Protective package for an automobile part

Abstract

A protective package for an automobile part; as assembled, packaged and buttressed for shipping; minimizes or eliminates damage to the automobile part being shipped, by providing a carton, side rail supports in the carton to receive the part and padded supports to secure the part in the carton.

What is claimed and sought to be protected by Letters Patent of the United States is: 
     
       1. A protective package for shipping a part comprising:
 (a) a carton having a packing assembly therein; 
 (b) the packing assembly including a first side rail support and a second side rail support adapted to position the part in the carton; 
 (c) the packing assembly including a first rear support in the first side rail in the carton to support a rear portion of the part; 
 (d) the packing assembly including a second rear support in the second side rail in the carton to support the rear portion of the part; 
 (e) the packing assembly including a first front support in the front side rail in the carton to support a front portion of the part; 
 (f) the packing assembly including a second front support in the second side rail in the carton to support the front portion of the part; 
 (g) a first slot being present in the first side rail support; 
 (h) a second slot being present in the second side rail support; 
 (i) the first slot receiving the first rear support and the first front support; 
 (j) the second slot receiving the second rear support and the second front support; 
 (k) a first spacer pad being inserted between the carton and the first side rail; 
 (l) a second spacer pad being inserted between the carton and the second side rail; 
 (m) the first spacer pad, the second spacer pad, the first rear support, the first front support, the second rear support and the second front support cooperating to support the part within the carton and at least minimize damage to the part; 
 (n) the first spacer pad forcing the first side rail inwardly to provide additional support for the part; 
 (o) the second spacer pad forcing the second side rail inwardly to provide additional support for the part; 
 (p) the first spacer pad and the second spacer pad forming part of the packing assembly; 
 (q) the first front support and the second front support being substantially similar in appearance; 
 (r) the first front support being formed from a corrugated front insert die-cut flat with a front foam support mounted therein; 
 (s) the front foam support having a front jaw slot; and 
 (t) the front jaw slot being adapted to receive and partially support the part. 
 
     
     
       2. The protective package of  claim 1  further comprising:
 (a) the first rear support and the second rear support being substantially similar in appearance; 
 (b) the first rear support being formed from a corrugated rear insert die-cut flat with a rear foam support mounted therein; 
 (c) the rear foam support having a rear jaw slot; and 
 (d) the rear jaw slot being adapted to receive and partially support the part. 
 
     
     
       3. The protective package of  claim 1  further comprising:
 (a) the first side rail and the second side rail being substantially similar in appearance; 
 (b) the first side rail being formed from a scored flat corrugated piece of material; 
 (c) the first side rail having an inner side and an outer side; 
 (d) a large top panel joining the inner side and the outer side; 
 (e) the large top panel extending into a larger inner panel; 
 (f) the larger inner panel forming a first part of the inner side; 
 (g) the larger inner panel being substantially parallel to the outer side; 
 (h) the larger inner panel extending into a first slot side and then into a second base side; 
 (i) a small bottom panel extending from the outer side in a substantially perpendicular relationship; 
 (j) the small bottom panel then forming a smaller inner panel; 
 (k) smaller inner panel extending into a second slot side; 
 (l) the second slot side extending into a first slot base in order to form the rail channel slot with second base side; and 
 (m) the rail channel slot thus formed receiving the part. 
 
     
     
       4. The protective package of  claim 3  further comprising:
 (a) the first rear support and the second rear support being substantially similar in appearance; 
 (b) the first rear support being formed from a corrugated rear insert die-cut flat with a rear foam support mounted therein; 
 (c) the rear foam support having a rear jaw slot; and 
 (d) the rear jaw slot being adapted to partially receive and partially inset the part. 
 
     
     
       5. The protective package of  claim 4  further comprising:
 (a) the outer side including a large top swing brace panel and a smaller top swing brace panel scored in the outer side; 
 (b) the large top swing brace panel forming a large top brace support as substantially perpendicular to the large top panel; and 
 (c) the smaller top swing brace forming a smaller top brace support as substantially perpendicular to the large top panel. 
 
     
     
       6. The protective package of  claim 5  further comprising:
 (a) the shipping carton being a seamed shipping carton or a fold over carton; 
 (b) the large top brace support forming a larger top rest lip; 
 (c) the smaller top swing brace forming a smaller top rest lip; and 
 (d) the smaller top swing brace panel being spaced apart from the large top swing brace panel in order to support the side rail. 
 
     
     
       7. A method of forming a protective package for shipping a part comprising:
 (a) providing a shipping carton with a generally rectangular shape for the protective package; 
 (b) shaping the carton with rear dust flaps mounted thereon; 
 (c) shaping a first side rail to have a first part receiving slot and a second side rail to have a second part receiving slot; 
 (d) fitting the first side rail and the second side rail into the carton on opposing sides thereof; 
 (e) spacing the first side rail and the second side rail from the respective opposing sides of the carton with a side spacer; 
 (f) forming a first front insert from a corrugated front insert die-cut flat; 
 (g) folding a rear die-cut flat to form a first rear insert; 
 (h) placing a front foam support in the first front insert; 
 (i) inserting a larger jaw angle cut spacer into the first rear insert; 
 (j) inserting a foldable tongue from the rear die-cut flat into the larger jaw angle cut spacer; 
 (k) having a second front insert being similar in shape to the first front insert; 
 (l) having a second rear insert being similar in shape to the first rear insert;  
 (fm) placing a the first rear insert in the first side rail; 
 (gn) placing a the second rear insert in the second side rail; 
 (ho) inserting the part into the carton in contact with the first side rail, the second side rail into the first rear insert and the second rear insert; 
 (ip) placing a the first front insert in the first side rail and in contact with the part; 
 (jq) placing a the second front insert in the second side rail and in contact with the part; and  
 (kr) closing the carton; 
 (l) having the first rear insert being similar in shape the second rear insert; 
 (m) folding a rear die-cut flat to form the first rear insert; 
 (n) inserting a larger jaw angle cut spacer into the first rear insert; 
 (o) inserting a foldable tongue from the rear die-cut flat into the larger jaw angle cut spacer; 
 (p) having the first front insert being similar in shape to the second front insert; 
 (q) forming the first front insert from a corrugated front insert die-cut flat; and 
 (r) placing a front foam support in the first front insert. 
 
     
     
       8. The method of  claim 7  further comprising:
 (a) folding a pair of the rear dust flaps for the carton inwardly in order to hold the carton in a proper position for packing; and  
 (b) folding a rear bottom flap over pair of the rear dust flaps; 
 (c) inserting the first side rail and the second side rail into the carton; 
 (d) inserting the part into the shipping carton; and 
 (e) closing the carton. 
 
     
     
       9. The method of  claim 8  further comprising:
 (a) inserting a first spacer pad between the carton and the first side rail to push in the first side rail; 
 (b) inserting a second spacer pad between the shipping carton and the second side rail to push in the second side rail; 
 (c) providing a rear closable end oppositely disposed from a front closable end for the carton; 
 (d) having a rail channel slot in the first side rail and second side rail to receive the part; and 
 (e) supporting the part in the rail channel slot. 
 
     
     
       10. A protective package for shipping a part comprising:
 a carton having a packing assembly therein; 
 the packing assembly including a first side rail support and a second side rail support adapted to position the part in the carton; 
 the packing assembly including a first rear support in the first side rail in the carton to support a rear portion of the part; 
 the packing assembly including a second rear support in the second side rail in the carton to support the rear portion of the part; 
 the carton being a seamed carton or a fold over carton; 
 the packing assembly including a first front support in the second first side rail in the carton to support a front portion of the part; 
 the packing assembly including a second front support in the second side rail in the carton to support the front portion of the part; 
 a first slot being present in the first side rail support; 
 a second slot being present in the second side rail support; 
 the first slot receiving the first rear support and the first front support; 
 the second slot receiving the second rear support and the second front support; 
 a first spacer pad being inserted between the carton and the first side rail; 
 a second spacer pad being inserted between the carton and the second side rail; 
 the first spacer pad, the second spacer pad, the first rear support, the first front support, the second rear support and the second front support cooperating to support the part within the carton and at least minimize damage to the part; 
 the first spacer pad forcing the first side rail inwardly to provide additional support for the part; 
 the second spacer pad forcing the second side rail inwardly to provide additional support for the part; 
 the first spacer pad and the second spacer pad forming part of the packing assembly; 
 the first front support and the second front support being substantially similar in appearance; 
 the first front support being formed from a corrugated front insert die-cut flat with a front foam support mounted therein; 
 the front foam support having a front jaw slot; and 
 the front jaw slot being adapted to receive and partially support the part. 
 
     
     
       11. A hood packing assembly, comprising:
 a carton having a first wall and a second wall;   a first sidewall within the carton having a first upper panel and a first lower panel, wherein a first rail channel slot is formed between the first upper panel and the first lower panel, and the first rail channel slot is located a greater distance from the first wall than the second wall of the carton;   a second sidewall within the carton, separate and apart from the first sidewall, having a second upper panel and a second lower panel, wherein a second rail channel slot is formed between the second upper panel and the second lower panel, and the first rail channel slot faces the second rail channel slot, and the second rail channel slot is located a greater distance from the first wall than the second wall of the carton;   a first rail channel slot spacer and a second rail channel slot spacer located within the first rail channel slot;   a third rail channel slot spacer and a fourth rail channel slot spacer located within the second rail channel slot;   said first, second, third and fourth rail channel slot spacers each include a slot for receiving a portion of an edge of an automobile hood; and   said slots in the first and second rail channel slot spacers face each other, and said slots in the third and fourth rail channel slot spacers face each other.    
     
     
       12. The hood packing assembly of claim 11, further comprising:
 an automobile hood located within the carton, wherein at least a portion of a first edge of the automobile hood is located within the first rail channel slot, and wherein at least a portion of a second edge of the automobile hood is located within the second rail channel slot.    
     
     
       13. The hood packing assembly of claim 11, further comprising:
 an automobile hood located within the carton, wherein at least a portion of a first edge of the automobile hood is located within the first rail channel slot and between the first and second rail channel slot spacers and wherein at least a portion of a second edge of the automobile hood is located within the second rail channel slot and between the third and fourth rail channel slot spacers.    
     
     
       14. The hood packing assembly of claim 11, wherein the first rail channel slot and the second rail channel slot are aligned to be at a similar height within the carton.  
     
     
       15. The hood packing assembly of claim 11, wherein the first lower panel, the first upper panel, the second lower panel, and the second upper panel are formed by folded corrugated cardboard.  
     
     
       16. The hood pack packing assembly of claim 11, wherein the first, second, third, and fourth rail channel slot spacers are constructed of compressible material.  
     
     
       17. The hood pack packing assembly of claim 16, wherein the compressible material includes foam.  
     
     
       18. The hood packing assembly of claim 11, wherein the first sidewall, the first upper panel, the first lower panel, and the first rail channel slot are formed from a first single sheet of corrugated cardboard, and wherein the second sidewall, the second upper panel, the second lower panel, and the second rail channel slot are formed from a second single sheet of corrugated cardboard.  
     
     
       19. The hood packing assembly of claim 11, wherein the first and second rail channel slot spacers are positioned proximate opposing ends of the first rail channel slot, and the third and fourth rail channel slot spacers are positioned proximate opposing ends of the second rail channel slot.  
     
     
       20. The hood packing assembly of claim 11, wherein the first and second sidewalls are constructed separately from walls of the carton, and further comprising:
 a first sidewall spacer located between the first sidewall and the carton; and   a second sidewall spacer located between the second sidewall and the carton.    
     
     
       21. The hood packing assembly of claim 20, wherein the first and second sidewall spacers are constructed of compressible material.  
     
     
       22. The hood packing assembly of claim 21, wherein the compressible material of the first and second sidewall spacers includes foam.  
     
     
       23. The hood packing assembly of claim 11, further comprising:
 a separate foldable tongue located in each of the slots in the first, second, third and fourth rail channel slot spacers.    
     
     
       24. A protective package, comprising:
 a carton having a first wall and a second wall;   a packing assembly within the carton, comprising;
 a first side rail having a first rail channel slot; 
 a second side rail, separate and apart from the first side rail, having a second side rail channel slot substantially parallel to the first rail channel slot, and the first and second rail channel slots are located a greater distance from the first wall than the second wall of the carton; 
 a first rail channel slot spacer and a second rail channel slot spacer constructed of compressible material and positioned within the first rail channel slot, wherein the first and second rail channel slot spacers are located proximate opposing ends of the first rail channel slot; and 
   a third rail channel slot spacer and a fourth rail channel slot spacer constructed of compressible material and positioned within the second rail channel slot, wherein the third and fourth rail channel slot spacers are located proximate opposing ends of the second rail channel slot;   said first, second, third and fourth rail channel slot spacers each include a slot for receiving a portion of an edge of an automobile hood; and   said slots in the first and second rail channel slot spacers face each other, and said slots in the third and fourth rail channel slot spacers face each other.    
     
     
       25. The protective package of claim 24, wherein the compressible material is foam.  
     
     
       26. The hood packing assembly of claim 11, wherein the first and second sidewalls and the first and second rails channel slots formed therein extend the substantial length of the carton within which the first and second sidewall are contained.  
     
     
       27. The hood packing assembly of claim 11, wherein the widths of the first, second, third and fourth rail channel slot spacers are substantially similar to the depths of the first and second rail channel slots.  
     
     
       28. The hood packing assembly of claim 11, wherein the first and second sidewalls are positioned at opposing sides of the carton.