Composite Shipping Base with Interlocking Detachable Sub-Structure

• US 20140151521A1
• Filed: 12/05/2012
• Published: 06/05/2014
• Est. Priority Date: 12/05/2012
• Status: Active Grant

• Current Assignee: Sonoco Development Inc (Sonoco Products Company)
• Original Assignee: Sonoco Development Inc (Sonoco Products Company)
• Inventors: Marrow, Matthew
• Granted Patent: US 8,955,812 B2
• Time in Patent Office: Days
• US Class Current: 248/346.03
• CPC Class Codes: B65D 19/0002 Platforms, i.e. load supporting devices without provision for handling by a forklift
• CPC Class Codes: B65D 19/44 Elements or devices for locating articles on platforms
• CPC Class Codes: B65D 2585/6855 washing machine
• CPC Class Codes: D06F 39/001 Arrangements for transporting, moving, or setting washing machines; Protective arrangements for use during transport transport in general B65
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A composite shipping base for supporting an appliance such as a washing machine is provided having a detachable sub-structure that can be added during the washing machine assembly to restrict the vertical and lateral movement of a centralized load of the washing machine during assembly, shipping and handling. A rigid bottom frame allows for the composite shipping base and appliance to move down virtually any form of conveyance and to be lifted or turned during the course of conveyance.

Claims

1. A shipping base for an appliance, the shipping base comprising:

a rigid bottom frame comprising opposing side members forming a rigid support structure and a cross member extending between two opposing side members;

a bottom panel affixed to the bottom frame and having a top surface opposite the bottom frame, the bottom panel defining a center opening; and

a center insert detachably secured within the center opening and extending upwardly from the top surface.

2. The shipping base of claim 1 wherein:

the center opening is in vertical alignment with at least a portion of the cross member.

3. The shipping base of claim 1 wherein the bottom panel has four corners, the shipping base further comprising:

a corner support affixed to the top surface of the bottom panel near each of the four corners.

4. The shipping base of claim 3 wherein:

each corner support defines a hole for receiving an appliance foot.

5. The shipping base of claim 1 further comprising:

means for preventing the center insert from rotating with respect to the bottom panel.

6. The shipping base of claim 1 wherein the center insert comprises a body having a non-circular horizontal cross-sectional area at its base that registers within a similarly shaped center opening to prevent the center insert from rotating with respect to the bottom frame.

7. The shipping base of claim 1 wherein:

the center insert comprises a substantially cylindrical body having a circular horizontal cross-sectional profile and at least one boss member extending laterally from a lower portion of the body that registers with the center opening to prevent the center insert from rotating with respect to the bottom frame.

8. The shipping base of claim 7 wherein:

the center opening includes at least one locating cutout; and

the center insert comprises a substantially cylindrical body having a circular horizontal cross-sectional profile and at least one boss member extending laterally from a lower portion of the body that registers with the at least one locating cutout to prevent the center insert from rotating with respect to the bottom frame.

9. The shipping base of claim 1 wherein:

the center insert has a body having a top surface and a bottom surface, the body defining a diametrically extending slot located in the bottom surface and configured to receive the cross member.

10. The shipping base of claim 1 wherein:

the top surface is configured to abut a centralized load located within the appliance.

11. The shipping base of claim 1 wherein:

the bottom frame is made of a rigid first material;

the bottom panel is made of a second material that is less rigid than the first material; and

the center insert is made of a third material that is different from the first material and the second material.

12. The shipping base of claim 1 wherein:

the bottom frame is made of wood;

the bottom panel is made of corrugated fiberboard; and

the center insert is made of a plastic foam material.

13. An appliance and shipping base assembly comprising:

an appliance having a tub, a frame surrounding the tub and having a bottom surface, and a centralized load suspended underneath the tub; and

a composite shipping base comprising a primary structure and a detachable sub-structure, the primary structure comprising a bottom panel having a top surface, the sub-structure comprising a center insert that is detachably affixed to the primary structure;

wherein the composite shipping base is disposed under the appliance, the frame rests on the primary structure and the center insert supports the centralized load.

14. The appliance and shipping base assembly of claim 13 wherein:

the primary structure further comprises a rigid bottom frame affixed to the bottom panel and having opposing side members and a cross member extending between two opposing side members;

the bottom panel defines a center opening; and

the center insert is secured within the center opening and extends upwardly from the bottom panel to support the centralized load.

15. The appliance and shipping base assembly of claim 14 wherein:

the primary structure further comprises corner supports affixed to a top surface of the bottom panel; and

the appliance rests on the corner supports.

16. The appliance and shipping base assembly of claim 15 wherein:

the appliance further comprises feet extending below the bottom surface; and

each corner support defines a hole for receiving one of the feet.

17. A method of assembling an appliance and base assembly, the method comprising the steps of:

(a) providing a partially assembled composite shipping base comprising a bottom panel and a rigid frame affixed to an underside of the bottom panel, the bottom panel having a top surface defining a center opening, the rigid frame having opposing side members and a cross member extending between two opposing side members, wherein the center opening and a portion of the cross member are in vertical alignment;

(b) providing a partially assembled appliance having a frame having a bottom surface;

(c) locating the partially assembled appliance onto the partially assembled composite shipping base;

(d) lifting up or tilting the partially assembled appliance;

(e) installing a centralized load while the partially assembled appliance is lifted up or tilted;

(f) inserting a portion of a center insert into the center opening after the centralized load is installed so that the center insert cannot move laterally to provide a fully assembled composite shipping base; and

(g) re-positioning the partially assembled appliance onto the fully assembled composite shipping base so that so that the center insert is supporting the centralized load and preventing the centralized load from moving vertically.

18. The method of claim 17 wherein:

step (f) further comprises inserting a portion of the center insert into the center opening so that a slot located on a bottom surface of the center insert mates with a portion of the cross member.

19. The method of claim 17 wherein:

step (f) further comprises inserting a portion of the center insert into the center opening so that at least one boss member extending laterally from the center insert mates with a locating cutout defined by the bottom panel, thereby preventing rotational movement of the center insert with respect to the bottom panel.

20. The method of claim 17 wherein:

step (a) further comprises providing a partially assembled composite shipping base having corner supports affixed to the bottom panel, each corner support defining a hole;

step (b) further comprises and providing a partially assembled appliance having feet extending from the frame and below the bottom surface; and

step (e) further comprises inserting the appliance feet into the holes so that the bottom surface rests on the corner supports.