Vehicle part packaging system, package, jig, and method

Abstract

A part packaging system and method includes a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The system further includes a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The jig includes contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.

1 . A part packaging system, comprising:
 a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package; and   a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the jig including contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.   
     
     
         2 . The part packaging system of  claim 1  further including:
 a vehicle part received on the package blank and being contained within the enclosed package, the vehicle part having a shape that is complementarily fit by the enclosed package. 
 
     
     
         3 . The part packaging system of  claim 2  wherein the package blank is dimensioned so that the enclosed package has dimensions closely conforming to the shape of the vehicle part. 
     
     
         4 . The part packaging system of  claim 2  wherein the vehicle part is a vehicle headlamp, wherein the vehicle headlamp includes a body portion and at least one fragile feature extending from the from the body portion, and wherein the at least one fragile feature is spaced apart from the walls of the enclosed package and inhibited from contacting the walls of the enclosed package. 
     
     
         5 . The part packaging system of  claim 4  wherein the vehicle headlamp includes a lens and the vehicle part packaging system further includes a cushion member is interposed between the lens and the enclosed package. 
     
     
         6 . The part packaging system of  claim 2  further including:
 a cushioning member affixed to an inner side of the package blank for contacting the vehicle part and maintaining a position of the vehicle part within the enclosed package, the cushioning member further maintaining a spaced apart relation between a portion of the vehicle part that the cushioning member contacts and the enclosed package. 
 
     
     
         7 . The part packaging system of  claim 1  wherein a cushioning member is adhered to an inner side of the package blank for contact with a part received on the package blank to inhibit movement of the part within the enclosed package. 
     
     
         8 . The part packaging system of  claim 1  wherein the single sheet is formed of a corrugated material and is die cut to form the package blank. 
     
     
         9 . The part packaging system of  claim 1  wherein the package blank includes inner side and an opposite outer side, the inner side configured to contact a vehicle part received on the package blank, and the outer side forming an exposed outer side of the enclosed package. 
     
     
         10 . A method for packaging a part, comprising:
 providing a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package;   installing the package blank within a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package;   positioning a part to be packaged on the package blank; and   folding the package blank into the enclosed package to contain the part therein, the part having a shape that is complementarily fit by the enclosed package.   
     
     
         11 . The method of  claim 10  wherein installing the package blank within the jig includes applying pressure to the package blank such that contact portions of the jig corresponding to the fold lines of the package blank force the package blank to fold along the fold lines toward the configuration of the enclosed package, and
 wherein applying pressure to the package blank includes the jig forcing projection portions of the package blank inward to form a shaped cavity within the enclosed package for complementarily fitting the part. 
 
     
     
         12 . The method of  claim 10  wherein the package blank includes overlapping sides secured together via a tab of the overlapping sides being received in an aperture of the overlapping sides. 
     
     
         13 . The method of  claim 10  wherein the package blank includes end flaps defined by the cutout portions, the end flaps overlapping one another during installing of the package blank within the jig and folding the package blank into the enclosed package. 
     
     
         14 . The method of  claim 10  further including:
 installing a cushioning member on the package blank prior to positioning the part on the package blank for contacting the part and maintaining a position of the part within the enclosed package. 
 
     
     
         15 . The method of  claim 14  wherein the part is a vehicle headlamp that includes a lens and the cushion member is interposed between the lens and the enclosed package in contact with the lens. 
     
     
         16 . The method of  claim 10  wherein installing the package blank within the jig includes moving the package blank into the jig until vertical supports of the jig limit further movement of the package blank into the jig, and
 wherein installing the package blank within the jig further includes, after the step of moving the package blank into the jig until the vertical supports limit further movement, applying pressure at a target location on the package blank such that the package blank folds along the fold lines and jig erects a back wall of the enclosed package and forces projection portions inward toward an interior of the enclosed package. 
 
     
     
         17 . An enclosed package for a part, comprising:
 a package blank formed from a single sheet of foldable material folded about fold lines disposed thereon with the assistance of a jig into a box shape; and   a part enclosed by the package blank when folded into the box shape, the part having a shape that is complementarily fit by the enclosed package.   
     
     
         18 . The enclosed package of  claim 17  wherein the part is a vehicle headlamp. 
     
     
         19 . The enclosed package of  claim 17  in combination with the jig, the jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the jig including contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package. 
     
     
         20 . A jig for folding a package blank into an enclosed package to contain a part, comprising:
 a body structure configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the body structure including contact portions that correspond to fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.