End support for wound rolls made from molded paper pulp

Abstract

An improved monolithic end support, made from paper pulp and adapted for supporting a roll of material wound on a substantially tubular core during shipping and storage. The roll of material has a predetermined weight up to about 70 lbs. (32 kg). The end support of the invention supports the roll of material in a substantially horizontal orientation. The end support includes a substantially planar rim and a central hub. The rim includes an annular rib, disposed about the hub, defining an annular support region therebetween. The annular support region and the hub have predetermined minimum cross-sectional thickness of a value sufficient for the end support to pass the Test in Test Procedure 2A of the International Safe Transit Association at the predetermined weight of the material and core.

What is claimed is:  
     
         1 . An improved monolithic end support, adapted for supporting a roll of material wound on a substantially tubular core in a substantially horizontal orientation, said material and core having a predetermined weight up to about 70 pounds (32 kg), said improved end support comprising: 
 a substantially planar rim having at least one flat base member;    a central hub member affixed to said rim in the shape of a frustum, said frustum defining a central axis, said central axis being substantially normal to said planar rim, and said central hub member defining a wall having a first predetermined cross-sectional thickness measured in a direction perpendicular to the central axis;    an annular rib formed in said planar rim and disposed circumferentially about said central hub;    said annular rib and said central hub defining an annular core support region on said rim, disposed adjacent said central hub, said annular core support region having a second predetermined cross-sectional thickness measured in a direction parallel to the central axis at a plurality of locations in the annular support region;    said end support being molded from paper pulp and said first and second predetermined thickness being of a value sufficient for the end support to pass the Test in Test Procedure 2A of the International Safe Transit Association at the predetermined weight of the material and core.    
     
     
         2 . An improved end support in accordance with  claim 1  wherein said predetermined weight is about 50 lbs. (22.5 kg) or less, the first predetermined cross-sectional thickness is greater than about 0.15 inch (0.381 cm) and the second predetermined cross-sectional thickness is at least 0.25 inches (0.64 cm).  
     
     
         3 . An improved end support in accordance with  claim 1  wherein said annular support region is has a uniform second predetermined cross-sectional thickness.  
     
     
         4 . An improved end support in accordance with  claim 1  wherein said central hub has a plurality of ribs formed thereon and said second predetermined cross-sectional thickness is measured in said annular support region between said ribs on said central hub and said annular rib.  
     
     
         5 . An improved end support in accordance with  claim 1  wherein said rim is substantially rectangular in shape and defines four flat base members, includes a rib parallel and adjacent to each of said four base members and has a plurality of radial ribs formed therein that extend radially from said annular rib to said base members.  
     
     
         6 . An improved end support in accordance with  claim 5  further comprising a plurality of reinforcing webs between the radial ribs and contiguous therewith.  
     
     
         7 . An improved end support in accordance with  claim 1  wherein the paper pulp is selected from recycled newspaper pulp, recycled cardboard pulp, and mixtures thereof.  
     
     
         8 . An improved end support in accordance with  claim 7  wherein the paper pulp is reinforced by the addition of a material selected from organic binders, particulate fillers, woven materials, and combinations thereof.  
     
     
         9 . An improved end support in accordance with  claim 7  wherein the end support has an outer coating to minimize abrasion and dust formation.  
     
     
         10 . An improved end support in accordance with  claim 9  wherein the outer coating comprises a paraffin wax.