Stacking apparatus and method of stacking elongate items

Abstract

Stacking apparatus comprising a contour plug and an insert for stacking and securing a stack of irregularly contoured items. Contour plug and insert fit between two stacked items to hold them in alignment and prevent shifting; the insert has a loop for receiving a restraining strap. The stacking apparatus remains with a stacked product from manufacture to final delivery.

What is claimed is:  
     
         1 . A first stacking device for stacking items, each item having an outer side and an irregular contour, said contour including a lower contour, an upper contour, said first stacking device comprising: 
 an insert having a first contour and a second contour, and a restraining loop through which a restraining strap is insertable,    wherein said first contour of said insert corresponds to said upper contour of a first item and said second contour of said insert corresponds to said lower contour of a second item so as to provide a form-positive fit with said first item and said second item, and    wherein, when said insert is inserted between said first item and said second item, said restraining loop of said insert extends beyond said outer side of said first item and said second item.    
     
     
         2 . The first stacking device of  claim 1 , wherein said insert is formed as a contoured sheet having a first end and a second end, and wherein said insert is foldable such that said first end and said second end overlap each other.  
     
     
         3 . The first stacking device of  claim 1 , wherein said insert is made of one or more materials from a group consisting of synthetic material, rubber, plant fiber, and metallic materials.  
     
     
         4 . The first stacking device of  claim 3 , wherein said synthetic material is a thermoformed plastic.  
     
     
         5 . The first stacking device of  claim 3 , wherein plant fiber includes paper products.  
     
     
         6 . The first stacking device of  claim 5 , wherein said paper products includes cardboard.  
     
     
         7 . The first stacking device of  claim 5 , wherein said paper product includes coated paper.  
     
     
         8 . The first stacking device of  claim 3 , wherein said insert is made substantially of sheet metal.  
     
     
         9 . A second stacking device for stacking items, each item having an irregular contour, said contour including a lower contour and an upper contour, said second stacking device comprising: 
 a contour plug having a first contour and a second contour, wherein said first contour of said contour plug corresponds to and is insertable into said upper contour of a first item and said second contour of said contour plug corresponds to and is insertable into said lower contour of a second item so as to provide a form-positive fit with said first item and said second item.    
     
     
         10 . The second stacking device of  claim 9 , wherein said contour plug is a form-rigid plug of material that is sufficiently stiff to support said items to be stacked.  
     
     
         11 . The second stacking device of  claim 10 , wherein said contour plug is made off material from the group consisting of rubber, synthetic material, and plant fiber.  
     
     
         12 . The second stacking device of  claim 11 , wherein said synthetic material is extruded polystyrene.  
     
     
         13 . The second stacking device of  claim 12 , wherein said polystyrene has a density of about 2.2 lb/ft 3  or greater.  
     
     
         14 . The second stacking device of  claim 11 , wherein said plant fiber includes paper products.  
     
     
         15 . The second stacking device of  claim 14 , wherein said paper product is corrugated cardboard.  
     
     
         16 . A third stacking device for stacking items, each item having an irregular contour, wherein each of said items has a lower contour and an upper contour, said third stacking device comprising: 
 a universal plug having a lower portion with a form-rigid contour and an upper portion, and    wherein said form-rigid contour of said universal plug corresponds to and is insertable into said upper contour of a first item and said upper portion of said universal plug is relatively soft so that it is compressible by a second item that is placed on top of said universal plug so as to provide a form-positive fit of said universal plug with said first item and secure seating for said second item.    
     
     
         17 . The third stacking device of  claim 16 , wherein said universal plug is made substantially of a material from the group consisting of rubber, wood, plant fiber, glass fiber, synthetic material and metallic material.  
     
     
         18 . The third stacking device of  claim 17 , wherein said lower portion has a first density and said upper portion has a second density, wherein said synthetic material is extruded polystyrene and said first density is greater than that of said second density.  
     
     
         19 . The third stacking device of  claim 18 , wherein said density of said lower portion is greater than 2.2 lb/ft 3 .  
     
     
         20 . The third stacking device of  claim 16 , wherein said universal plug is made of a combination of material, said lower portion having a density greater than said upper portion.  
     
     
         21 . A stacking apparatus for stacking items having irregular contours, each of said items having a lower contour, an upper contour, and an outer side, wherein said items include a first item and a second item, said apparatus comprising: 
 an insert having a first insert contour and a second insert contour, and a restraining loop, wherein said first insert contour corresponds to and is insertable into said upper contour of said first item and said second insert contour corresponds to and is insertable into said lower contour of said second item so as to provide a form-positive fit of said insert with said first item and said second item, and wherein said restraining loop of said insert extends beyond said outer side of said first item and said second item;    a contour plug having a first plug contour and a second plug contour, wherein said first plug contour of said contour plug corresponds to and is insertable into said upper contour of said first item and said second plug contour of said contour plug corresponds to and is insertable into said lower contour of said second item so as to provide a form-positive fit with said first item and said second item.    
     
     
         22 . The apparatus of  claim 22 , further comprising a universal plug having a lower portion with a first contour and an upper portion, 
 wherein said first contour of said universal plug corresponds to and is insertable into said upper contour of said first item and said upper portion of said contour plug is relatively soft so that it is conformable to said upper contour of said second item so as to provide a form-positive fit with said first item and secure seating for said second item.    
     
     
         23 . The apparatus of  claim 23 , wherein said universal plug is said third stacking device of  claim 16 .  
     
     
         24 . The apparatus of  claim 22 , wherein said insert is said first stacking device according to  claim 1 .  
     
     
         25 . The apparatus of  claim 22 , wherein said contour plug is said second stacking device according to  claim 9 .  
     
     
         26 . A method of stacking elongate items, using the stacking apparatus of  claim 22 , wherein a stack includes a plurality of items, including a first item, a second item, a third item, a penultimate item, and a final item, said method comprising the steps of: 
 a) placing at least one said insert between said first item and said second item, wherein said stack has an outer side and said loop of said insert extends beyond said outer side of said stack;    b) placing at least one said contour plug between said second item and said third item;    c) placing at least one said contour plug between any two adjacent items that are situated between said third item and said penultimate item;    d) placing at least one said insert between said penultimate and said final item, wherein said loop of said insert extends beyond said outer side of said stack.    
     
     
         27 . Said method of  claim 26 , further comprising the step of: 
 inserting a restraining means through each said loop of said inserts in said stack and securing said stack to a bundle.