Tub Insert System with Cross-Brace Holder for Top Loading Washer
20260022507 ยท 2026-01-22
Assignee
Inventors
- Jonathan E. Senn (Nashville, TN, US)
- Clifton T. Moore (Murfreesboro, TN, US)
- Matthew Wayne Marrow (Hendersonville, TN, US)
Cpc classification
B65D57/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
D06F39/00
TEXTILES; PAPER
Abstract
Tub Insert System with Cross-Brace Holder for Top Loading Washer A tub insert for a top loading washing machine having a cabinet with a top opening, a lid, and a wash tub disposed within the cabinet may include a tub insert body shaped to engage the cabinet and the wash tub when the tub insert body is inserted through the top opening to substantially prevent movement of the wash tub relative to the cabinet. Cross-brace support panels having cross-brace openings extend from a top edge of the tub insert body upward through a gap between the lid and the cabinet on opposite sides of the lid. The cross-brace openings receive a cross-brace that extends across the cabinet to provide lateral support for a container in which the washing machine is shipped.
Claims
1. A tub insert for a top loading washing machine having a cabinet with a top surface and a top opening in the top surface, a lid movable between an open position and a closed position, and a wash tub disposed within the cabinet, the tub insert comprising: a tub insert body shaped to engage the cabinet and the wash tub when the tub insert body is inserted through the top opening to substantially prevent movement of the wash tub relative to the cabinet; and cross-brace support panels operatively connected to a top edge of the tub insert body on opposite sides of the tub insert body and each of the cross-brace support panels having a cross-brace opening for receiving a cross-brace, wherein the cross-brace support panels extend upward through a gap between the lid and the top surface of the cabinet with the cross-brace opening disposed above the lid when the tub insert body is inserted through the top opening and the lid is in the closed position.
2. The tub insert of claim 1, wherein the cross-brace opening of each of the cross-brace support panels has an open end through which the cross-brace can be inserted.
3. The tub insert of claim 2, wherein the cross-brace opening of each of the cross-brace support panel has a cross-brace detent extending into the cross-brace opening and engaging the cross-brace disposed within the cross-brace opening to resist the cross-brace exiting the cross-brace opening through the open end.
4. The tub insert of claim 1, wherein the cross-brace opening is shaped to receive a cross-brace having a rectangular cross-section.
5. The tub insert of claim 1, wherein the tub insert body includes a bottom wall, a front wall, a rear wall and oppositely disposed side walls, wherein the tub insert comprises: a front lock flap attached to side wall front edges of each side wall, wherein the front lock flaps wrap around the front wall to secure the front wall to the side walls; and a rear lock flap attached to side wall rear edges of each side wall, wherein the rear lock flaps wrap around the rear wall to secure the rear wall to the side walls.
6. The tub insert of claim 5, wherein each of the front lock flaps and the rear lock flaps comprises a lock tab at an end opposite the respective side wall front edge and side wall rear edge, wherein the bottom wall includes lock slots disposed adjacent the front wall and proximate each side wall and adjacent the rear wall and proximate each side wall, wherein each of the lock tabs is inserted into a corresponding one of the lock slots to secure the front lock flaps around the front wall and the rear lock flaps around the rear wall.
7. A tub insert system, comprising: a cross-brace; and the tub insert of claim 1, wherein the cross-brace is inserted into the cross-brace openings when the tub insert is inserted into the top opening and the lid is in the closed position with the cross-brace support panels extending upward through the gap.
8. A tub insert for a top loading washing machine having a cabinet with a top surface and a top opening in the top surface, a lid movable between an open position and a closed position, and a wash tub disposed within the cabinet, the tub insert comprising: a tub insert blank fabricated from a paperboard sheet; a front wall fold line, a rear wall fold line and oppositely disposed side wall fold lines extending between the front wall fold line and the rear wall fold line to define a bottom wall having a front wall, a rear wall and oppositely disposed side walls extending therefrom such that the front wall, the rear wall and the side walls form a tub insert body when folded toward each other with front wall side edges of the front wall adjacent a corresponding one of side wall front edges and rear wall side edges of the rear wall adjacent a corresponding one of side wall rear edges, wherein the tub insert body is shaped to engage the cabinet and the wash tub when the tub insert body is inserted through the top opening to substantially prevent movement of the wash tub relative to the cabinet; and for each side wall, a support panel bottom edge fold line between the side wall and a cross-brace support panel, the cross-brace support panel having a cross-brace opening cut out of the tub insert blank for receiving a cross-brace, wherein the cross-brace support panels are folded about the support panel bottom edge fold lines so that the cross-brace support panels extend upward through a gap between the lid and the top surface of the cabinet with the cross-brace opening disposed above the lid when the tub insert body is inserted through the top opening and the lid is in the closed position.
9. The tub insert of claim 8, wherein the cross-brace opening of each of the cross-brace support panels has an open end cut out of the tub insert blank that faces toward the front wall when the tub insert blank is folded into the tub insert body.
10. The tub insert of claim 9, wherein each of the cross-brace openings is cut out of the tub insert blank with a cross-brace detent extending into the cross-brace opening, wherein the cross-brace detents engage the cross-brace disposed within the cross-brace opening to resist the cross-brace exiting the cross-brace opening through the open end.
11. The tub insert of claim 8, wherein the top loading washing machine includes an agitator extending upward within the wash tub, and wherein the bottom wall comprises an agitator opening cut out of the tub insert blank having a size and position to allow the agitator to pass there through when the tub insert body is inserted through the top opening.
12. The tub insert of claim 8, wherein the cross-brace opening is cut out of the tub insert blank having a shape to receive a cross-brace having a rectangular cross-section.
13. The tub insert of claim 8, comprising: for each side wall, a side wall front edge fold line for a front lock flap extending from the side wall, wherein the front lock flaps are cut to wrap around the front wall to secure the front wall to the side walls after the tub insert body is formed; and for each side wall, a side wall rear edge fold line for a rear lock flap extending from the side wall, wherein the rear lock flaps wrap around the rear wall to secure the rear wall to the side walls after the tub insert body is formed.
14. The tub insert of claim 13, wherein each of the front lock flaps and the rear lock flaps comprises a lock tab cut into the tub insert blank at an end opposite the respective side wall front edge fold line and side wall rear edge fold line, wherein lock slots are cut out of the tub insert blank in the bottom wall adjacent the front wall fold line and proximate each side wall fold line and adjacent the rear wall fold line and proximate each side wall fold line, wherein each of the lock slots receive a corresponding one of the lock tabs to secure the front lock flaps around the front wall and the rear lock flaps around the rear wall.
15. A tub insert for a top loading washing machine having a cabinet with a top surface and a top opening in the top surface, a lid movable between an open position and a closed position, and a wash tub disposed within the cabinet, the tub insert comprising: a bottom wall having a front wall edge, a rear wall edge opposite the front wall edge, and oppositely disposed side wall edges extending between the front wall edge and the rear wall edge; a front wall extending upward from the front wall edge and having oppositely disposed front wall side edges and a front wall top edge opposite the front wall edge; a rear wall extending upward from the rear wall edge and having oppositely disposed rear wall side edges and a rear wall top edge opposite the front wall edge; oppositely disposed side walls each extending upward from one of the side wall edges, each side wall having a side wall front edge, a side wall rear edge opposite the side wall front edge, and a side wall top edge opposite the side wall edge, wherein the bottom wall, the front wall, the rear wall and the side walls form a tub insert body when each of the front wall side edges is adjacent a corresponding one of the side wall front edges and each of the rear wall side edges is adjacent a corresponding one of the side wall rear edges, and the tub insert body is shaped to engage the cabinet and the wash tub when the tub insert body is inserted through the top opening to substantially prevent movement of the wash tub relative to the cabinet; and a cross-brace support panel operatively connected to each of the side walls at the corresponding side wall top edge and having a cross-brace opening for receiving a cross-brace, wherein the cross-brace support panels extend upward through a gap between the lid and the top surface of the cabinet with the cross-brace opening disposed above the lid when the tub insert body is inserted through the top opening and the lid is in the closed position.
16. The tub insert of claim 15, wherein the cross-brace opening of each of the cross-brace support panels has an open end facing toward the front wall.
17. The tub insert of claim 16, wherein the cross-brace opening of each of the cross-brace support panel has a cross-brace detent extending into the cross-brace opening and engaging the cross-brace disposed within the cross-brace opening to resist the cross-brace exiting the cross-brace opening through the open end.
18. The tub insert of claim 15, wherein the cross-brace opening is shaped to receive a cross-brace having a rectangular cross-section.
19. The tub insert of claim 15, comprising: a front lock flap attached to each side wall front edge, wherein the front lock flaps wrap around the front wall to secure the front wall to the side walls; and a rear lock flap attached to each side wall rear edge, wherein the rear lock flaps wrap around the rear wall to secure the rear wall to the side walls.
20. A tub insert system, comprising: a cross-brace; and the tub insert of claim 15, wherein the cross-brace is inserted into the cross-brace openings when the tub insert is inserted into the top opening and the lid is in the closed position with the cross-brace support panels extending upward through the gap.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0008]
[0009]
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
DETAILED DESCRIPTION
[0016] Washing machines as discussed above may be protected during storage and transport in paperboard containers by tub inserts in accordance with the present disclosure having cross-brace supports for holding cross-braces to prevent crushing caused by lateral forces from material handling equipment such as clamping forklifts. The tub insert may be inserted into the top opening of the cabinet of the washing machine when the lid is open to engage the cabinet and wash tub to prevent substantial relative movement of the wash tub during transport that could damage the cabinet and other components. At the same time, the tub insert may have cross-brace support panels that extend through a gap between the lid and the cabinet and above the lid and top surface of the cabinet to receive and retain a cross-brace that extends to or slightly past the left and right sides of the washing machine. When the washing machines are packaged in paperboard containers and arranged side-by-side, the cross-braces of adjacent containers are aligned so that the cross-braces bear upon each other when the containers are clamped together from the sides to substantially prevent forces from being applied to the cabinets that could crush the containers and cause damage to the washing machines.
[0017]
[0018] The tub insert 10 as illustrated has a tub insert body 24 formed by a front wall 26, a rear wall 28, oppositely disposed side walls 30 and a bottom wall 32. The tub insert body 24 may have a complimentary shape to the top opening 16 of the cabinet 14 and the wash tub 18 such that the tub insert body 24 engages both the cabinet 14 and the wash tub 18 when the tub insert 10 is inserted through the top opening 16 to substantially prevent movement of the wash tub 18 relative to the cabinet 14 and contact between the components. The bottom wall 32 may include an agitator opening 34 through which a top end of the agitator 20 extends to allow the tub insert body 24 to be fully inserted through the top opening 16 and into engagement with the wash tub 18. In the illustrated embodiment, the walls 26, 28, 30 are inverted trapezoids that intersect at corners 36 of the tub insert body 24 so that the walls 26, 28, 30 taper outward as they extend upward from the bottom wall 32. Further, the tub insert body 24 may be sized so that upper edges of the walls 26, 28, 30 are approximately level with or below the top surface of the cabinet 14 at the top opening 16 when inserted into the top opening 16 so that the lid 22 can be closed. Those skilled in the art will understand that the tub insert body 24 may have alternative shapes that allow the tub insert body 24 to simultaneously engage the cabinet 14 at the top opening 16 and the wash tub 18 to substantially prevent relative movement there between, and such alternative shapes are contemplated by the inventors.
[0019] As discussed above, the tub insert 10 in accordance with the present disclosure provides support for a cross-brace (
[0020] The cross-brace support panel 40 may include a cross-brace opening 50 having a complimentary shape to a cross-sectional shape of the cross-brace to be used to support the container for the washing machine 12. In the illustrated embodiment, the cross-brace opening 50 has a generally rectangular shape corresponding to the cross-sectional shape of a 24 stud or a rectangular paperboard post. The cross-brace opening 50 may have other shapes corresponding to the cross-sectional shapes of particular structures being used as the cross-brace. The cross-brace opening 50 may facilitate insertion of the cross-brace by being provided with an open end 52 proximate the front wall 26 of the tub insert 10. The cross-brace may be inserted through the open ends 52 of the cross-brace openings 50 and past cross-brace detents 54 extending into the cross-brace openings 50 that will retain the cross-brace within the cross-brace openings 50 and in a particular position relative to the cabinet 14 so that the cross-brace will align with and engage cross-braces of adjacent washing machine containers. Alternatively, the cross-brace may slide into the cross-brace openings 50 from the side and rearward of the cross-brace detents 54. The material from which the tub insert 10 is fabricated, such as paperboard, may be sufficiently resilient to allow the cross-brace to be forced past the cross-brace detents 54 and into the cross-brace openings 50 while preventing the cross-brace from being removed past the cross-brace detents 54 without application of a similar force in the forward direction toward the open end 52.
[0021] The tub support 10 can be made from a single, unitary (one piece) blank 60 such as that shown in
[0022] The tub insert blank 60 may be configured to facilitate securing the walls 26, 28, 30 to form the tub insert body 24 when the tub insert 10 is formed from the tub insert blank 60. Front lock flaps 80 may extend from side wall front edges 76, and rear lock flaps 82 may extend from side wall rear edges 78. Each of the lock flaps 80, 82 may include a lock flap outer panel 84 at the side wall edges 76, 78, respectively, and a lock flap inner panel 86 separated from the lock flap outer panel 84 by lock flap fold lines 88, 90 that define a lock flap top edge panel 92. The lock flap inner panels 86 may include lock flap tabs 94 at free ends opposite the lock flap fold lines 90. Lock slots 96 may be formed in the bottom wall 32 by laser cutting, die cutting or other cutting method and disposed adjacent the front wall fold line 62 and the rear wall fold line 64 near each side wall fold line 66. The lock slots 96 may be configured to receive and engage the corresponding lock flap tabs 94 when the tub insert 10 is formed as described below.
[0023]
[0024] After the walls 26, 28, 30 are folded together, the routine 100 may pass to a block 106 where the lock flaps 80, 82 are folded around the side wall edges 76, 78, respectively, toward the outer surfaces of the corresponding walls 26, 28. With the lock flap outer panels 84 of the lock flaps 80, 82 facing and engaging the outer surfaces of the wall 26, 28, the routine 100 may pass to a block 108 where the lock flap inner walls 86 are folded around the lock flap fold lines 88, 90 toward the inner surfaces of the walls 26, 28. Folding the lock flap inner walls 86 wraps the lock flaps 80, 82 around the respective walls 26, 28 with the lock flap top edge panels 92 disposed above the wall top edges 70, 74. With the lock flaps 80, 82 folded around the walls 26, 28, the routine 100 may pass to a block 110 where the lock tabs 94 are inserted into the corresponding lock slots 96 to secure the walls 26, 28, 30 together as the tub insert body 24.
[0025] After forming the tub insert body 24 at steps 102-110, the routine may pass to a block 112 where the transition panels 44 are folded around the side wall top edges 46 away from the interior of the tub insert body 24 and toward the outer surfaces of the side walls 30. This fold will allow the transition panels 44 to lie against the top surface of the cabinet 14 proximate the top opening 16 when the lid 22 is closed. At a block 114, the cross-brace support panels 40 may be folded around the support panel bottom edges 48 in the opposite direction as the transition panels 44 were folded and toward the top surfaces of the transition panels 44. The distance between the edges 46, 48 is set so the support panel bottom edges 48 are aligned with the gap 42 when the tub insert 10 is installed through the top opening 16 and the lid 22 forces the transition panels 44 down against the top surface of the cabinet 14.
INDUSTRIAL APPLICABILITY
[0026] The tub insert in accordance with the present disclosure may protect the top loading washing machine 12 from both internal damage and external damage during storage and transit. As shown in
[0027] The tub insert 10 also protects the washing machine 12 from external damage by supporting a cross-brace that will bear lateral loads that can be experienced by lightweight shipping containers that may not be sufficiently rigid to bear all loading during storage and transit. As shown in the side view of
[0028]
[0029] As shown in
[0030]
[0031] The design of the tub insert 10 and the tub insert blank 60 also facilitate efficient storage and transport to the location where the tub inserts 10 will be installed in the washing machines 12. If the tub insert blanks 60 have not been folded into the tub inserts 10, the tub insert blanks 60 are flat and can be stacked without occupying excess space. If the tub insert blanks 60 have been folded into the tub inserts 10, the tapered shape of the tub insert bodies 24 created by the inverse trapezoidal walls 26, 28 in the embodiment illustrated herein create draft angles that allow the tub inserts 10 to nest when stacked. The nesting and stacking allows more tub inserts 10 per pallet than tub inserts that are not capable of nesting and thereby making the tub inserts 10 more efficient and cheaper to ship to the location where they will be inserted into the washing machines 12.
[0032] While the preceding text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of protection is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the scope of protection.
[0033] It should also be understood that, unless a term was expressly defined herein, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to herein in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term be limited, by implication or otherwise, to that single meaning.