in use.

As can be seen in the drawings, the support panel 10 provides substantially free air or gas flow in a direction 30, ie parallel to the support planes 12, 16, between the edges 13, 14. The only obstruction (Fig 4) to this flow is the thickness of the leg members 17 and the bar and web members 22, 23, 28 and 30 24, 25, 29. Gas flow obstruction in a direction parallel to the support planes 12, 16 perpendicular to the direction 30 (Fig 5) is slightly higher but still reasonably open. The same applies to gas flow perpendicular to the planes 12, 16, either upwardly or downwardly. 578251 7 Figs 6 and 7 illustrate another possible embodiment similar to Figs 1, 2 except that the first support sections 11 in the first support plane 12 are discontinuous across the panel member 10 with a plurality of spaced openings 60 being formed therein. This embodiment also includes bridging parts 61 5 connecting adjacent first support sections 11 at spaced locations between the edges 13, 14. The arrangement, however remains such as to allow similarly formed panel members 10 to be stacked into one another when in a particular orientation. Figs 8, 9 show yet another embodiment which is again similar to Figs 6, 7 except that adjacent panel members can stack into one another in either of 10 two orientation positions rather than one in the case of Figs 6, 7. Figs 10, 11 is yet another embodiment similar to Figs 6 to 9 except that support sections 11 and in the support planes 12, 16 are formed in quarter zones whereby they can stack into one another in any of three different orientations. In this manner, the worker can stack the panel members easily without worrying about their orientation. The quarter (corner) sections are the same except their relative orientation is varied from corner to corner.

The panel member 10 as shown in Figs 1 to 11 may be produced by injection moulding techniques or alternatively by producing the mesh like structure of the panel member 10 in the form of a generally flat sheet with the 20 sheet then being vacuum formed or similar to the three dimensional structure as illustrated. In the embodiment illustrated in Figs 1 to 5, the support sections 12, 16 are shown extending fully across the panel member 10 between the edges 13 and 14. It is, however, also possible to produce the support sections 11, 15 as discrete portions separated by troughs on each side to provide a checker board like appearance of support sections 11, 15 in the respective support planes 12, 16.

Fig 12 illustrates a possible stacking arrangement in a cool room situation or the like where a first panel member 10 is positioned on a support surface 31 of any suitable kind with an array of cartons (or similar) 32 stacked thereon, 30 preferably leaving gas flow spaces 33 therebetween. A second panel member 10' may then be placed on the first layer of cartons 32 with a second layer of cartons 34 positioned there above as shown. Further layers of panel members 10" and cartons 35 can be stacked there above as illustrated. The arrangement INTELLECTUAL PROPERTY OFFICE OF N.Z.

SEP 2009 RECEIVED 578251 8 is restricted by space requirements in any cool room racking situation and by the load carrying capacity of the lowermost panel member 10. In the arrangement illustrated cooling air might be directed towards the stack of cartons 32, 34, 35 (ie into or out of the page as illustrated) whereby the cooling air flows between the 5 layers of cartons and upwardly or downwardly through the internal spaces 33. As the maximum amount of cooling air reaches all of the outer surfaces of every carton stacked as opposed to conventionally close stacking of cartons, the products within the cartons cool down considerably more quickly. It is believed that cooling retention times in the cool room can be reduced up to 50%. Even if 10 the cartons are close packed on the panel member not leaving any gaps 33 as shown in Fig 12, cooling air flow still searches the top and bottom surfaces of all of the cartons allowing the contained products to cool or chill down to the required temperature much more quickly.

Fig 13 illustrates schematically a possible method of utilizing panel 15 members 10 in accordance with the present invention. A cool room stacking of cartons 32 to be cooled is shown at 36 with each stack of cartons 32 being identified by the numeral 37. Each stack 37 comprises typically a lower pallet 44, a layer of cartons or similar 32, a panel member 10 and a further layer of cartons 32 with the stack being built up with panel members 10 between each layer of 20 cartons 32. As with Fig 12, cooling air is conveniently delivered in a direction into or out of the page generally over the stacked cartons in the racking 38. Once cooling is completed, a stack 37 of cartons 32 is moved to a reprocessing station 39 where a dedicated robot 40 lifts each layer of cartons 32 off the stack and repositions same on a delivery pallet 41. The panel members 10 are sequentially 25 picked up by a second robot 42 and packed onto a second pallet 43. The pallet 41, once stacked as desired might be wrapped with stretch plastics film and then forwarded to a dispatch station 45 or the like. The pallets 44 might be moved to a pallet storage area 46 by the robot 42 or by other suitable means.

While a preferred embodiment has been illustrated in the drawings and 30 described above, it will be appreciated that many variations or modifications could be made falling within the scope of the annexed claims which are hereby made part of the disclosure of this specification by this reference thereto.

I ' 5 SEP 2089 I IRECFiyp q 578251 9

Claims

WHAT WE CLAIM IS:

1. A support and gas flow panel member for at least one stored object, the support and gas flow panel member being integrally formed from a plastic material having opposed support planes spaced apart by a uniform first distance, each said support plane having a plurality of support sections spaced from one another in the support plane with each said support section being defined by a perimeter plastic material web with at least one internal gas flow opening within said perimeter plastic material web permitting gas flow transversely through the support section, the support sections in each said support plane being connected to at least one support section in the other said support plane by a plurality of separate leg members, each said support section in one said support plane being disposed directly opposite an open zone in the other said support plane, whereby a first said panel member positioned overlaying a second similar said panel member will nest into the second said panel member.

2. A support and gas flow panel member according to claim 1 wherein the first said panel member will nest into said second panel member in at least two different relative rotational positions.

3. A support and gas flow panel member according to claim 2 wherein the panel member has a square or rectangular perimeter edge region and a pattern of said support sections in each said support plane being divided by a median line between two opposed edges of said perimeter edge region of said panel member.

4. A support and gas flow panel member according to claim 1 wherein the first panel member will nest into said second panel member in four different relative rotational positions.

5. A support and gas flow panel member according to claim 4 wherein the panel member has a square or rectangular perimeter edge region and a pattern of said support sections in each said support plane is divided by four median line sections, each said median line section extending from a centre of the panel member to an edge of the perimeter edge region of said panel member. 578251 10

6. A support arid gas flow panel member according to any one of claims 1 to 5 wherein said perimeter plastic material web of at least some of said support sections define a rectangular perimeter shape in a said support plane having two opposed side edge webs and two opposed end edge webs, at least one intermediate connecting web extending between said two opposed side edge webs.

7. A support and gas flow panel member according to any one of claims 1 to 6 wherein gas flow in a direction parallel to and between said support plans is obstructed only by said leg members.

8. A support and gas flow panel member according to claim 7 wherein the panel member has a square or rectangular perimeter edge region and when viewed perpendicular to said perimeter edge region parallel to said support planes, the leg members are arranged in aligned rows.

9. A support and gas flow panel member according to claim 1 wherein the plurality of separate leg members each have a thickness and a width, the leg members in a first direction parallel to said support planes being arranged in aligned groups on either side of a respective said support section or a respective group of said support sections extending across said panel member, the leg members in each said aligned group presenting substantially only the thickness of one of said leg members in the aligned group as an obstruction to gas flow in said first direction.

10. A support and gas flow panel member according to claim 9 including a plurality of first said support sections in a first one of said support planes where said first support sections are transversely spaced from one another and extend between opposed edge regions of said panel member.

11. A support and gas flow panel member according to claim 10 including a plurality of second said support sections in a second one of said support planes where said second support sections are transversely spaced from one another 578251 11 and each said second support section is located between a pair of said first support sections.

12. A support and gas flow panel member according to claim 11 wherein a respective said aligned group of said leg members connect a lateral edge of a said first support section to a lateral edge of a said second support section.

13. A support and gas flow panel member according to claim 12 wherein gas flow in a direction perpendicular to said first direction is obstructed by a multiple of the widths of said leg members in a said aligned group of said leg members.

14. A support and gas flow panel member according to any one of claims 9 to 13 wherein a flange member extends peripherally around the panel member.

15. A support and gas flow panel member according to any one of claims 9 to 14 wherein at least one connecting web member extends across the internal gas flow opening in each said support section.

16. A support and gas flow panel member according to claim 15 wherein a said connecting web member is aligned with each said leg member.

17. A support and gas flow panel member according to any one of claims 9 to 16 wherein the support sections and said leg members have a substantially uniform thickness.

18. A support and gas flow panel member according to claim 9 wherein adjacent groups of said aligned leg members are splayed outwardly relative to one another.