Packaging device and method for shipping furniture

• US 6,804,938 B2
• Filed: 10/31/2001
• Issued: 10/19/2004
• Est. Priority Date: 04/24/2001
• Status: Expired due to Fees

• Current Assignee: The Ultimate Back Store Incorporated
• Original Assignee: The Ultimate Back Store Incorporated
• Inventors: Levin, Marc A., Donahue, Barry L.
• Primary Examiner(s): Gerrity, Stephen F.
• Assistant Examiner(s): HUYNH, LOUIS K
• Application Number:
  US10/004,383
• Publication Number:
  US 20030079441A1
• Time in Patent Office: 1,084 Days
• Field of Search: 533/97, 533/99, 534/49, 534/67, 534/72, 534/74, 531/395, 531/397, 206/326, 206/320, 297/440.1, 297/440.13, 297/440.14, 297/440.15, 297/440.22, 297/440.23, 297/440.24
• US Class Current: 53/449
• CPC Class Codes: A47C 31/11 for chairs for headrests only A47C7/386; removable protective covers for car seats B60N2/60
• CPC Class Codes: B65B 5/04 Packaging single articles
• CPC Class Codes: B65D 2585/648 chairs and armchairs
• CPC Class Codes: B65D 81/05 maintaining contents at spaced relation from package walls, or from other contents B65D81/022, B65D81/025, B65D81/03 take precedence

Abstract

A method for shipping a piece of furniture having a base section removably secured to a seat section that involves removing the seat section from the base section and inserting the seat section and the base section into a shipping container. A packaging apparatus suitable for overnight delivery which includes a shipping container and at least one shipping sleeve capable of receiving an edge portion of the seat section of the furniture with the at least one shipping sleeve positionable within the shipping container to abut a side wall of the shipping container is also disclosed.

Claims

1. A method comprising the steps of:

providing an office chair including a seat section, a back section, and a base section, the base section including a central axis, and a plurality of leg members extending in a radial direction relative to the central axis and wherein each of the plurality of leg members is adapted to accept wheels;

providing a single shipping container including a DIM of no greater than 150 inches;

arranging the base section, the seat section and the back section inside the single shipping container so that the single shipping container is capable of closing;

closing the single shipping container; and

sending the single shipping container via an overnight delivery service.

2. The method of claim 1 further providing the shipping container including outside dimensions of approximately 26 inches in width, 26 inches in depth, and 25 inches in height.

3. The method of claim 1 wherein the shipping container has a DIM of no greater than 130 inches.

4. The method of claim 1 wherein the shipping container is suitable for use by an overnight delivery service.

5. The method of claim 1 wherein the shipping container has a DIM no greater than 135 inches.

6. The method of claim 1 wherein the shipping container has a DIM no greater than 140 inches.

7. The method of claim 1 wherein the seat section and the base section are in a separated condition.

8. The method of claim 1 further comprising the step of covering at least a portion of the office chair with a protective material.

9. The method of claim 8 wherein the protective material is constructed of a bubble wrap.

10. The method of claim 8 wherein the protective material is constructed of a fiber-filled wrap.

11. The method of claim 8 wherein the protective material is constructed of an air-filled wrap.

12. The method of claim 8 wherein the step of covering includes placing protective material around the seat section.

13. The method of claim 1 further comprising the step of enclosing the seat section or the base section in a bag.

14. The method of claim 1 further comprising the steps of providing accessory parts and securing the accessory parts to the office chair before the closing step.

15. The method of claim 14 further comprising placing the accessory parts in to an accessory bag.

16. The method of claim 15 further comprising the step of taping the accessory bag to the office chair.

17. The method of claim 1 wherein the back section is removably secured to the seat section and the method further comprises the steps of:

removing the back section from the seat section; and

inserting the back section into the shipping container.

18. The method of claim 17 further comprising the step of placing at least one protective shipping sleeve in contact with an edge portion of the back section prior to inserting the back section into the shipping container.

19. The method of claim 18 wherein the step of inserting further includes the step of positioning a portion of the at least one sleeve to abut at least one side wall of the shipping container.

20. The method of claim 18 wherein the step of inserting includes positioning the at least one shipping sleeve to abut opposing side walls of the shipping container.

21. The method of claim 18 comprising the further step of providing the at least one shipping sleeve constructed of corrugated cardboard.

22. The method of claim 18 wherein the step of placing includes positioning two shipping sleeves such that a first sleeve is placed in contact with the edge portion of the back section and a second sleeve is placed in contact with an opposing edge portion of the back section.

23. The method of claim 22 wherein the step of arranging further comprises:

abutting the first shipping sleeve against a first side wall of the container adjacent an edge of the back section; and

abutting the second shipping sleeve against an opposing second side wall of the container, where the second side wall of the container is adjacent an opposing edge of the back section.

24. The method of claim 22 further comprising the steps of:

placing a first protective shipping sleeve and a second protective shipping sleeve in contact with the edge portion of the back section and an opposing edge portion of the back section, respectively;

wrapping the seat section in a protective material;

positioning the back section to overlie the seat section;

placing the back and seat section within a protective bag; and

positioning the protective bag into a shipping container with the first and second protective shipping sleeves each abutting at least one side wall of the shipping container.

25. The method of claim 1 in which the step of inserting includes positioning the back section and the seat section in the container generally aligned in a direction of two opposing corners of the shipping container.

26. The method of claim 1 wherein the back section and the seat section are individually wrapped in a protective cover.

27. The method of claim 1 in which the step of inserting includes positioning the back section between the base section and a side wall of the shipping container in a non-parallel relationship to the base section.

28. The method of claim 1 further comprising the step of positioning the back section to overlie the seat section.

29. The method of claim 1 wherein a pair of arms are connected to the seat section and the method further comprises the step of positioning the back section to overlie the arms.

30. The method of claim 1 wherein a pair of arms are connected to the seat section and the method further comprises the step of nesting the back section between the arms.

31. The method of claim 1 further comprising the step of placing at least one protective shipping sleeve over an edge portion of the back section prior to arranging the back section in the shipping container.

32. The method of claim 31 wherein the step of arranging further includes the step of positioning a portion of the at least one sleeve to contact at least one side wall of the shipping container.

33. The method of claim 31 wherein the step of arranging includes positioning the at least one shipping sleeve to abut opposing side walls of the shipping container.

34. The method of claim 31 comprising the further the step of providing the at least one shipping sleeve constructed of corrugated cardboard.

35. The method of claim 31 wherein the step of placing includes positioning two shipping sleeves such that a first sleeve is placed over the edge portion of the back section and a second sleeve is placed over an opposing edge portion of the back section.

36. The method of claim 35 wherein the step of arranging further comprises:

abutting the first shipping sleeve against a first side wall of the container adjacent an edge of the back section; and

abutting the second shipping sleeve against an opposing second side wall of the container, where the second side wall of the container is adjacent an opposing edge of the back section.

37. The method of claim 36 further comprising the steps of:

wrapping the seat section in a protective material;

positioning the back section to overlie the seat section;

placing the back and seat section within a protective bag; and

positioning the protective bag into a shipping container with the first and second protective shipping sleeves each abutting at least one side wall of the shipping container.

38. A method comprising the steps of:

providing an office chair including a seat section, a back section, and a base section including a central axis, wherein the base section comprises a plurality of leg members extending in a radial direction relative to the central axis;

providing a single shipping container including a DIM of no greater than 130 inches;

arranging the seat section, the back section and the base section inside the single shipping container so that the single shipping container is capable of closing;

closing the single shipping container; and

sending the single shipping container via overnight delivery.

39. The method of claim 38 further comprising providing the shipping container including outside dimensions of approximately 26 inches in width, 26 inches in depth, and 25 inches in height.

40. The method of claim 38 wherein the shipping container is suitable for use by an overnight delivery service.

41. The method of claim 38 wherein the seat section and the back section are in a separated condition.

42. The method of claim 38 further comprising the step of covering at least a portion of the office chair with a protective material.

43. The method of claim 42 wherein the protective material is constructed of a bubble wrap.

44. The method of claim 43 further providing the shipping container including outside dimensions of approximately 26 inches in width, 26 inches in depth, and 25 inches in height.

45. The method of claim 42 wherein the protective material is constructed of a fiber-filled wrap.

46. The method of claim 42 wherein the protective material is constructed of an air-filled wrap.

47. The method of claim 42 wherein the step of covering includes placing protective material around the seat section.

48. The method of claim 42 further comprising the step of enclosing the covered office chair in a bag.

49. The method of claim 38 further comprising providing accessory parts and securing the accessory parts to the office chair before the closing step

50. The method of claim 49 further comprising placing the accessory parts in an accessory bag.

51. The method of claim 49 further comprising the step of taping the accessory bag to the office chair.

52. The method of claim 38 wherein the base section is individually wrapped in a protective cover.

53. The method of claim 38 further comprising the step of positioning the base section under the seat section.

54. The method of claim 38 wherein arms are connected to the seat section and the method further comprises the step of positioning the back section to overlie the arms.

55. The method of claim 54 wherein arms are connected to the seat section and the method further comprises the step of nesting the back section between the arms.

56. The method of claim 38 further comprising the step of placing at least one protective shipping sleeve over an edge portion of the back section prior to the arranging step.

57. The method of claim 56 wherein the step of arranging further includes the step of positioning a portion of the at least one sleeve to abut at least one side wall of the shipping container.

58. The method of claim 56 wherein the step of arranging includes positioning the at least one shipping sleeve to contact opposing side walls of the shipping container.

59. The method of claim 56 further comprising the step of providing the at least one shipping sleeve constructed of corrugated cardboard.

60. The method of claim 56 wherein the step of placing includes positioning two shipping sleeves such that a first sleeve is placed over the edge portion of the back section and a second sleeve is placed over an opposing edge portion of the back section.

61. The method of claim 56 wherein the step of inserting further comprises:

abutting the first shipping sleeve against a first side wall of the container;

abutting the second shipping sleeve against an opposing second side wall of the container.

62. A method comprising the steps of:

providing an office chair including a seat section, a back section, and a base section including a central axis, wherein the base section comprises a plurality of leg members extending in a radial direction relative to the central axis and wherein each of the plurality of leg members is adapted to accept wheels;

providing a single shipping container including a DIM of no greater than 130 inches;

positioning the back section between the base section and a sidewall of the shipping container in a non-parallel relationship to the base section;

arranging the seat section inside the single shipping container relative to the back section and the base section so that the single shipping container is capable of closing;

closing the single shipping container; and

sending the single shipping container via overnight delivery.

63. The method of claim 62 further comprising the step of covering at least a portion of the office chair with a protective material.

64. The method of claim 63 wherein the step of covering includes providing the protective material constructed of a bubble wrap.

65. The method of claim 63 wherein the step of covering includes placing protective material around the seat section.

66. The method of claim 63 further comprising the step of enclosing the covered office chair in a bag prior to the step of inserting.

67. The method of claim 62 further comprising the steps of providing accessory parts and securing accessory parts to the office chair prior to the closing step.

68. The method of claim 67 further comprising placing the accessory parts in to a bag.

69. The method of claim 68 further comprising the step of taping the bag to the office chair.

70. The method of claim 68 further comprising the step of providing a shipping sleeve and securing accessory parts to the shipping sleeve.

71. The method of claim 62 further comprising the step of positioning the back section to overlie the seat section.

72. The method of claim 62 further comprising the step of placing the back section to overlie arms which are connected to the seat section.

73. The method of claim 72 further comprising the step of nesting the back section between the arms.

74. A method comprising the steps of:

providing an office chair including a seat section, a back section, and a base section including a central axis, wherein the base section comprises a plurality of leg members extending in a radial direction relative to the central axis and wherein each of the plurality of leg members is adapted to accept wheels;

providing a single shipping container including a DIM of no greater than 150 inches;

positioning the back section and the seat section in the single shipping container in such a manner so as to position the back section between the seat section and a portion of the shipping container;

arranging the base section inside the single shipping container relative to the back section and the seat section so that the single shipping container is capable of closing;

closing the single shipping container; and

sending the single shipping container via overnight delivery.

75. The method of claim 74 further comprising the step of covering at least a portion of the office chair with a protective material.

76. The method of claim 75 wherein the step of covering includes providing the protective material constructed of a bubble wrap.

77. The method of claim 75 wherein the step of covering includes placing protective material around the seat section.

78. The method of claim 75 further comprising the step of enclosing the covered office chair in a bag prior to the step of inserting.

79. The method of claim 74 further comprising the step of providing accessory parts and securing the accessory parts to the office chair before the closing step.

80. The method of claim 79 further comprising placing the accessory parts in to a bag before the step of securing the accessory parts to the office chair.

81. The method of claim 79 further comprising the step of providing a shipping sleeve and securing accessory parts to the shipping sleeve.

82. The method of claim 74 further comprising the step of taping a bag to the office chair.

83. The method of claim 74 further comprising the step of positioning the back section to overlie the seat section.

84. The method of claim 74 further comprising the step of nesting the back section between the arms.

85. The method of claim 74 further providing the shipping container including outside dimensions of approximately 26 inches in width, 26 inches in depth, and 25 inches in height.

86. The method of claim 74 further providing the shipping container including a DIM of no greater than 130 inches.

87. The method of claim 74 further providing the shipping container including a DIM of no greater than 135 inches.

88. The method of claim 74 further providing the shipping container including a DIM of no greater than 140 inches.

89. The method of claim 74 further providing the shipping container including a DIM of no greater than 145 inches.

90. A method comprising the steps of:

providing an office chair including a seat section, a back section, and a base section including a central axis and a plurality of leg members that extend in a radial direction relative to the central axis, wherein the plurality of leg members is adapted to accept wheels;

placing at least one protective shipping sleeve over an edge portion of the back section, wherein the shipping sleeve is sized and shaped so as to cover the edge portion of the back section;

providing a single shipping container including a DIM of no greater than 130 inches;

arranging the seat section, the back section and the base section of the office chair inside the single shipping container so that the single shipping container is capable of closing;

closing the single shipping container; and

sending the single shipping container via overnight delivery.

91. A method comprising the steps of:

providing an office chair including a seat section, a back section and a base section, the base section including a central axis and a plurality of leg members that extend in a radial direction relative to the central axis, wherein the plurality of leg members is adapted to accept wheels;

placing at least one protective shipping sleeve in contact with an edge portion of the back section and partially over a portion of the back section;

providing a single shipping container including a DIM of no greater than 150 inches;

arranging the seat section, the back section and the base section inside the single shipping container so that the single shipping container is capable of closing;

closing the single shipping container; and

sending the single shipping container via overnight delivery.