Packaging system for vertically packaged rolls

Abstract

A packaging and stabilizing system and method for creating a pallet of vertically aligned rolls of material. The packaging system includes a plurality of individual interlocking devices that each extend between the cores of a pair of rolls on the pallet. The interlocking devices are installed to create a lattice pattern between the rolls on the pallet such that the rolls are stabilized and prevented from tipping. Each individual roll of the pallet can be removed by first removing the interlocking devices connecting the roll to the remaining rolls in the pallet. Once the interlocking devices are removed, the roll can be removed without compromising the stability of the remaining rolls on the pallet.

What is claimed is:  
     
         1 . A method of stabilizing a plurality of rolls on a pallet, each roll being vertically-oriented and having a core extending therethrough, the method comprising the steps of: 
 positioning a plurality of rolls on the pallet, each roll being vertically-oriented;    providing a plurality of independent interlocking devices;    inserting each of the interlocking devices between the cores of a pair of adjacent rolls on the pallet;    arranging the plurality of interlocking devices in a lattice pattern to stabilize the plurality of rolls on the pallet;    wherein each of the interlocking devices are separate from the remaining interlocking devices and can be inserted and removed individually.    
     
     
         2 . The method of claim I wherein the plurality of rolls are positioned in a plurality of rows, wherein at least one interlocking device extends between the rolls of adjacent rows.  
     
     
         3 . The method of  claim 1  wherein the interlocking devices are positioned between the rolls as the rolls are sequentially positioned on the pallet.  
     
     
         4 . The method of  claim 1  wherein the lattice pattern of the interlocking devices is arranged such that each roll is coupled to at least two other rolls on the pallet.  
     
     
         5 . The method of  claim 1  wherein the interlocking devices each include a spanning section extending between two spaced vertical legs, wherein the vertical legs are inserted into the cores of the rolls.  
     
     
         6 . The method of  claim 5  further comprising the step of modifying the length of the spanning section prior to insertion of the interlocking device into the core of the rolls.  
     
     
         7 . The method of  claim 5  wherein the step of modifying the length of the spanning section includes bending the spanning section along a fold line to modify the length of the spanning section.  
     
     
         8 . A method of stacking and unstacking a plurality of rolls on a pallet, each roll being vertically-oriented and having a core extending therethrough, the method comprising the steps of: 
 sequentially placing the plurality of rolls on the pallet to define a plurality of rows;    inserting an interlocking device between each roll and at least one other of the plurality of rolls as each roll is placed onto the pallet, such that each roll is stabilized prior to additional rolls being placed on the pallet;    arranging the plurality of interlocking devices in a lattice pattern among the plurality of rolls to stabilize the plurality of rolls on the pallet, wherein the lattice pattern is arranged such that each roll is coupled to at least two other rolls on the pallet and at least one interlocking device extends between rolls of adjacent rows; and    removing all of the interlocking devices from the core of the roll to be removed from the pallet, wherein the interlocking devices of the lattice pattern remain between the rolls remaining on the pallet to stabilize the rolls.    
     
     
         9 . The method of  claim 8  wherein each of the interlocking devices are independent from the remaining interlocking devices such that each of the interlocking devices can be individually inserted and removed between the plurality of rolls on the pallet.  
     
     
         10 . The method of  claim 8  wherein the interlocking devices each include a spanning section extending between two spaced vertical legs, wherein the vertical legs are inserted into the cores of the rolls.  
     
     
         11 . The method of  claim 10  further comprising the step of modifying the length of the spanning section prior to insertion of the interlocking device into the core of the roll.  
     
     
         12 . The method of  claim 11  wherein the step of modifying the length of the spanning section includes bending the spanning section along a fold line.  
     
     
         13 . An interlocking device for stabilizing a plurality of rolls on a pallet, each roll being vertically-oriented and having a core extending therethrough, the interlocking device comprising: 
 a spanning section extending between a first end and a second end;    a first vertical leg connected to the first end of the spanning section;    a second vertical leg connected to the second end of the spanning section, wherein the first vertical leg and the second vertical leg are configured to be received within the core of one of the plurality of rolls,    wherein the spanning section, the first vertical leg and the second vertical leg are coplanar with each other in a stacking condition and wherein the first vertical leg and the second vertical leg are perpendicular to the spanning section in an operating condition.    
     
     
         14 . The interlocking device of  claim 13  wherein the spanning section includes at least one fold line such that the length of the spanning section can be modified by folding the spanning section along the fold line.  
     
     
         15 . The interlocking device of  claim 13  further comprising a pair of wings each coupled to one of the first and second vertical legs, wherein the wings are generally coplanar with the spanning section in the storage condition.  
     
     
         16 . The interlocking device of  claim 13  wherein the spanning section, first vertical leg and the second vertical leg are integrally formed from cardboard.