Headliner packaging system for headliner having non-planar surface

Abstract

A headliner packaging system may be configured to package a headliner that has a non-planer surface and a width. The system may include one or more elongated clamps. Each elongated clamp may have a length that exceeds the width of the headliner. Each elongated clamp may be configured to releasable secure the headliner by applying clamping force to an area of the non-planer surface of the headliner in a manner that causes the elongated clamping force to be substantially uniform throughout the area of the non-planer surface of the headliner and in a direction that is not substantially perpendicular to the length of the elongated clamp. The packaging system may be configured to package an article other than a headliner.

1 . A headliner packaging system for packaging a headliner that has a non-planer surface and a width, comprising:
 one or more elongated clamps, each
 having a length that exceeds the width of the headliner; and 
 configured to releasable secure the headliner by applying clamping force to an area of the non-planer surface of the headliner in a manner that causes the elongated clamping force to be:
 substantially uniform throughout the area of the non-planer surface of the headliner; and 
 in a direction that is not substantially perpendicular to the length of the elongated clamp; and 
 
   a carton that is configured to house the elongated clamps and the headliner while secured within the elongated clamps, the carton having walls,   the elongated clamps being configured to cause all portions of the headliner to be substantially spaced from the walls of the carton while the headliner is secured within the elongated clamps and the elongated clamps and the headliner are both within the carton.   
   
   
       2 . The headliner packaging system of  claim 1  wherein each elongated clamp includes two opposing jaws at least one of which includes one or more cushions each positioned to cushion contact between the jaw and the portion of the non-planer surface of the headliner and to apply at least a portion of the elongated clamping force that is substantially uniform but not perpendicular. 
   
   
       3 . The headliner packaging system of  claim 2  wherein both opposing jaws include one or more of the cushions. 
   
   
       4 . The headliner packaging system of  claim 2  wherein each cushion includes a volume of expanded polypropylene abutting a volume of urethane. 
   
   
       5 . The headliner packaging system of  claim 4  wherein the urethane is positioned to directly contact the portion of the non-planer surface of the headliner and the expanded polypropylene is positioned not to directly contact the portion of the non-planer surface of the headliner. 
   
   
       6 . The headliner packaging system of  claim 5  wherein the volume of expanded polypropylene is larger than the volume of urethane. 
   
   
       7 . The headliner packaging system of  claim 6  wherein the expanded polypropylene is 0.9# expanded polypropylene and the urethane is 1.6# urethane. 
   
   
       8 . The headliner packaging system of  claim 6  wherein the volume of the expanded polypropylene is at least twice the volume of the urethane. 
   
   
       9 . The headliner packaging system of  claim 7  wherein the expanded polypropylene is 0.9# expanded polypropylene and the urethane is 1.6# urethane. 
   
   
       10 . The headliner packaging system of  claim 1  wherein there are at least two of the elongated clamps. 
   
   
       11 . The headliner packaging system of  claim 10  wherein the elongated clamps are attached to a common elongated clamp mount. 
   
   
       12 . The headliner packaging system of  claim 11  further comprising an elongated support brace attached to the elongated clamp mount that is configured to support a portion of the headliner, but not to clamp it. 
   
   
       13 . The headliner packaging system of  claim 1  wherein each elongated clamp is configured to apply a substantially constant force to the headliner when the headliner is secured within the elongated clamp, notwithstanding variation in the amount of bending which the elongated clamp undergoes when swung into the closed position to lock the headliner. 
   
   
       14 . An article packaging system for packaging an article that has a non-planer surface and a width, comprising:
 one or more elongated clamps, each
 having a length that exceeds the width of the article; and 
 configured to releasable secure the article by applying clamping force to an area of the non-planer surface of the article in a manner that causes the elongated clamping force to be:
 substantially uniform throughout the area of the non-planer surface of the article; and 
 in a direction that is not substantially perpendicular to the length of the elongated clamp; and 
 
   a carton that is configured to house the elongated clamps and the article while secured within the elongated clamps, the carton having walls,   the elongated clamps being configured to cause all portions of the article to be substantially spaced from the walls of the carton while the article is secured within the elongated clamps and the elongated clamps and the article are both within the carton.   
   
   
       15 . A headliner packaging system for packaging a headliner that has a non-planer surface and a width, comprising:
 a carton having a width and walls;   one or more elongated clamps, each elongated clamp having a length that is longer than the width of the headliner and shorter than the width of the carton;   each elongated clamp comprising two bendable arms releasably clamped to form a jaw around the headliner, all portions of the headliner being releasably secure away from the walls; and   one or more cushions, each cushion positioned between an arm and a non-planer portion of the non-planer surface of the headliner, each cushion having a first portion that is in contact with the arm, and a second portion that is compressible to the shape of the non-planer portion of the non-planer surface of the headliner.   
   
   
       16 . The headliner packaging system of  claim 15  wherein each cushion includes a volume of expanded polypropylene abutting a volume of urethane. 
   
   
       17 . The headliner packaging system of  claim 16  wherein the urethane is positioned in direct contact with the portion of the non-planer surface of the headliner and the expanded polypropylene is positioned not in direct contact with the portion of the non-planer surface of the headliner. 
   
   
       18 . The headliner packaging system of  claim 17  wherein the volume of expanded polypropylene is larger than the volume of urethane. 
   
   
       19 . The headliner packaging system of  claim 18  wherein the expanded polypropylene is 0.9# expanded polypropylene and the urethane is 1.6# urethane. 
   
   
       20 . The headliner packaging system of  claim 19  wherein the volume of the expanded polypropylene is at least twice the volume of the urethane.