Suspension packaging system and method

Abstract

Disclosed is a method of packaging a curved product with a concave back surface that includes positioning the curved product in contact with a suspension pad that includes a notch on the top and bottom edges then stretch wrapping a stretch film around the curved product and the suspension pad with the wrap received in the first and second notches to secure the curved product to the suspension pad which bends the suspension pad to form a planar curve shape that conforms to the periphery of the back surface of the product and minimizes the distance between the product and the pad and increases the surface contact area between the product and the pad.

I claim: 
     
         1 . A method of packaging a curved product with a concave back surface, a top surface, a bottom surface, a height, and a width, the method comprising:
 positioning the curved product on a suspension pad that includes a front side, a rear side, a top edge, a bottom edge, a left edge, a right edge, a first notch along the bottom edge and a second notch along the top edge, wherein the suspension pad is taller than the height of the product, wherein a distance between the first and second notches is approximately equal to the height of the curved product, wherein the curved product is positioned in contact against the front side of the suspension pad with the bottom surface in close proximity to the first notch and with the top surface of the curved product in close proximity to the second notch;   stretch wrapping a stretch film around the curved product and the suspension pad with the stretch film received in the first and second notches to secure the curved product to the suspension pad, thereby bending the suspension pad to form a planar curve shape that substantially conforms to an entire periphery of the concave back surface of the curved product thereby minimizing the distance between the concave back surface of the product and the suspension pad and increasing the surface contact area between the concave back surface and the suspension pad and wherein the stretch film is a stretchable material that exhibits elastic recovery when used as stretch film.   
     
     
         2 . The method of  claim 1 , further comprising:
 securing the suspension pad with the curved product secured to the suspension pad with the stretch film in a container such that no portion of the curved product contacts or is directly adjacent to the container.   
     
     
         3 . The method of  claim 2 , wherein the suspension pad with the curved product secured to the suspension pad and the container are constructed and arranged so that the suspension pad with the curved product secured to the suspension pad can be inserted and removed from the container as an intact unit without damaging the container. 
     
     
         4 . The method of  claim 2 , wherein the suspension pad with the curved product secured to the suspension pad and the container are constructed and arranged to transport the suspension pad and the curved product in a vertical orientation. 
     
     
         5 . The method of  claim 4 , wherein an entire area below the curved product within the container is free of bracing or support elements other than the suspension pad. 
     
     
         6 . The method of  claim 5 , wherein, in the event the container is dropped while containing the curved product secured to the suspension pad in a vertical orientation, the suspension pad bent in a planar curve permits the curved product to slide along the suspension pad in a vertical direction restrained primarily by the stretch wrap and friction between the curved product and the suspension pad, wherein the stretch wrap exhibits elastic recovery. 
     
     
         7 . The method of  claim 5 , wherein, when the suspension pad bends and forms the planar curve shape that substantially conforms to the entire periphery of the concave back surface of the curved product, the top edge of the suspension pad bends and forms a continuous curved shape. 
     
     
         8 . The method of  claim 1 , further comprising stretch wrapping the stretch film around the curved product and the suspension pad with the stretch film received a third notch along the bottom edge and a fourth notch along the top edge. 
     
     
         9 . The method of  claim 1 , wherein the entire top edge of the suspension pad is substantially free of bends or creases that would impair said top edge from curving when said suspension pad bends and forms a planar curve. 
     
     
         10 . The method of  claim 1 , wherein, when the suspension pad bends and forms the planar curve shape that substantially conforms to the entire periphery of the concave back surface of the curved product, the top edge of the suspension pad bends and forms a continuous curved shape. 
     
     
         11 . The method of  claim 10 , wherein the top edge of the suspension pad defines a straight shape before the curved product is secured on the suspension pad by the stretch wrapping film. 
     
     
         12 . The method of  claim 1 , wherein, after stretch wrapping the stretch film around the curved product and the suspension pad, substantially the entire periphery of the concave back surface of the product abuts the suspension pad. 
     
     
         13 . The method of  claim 1 , further comprising manually lifting the curved product secured to the suspension pad by the stretch film solely by a hand hole in the suspension pad positioned inside of the periphery of the concave back surface of the curved product. 
     
     
         14 . A packaged curved product with a concave back surface, a top surface, a bottom surface, a height, and a width, the package made a process comprising:
 positioning the curved product on a suspension pad that includes a front side, a rear side, a top edge, a bottom edge, a left edge, a right edge, a first notch along the bottom edge and a second notch along the top edge, wherein the suspension pad is taller than the height of the product, wherein a distance between the first and second notches is approximately equal to the height of the curved product, wherein the curved product is positioned in contact against the front side of the suspension pad with the bottom surface in close proximity to the first notch and wherein the top surface of the curved product in close proximity to the second notch;   stretch wrapping a stretch film around the curved product and the suspension pad with the stretch film received in the first and second notches to secure the curved product to the suspension pad, thereby bending the suspension pad to form a planar curve shape that substantially conforms to an entire periphery of the concave back surface of the curved product thereby minimizing the distance between the concave back surface of the product and the suspension pad and increasing the surface contact area between the concave back surface and the suspension pad, wherein the stretch film is a stretchable material that exhibits elastic recovery when used as stretch film.   
     
     
         15 . The packaged curved product of  claim 14 , the process further comprising:
 securing the suspension pad with the curved product secured to the suspension pad with the stretch film in a container such that no portion of the curved product contacts or is directly adjacent to the container.   
     
     
         16 . The packaged curved product of  claim 15 , wherein the suspension pad with the curved product secured to the suspension pad and the container are constructed and arranged so that the suspension pad with the curved product secured to the suspension pad can be inserted and removed from the container as an intact unit without damaging the container. 
     
     
         17 . The packaged curved product of  claim 15 , wherein an entire area below the curved product within the container is free of bracing or support elements other than the suspension pad. 
     
     
         18 . The packaged curved product of  claim 17 , wherein, in the event the container is dropped while containing the curved product secured to the suspension pad in a vertical orientation, the suspension pad bent in a planar curve permits the curved product to slide along the suspension pad in a vertical direction restrained primarily by the stretch wrap and friction between the curved product and the suspension pad, wherein the stretch wrap exhibits elastic recovery. 
     
     
         19 . The packaged curved product of  claim 14 , wherein the entire top edge of the suspension pad defines a continuous curved shape when the suspension pad forms the planar curve shape that substantially conforms to the entire periphery of the concave back surface of the curved product. 
     
     
         20 . The packaged curved product of  claim 14 , wherein substantially the entire periphery of the concave back surface of the product is in contact with the suspension pad after the stretch film is stretch wrapped around the curved product and the suspension pad.