Packaging base pad with plastic corners

Abstract

A packaging system for an appliance is provided. The packaging system includes a base pad for supporting an appliance. In preferred embodiments, the system includes pockets for supporting corner posts, and/or corner supports for aiding in the placement and stability of the appliance for use in packaging, stacking, and transporting the appliance.

What is claimed is: 
     
         1 . A packaging system for an appliance, the system comprising a base pad, a demarcated pocket at a corner of the base pad, and a corner post, the demarcated pocket comprising a perimeter wall defining lateral boundaries of the pocket into which a bottom end of the corner post is received. 
     
     
         2 . The packaging system of  claim 1 , wherein the demarcated pocket is adhered to the base pad. 
     
     
         3 . The packaging system of  claim 1 , wherein the demarcated pocket is integrally formed in the base pad. 
     
     
         4 . The packaging system of  claim 1 , the demarcated pocket further comprising a projection that extends inward from the perimeter wall, the projection being configured to aid in alignment of the bottom end of the corner post within the pocket. 
     
     
         5 . The packaging system of  claim 1 , said perimeter wall being a substantially continuous wall about said pocket. 
     
     
         6 . The packaging system of  claim 2 , wherein the demarcated pocket is provided as a cup that is used as a mold insert to which the base pad is molded and formed. 
     
     
         7 . The packaging system of  claim 6 , the base pad being made of expanded polystyrene. 
     
     
         8 . The packaging system of  claim 6 , the cup being made of high-density polyethylene. 
     
     
         9 . The packaging system of  claim 6 , the corner of the base pad comprising a recess that has a complementary shape to an exterior surface of the cup. 
     
     
         10 . A packaging system for an appliance, the system comprising a base pad, an appliance-corner support, and a corner post, the base pad comprising: (i) a molded corner region configured to receive the appliance-corner support and (ii) a pocket adjacent to said molded corner region configured to receive a bottom end of the corner post. 
     
     
         11 . The packaging system of  claim 10 , the pocket being defined by a substantially continuous perimeter wall that extends around a perimeter of the pocket. 
     
     
         12 . The packaging system of  claim 11 , the pocket further comprising a projection that extends inward from the perimeter wall, the projection being configured to aid in alignment of the bottom end of the corner post within the pocket. 
     
     
         13 . The packaging system of  claim 10 , the base pad being made of high-density polyethylene. 
     
     
         14 . The packaging system of  claim 10 , the appliance-corner support being made of expanded polystyrene or expanded polypropylene. 
     
     
         15 . The packaging system of  claim 10 , the appliance-corner support being made of injection molded plastic. 
     
     
         16 . A method of manufacturing and storing an appliance, comprising assembling the appliance, along an assembly line therefor, on a base pad comprising a demarcated pocket at a corner of the base pad, and inserting a corner post into the demarcated pocket, then shrink-wrapping the base pad, the corner post, and the appliance to form a completed packaged assembly, then stacking two or more said completed packaged assemblies, one on top of the other.