Title of Invention

Packed roof window products Technical Field

The present invention relates to a packed roof window product comprising a plurality of differently sized roof window related product components and packaging material components contained in a cardboard box.

Background Art

When installing windows in a roof it is vital to ensure that the roof window itself is securely attached to the roof structure and that the joint between the roof window and the roof structure is properly weather proofed. It is therefore important that all components of roof window products, such as the roof window itself or a flashing assembly for a roof window, are used and are used in the right way. To facilitate this, the components are typically arranged in the box in an intended order of use and small components, such as screws, are kept in plastic bags. Furthermore, blocks of expanded polystyrene or similar shock absorbing material are used for protecting the product and/or for keeping the components in the intended position within the box. An example of a packed roof window, where these principles are used, is known from EP2748071 B1 and an example of a packed flashing assembly for a roof window is known from EP1710163B1. While these packaging have worked very well, there is an ever- increasing demand for delivering products that are more environmentally friendly.

Summary of Invention With this background, it is an object of the invention to provide a packed roof window product, which has a smaller climate footprint, without increasing the risk of errors in the installation of the product and maintaining a good protection of the product during transportation. It is noted that “roof 2 window product” is intended to cover not only a roof window, but also products associated with the installation of a roof window, such as flashing assemblies, and products intended for being installed on a roof window, such as shutters.

This and further objects are achieved with a packed roof window product of the kind mentioned in the introduction, which is furthermore characterised in that at least one component is retained by a paper ribbon.

Traditionally small components have been attached to the cardboard box or to larger components, for example by means of an adhesive, to prevent them from becoming displaced or lost, either inside the box or when removed from the box. Product components have also or alternatively been wrapped in plastic, thereby also preventing them from scratching or otherwise damaging other components. Other components have been folded and retained by plastic strips, which have also been used for attaching one component to another. Larger components have been kept in place in the box by being attached to the box by means of an adhesive or by being fixated between blocks of expanded polystyrene (EPS). The use of adhesives, plastic, and EPS, however, requires that the packaging material will have to be separated in different fractions for recycling. A paper ribbon on the other hand belongs to the same fraction as the cardboard box, which considerably increases the likelihood of the packaging material being recycled instead of just being disposed of as combustible waste and reduces the risk of recycled material being polluted by other materials.

Another potential advantage of using a paper ribbon rather than for example a plastic strip is that it may be biologically degradable. Light-weight packaging items, such as bags, plastic wrappings, EPS, and strips, are easily caught by wind when installing a roof window product on a roof of building and may easily end up in nature or other places where it cannot be collected by the installer. While it is of course not the intention to leave packaging material behind, a biodegradable paper ribbon does little harm.

In one embodiment a paper ribbon is used for retaining a component in relation to the cardboard box. This may for example be advantageous if the 3 roof window product comprises flashing or covering components. Flashing or covering components are typically made of sheet metal, such as aluminium and copper, and flashing or covering components made from aluminium are typically painted and lacquered. As flashing or covering components will be at least partially visible in the installed state of the roof window product, it is important that they are not scratched or deformed. And even more importantly, a deformation is to be avoided as it may influence negatively on the weather proofing function of the flashing or covering components. By attaching them to the cardboard box using a paper ribbon, the flashing or covering components are prevented from moving too much around in the box, thus reducing the risk of them being jammed between other component, and the possibility for contact with other components, which might result in scratches, is also reduced. Another advantage of retaining flashing or covering components using a paper ribbon is that the need for blocks of material attached to the box for retaining them may be reduced or even eliminated, potentially leading to a reduction of the amount of material used.

Similar considerations apply to other components and in particular to mounting brackets and fasteners, such as screws, nails, or clamps, which are typically made of metal and may damage other components if provided loose in the box.

In one embodiment a paper ribbon is used for retaining a component in relation to one or more other components, for example by attaching a smaller flashing or covering component to a larger flashing or covering component.

In one embodiment a collection of fasteners, such as screws, nails, or clamps, are interconnected by a paper ribbon. This not only reduces the risk of one or more fasteners being lost. The paper ribbon may also be used as a holder facilitating use of the fasteners as will be described with reference to the drawing.

In one embodiment a paper ribbon is used for retaining a component in a folded state. Examples of components, which may advantageously be provided in a folded state are wires, cables, sealing strips, insulating 4 members, underroof collars, and vapour barriers. Such components may be provided on their own or form part of a larger component, one example being a wire connected to a motor unit. In that case the wire may be folded and retained in this state by a ribbon surrounding the folded wire only, or the folded wire may be attached to the motor unit by means of a paper ribbon thereby retaining it in the folded state. Another example is a packaging material component, which is given a desired shape and/or size by being folded and is then retained in this shape and/or size by the paper ribbon.

In one embodiment a paper ribbon is used for retaining a component in a compressed state. This particularly applies to sealing and insulating components, which are typically made of compressible and elastic materials. By compressing them their size is reduced, potentially allowing the use of a smaller cardboard box. The compression may be achieved by wrapping and tightening a paper ribbon around the components, or an already compressed component may be retained in the compressed state by applying a paper ribbon.

In one embodiment a paper ribbon is used for attaching a packaging material component, preferably a shock absorbing material, to a product component. As an example, a block of a shock absorbing material may be arranged on the pane of a roof window and be kept there by a paper ribbon attached to two opposite sides of the frame of the window, spanning the pane. Such a block of shock absorbing material may protect the pane by maintaining a distance between the pane and the cardboard box. As another example, blocks of a shock absorbing material may be arranged around the frame of a roof window and attached to each other by means of one or more paper ribbons. Such blocks of shock absorbing material may protect the roof window by softening the impact if the cardboard box containing the roof window is dropped or exposed to other impacts during handling or transportation. As a further example a block of a shock absorbing material may be arranged to protect other sensitive parts of a roof window product, such as electronic components or covering and flashing members, which might not be able to fulfil their weather-proofing function if deformed, and 5 which should not be scratched. As a still further example, a block of shock absorbing material can be used for retaining a component in a desired position within the cardboard box. By attaching the product component to the block of shock absorbing material the product component may be prevented from moving unintentionally within the cardboard box simply by effectively becoming larger, but is it also possible to attach the block of shock absorbing material to the cardboard box thereby achieving an indirect attachment of the product component to the cardboard box. As a still further example, a block of shock absorbing material may be used for keeping a folded product component, such as a wire or cable, in a desired configuration, for example by being arranged between the sections of the folded product component so that sharp bents are avoided.

The shock absorbing material is preferably also made from paper or cardboard to facilitate recycling.

In one embodiment a paper ribbon is used for attaching a bag or a box containing a first product component to a second product component. As an example, a paper bag containing fasteners intended for connecting a mounting bracket to a roof window and/or a roof structure can be attached to the mounting bracket. As another example, a box containing a remote control for activating a motor of a roof window may be attached to the roof window by means of a paper ribbon.

In one embodiment a paper ribbon is used for attaching a bag or a box containing a first product component to a bag or a box containing a second product component. This may provide the advantage of keeping smaller bags and boxes together, so that they are more easily located inside a larger cardboard box, and/or allowing the roof window product to be composed of different subcomponents, which can be packaged individually and put together on demand. As an example, the need for insulating components may be different depending on the climate zone in which a roof window product is to be used, and the relevant product for a particular delivery can then be combined with for example a box containing an electronic component before being put into the cardboard box. 6

A paper ribbon may also be used for retaining a tool for use in the installation of a roof window product in relation to the cardboard box.

While embodiments paper ribbons have been described above for use with one or a collection of components of a particular type made from the same or like materials, it is to be understood that a paper ribbon may also be used for retaining a collection of components of different types. As an example, a paper ribbon may be used for attaching fasteners intended for connecting a mounting bracket to a roof window and/or a roof structure to the mounting bracket. As another example, insulating components and flashing components to be arranged in parallel with each other along a side of a roof window may be kept together by a paper ribbon.

The paper ribbon can be a simple strip of material, which is attached to itself, to the cardboard box, and/or to another item by an adhesive or glue, by one or more mechanical fasteners, and/or by physical engagement, such as a by tying a knot. The paper ribbon may also be a paper tape, i.e. a strip of paper provided with an adhesive or a glue on one or both sides, either as a continuous layer or as local depositions. The adhesive may be a pressure sensitive adhesive. The glue may be a dry glue activated by exposure to water.

The paper ribbon may be provided with local or continuous reinforcements, for example in the form of fibres integrated in the paper or additional material applied on a surface of the ribbon.

The paper ribbon may be made wholly or partially of a heat-sealable paper, so that the ribbon can be attach to itself or to another item by heating the paper, for example by welding.

It is to be understood that while paper and cardboard are usually made from wood-fibres, other plant fibres including fibres originating from straw, bamboo, bagasse, esparto, other grasses, hemp, flax, and cotton may also be used, including combinations of different types of fibres. In Europe, up to 5% of alternative materials, such as the glue or adhesive, is acceptable, but a maximum of 3% is recommended. 7

Brief Description of Drawings

In the following description embodiments of the invention will be described with reference to the schematic drawings, in which

Fig. 1 is a perspective view of a cardboard box containing a packed roof window product,

Fig. 2 is a perspective exploded view of a roof window with packaging material components,

Fig. 3 corresponds to Fig. 2 but showing the packaging material components in the positions, in which it will be located when inside a cardboard box as the one in Fig. 1 , and where elements underneath the pane of the roof window are also seen,

Fig. 4 is a perspective view of a roof window with packaging material components corresponding to substantially to those shown in Fig. 3, where some of the packaging material components and an installation guide positioned on the pane are retained by paper ribbons,

Fig. 5 is a perspective view of a lower end of a roof window with packaging material components corresponding to substantially to those shown in Fig. 3, where some of the packaging material components are retained by paper ribbons, Fig. 6 is a perspective view of an upper end of a roof window with packaging material components corresponding to substantially to those shown in Fig. 3, where some of the packaging material components and a carton positioned on the pane is retained by a paper ribbon,

Fig. 7 is a perspective view of a cardboard box containing a packed roof window product in the form of a flashing assembly, where some components of the flashing assembly are retained by a paper ribbon,

Fig. 8 is a top view of a cable retained by a paper ribbon,

Fig. 9 is a sketch of an underroof collar retained in a folded state by a paper ribbon, Fig. 10 shows the detail C in Fig. 7,

Figs 11 and 12 are perspective views of collections of screws retained by paper ribbons, and 8

Fig. 13 is a perspective view showing the use of the paper ribbon in Fig. 11 as a holder. Description of Embodiments

Referring initially to Fig. 1, a cardboard box 1 for containing a roof window product comprising a plurality of differently sized roof window related product components and packaging material components is shown. In this embodiment the cardboard box is of a rectangular configuration having two major sides 11 and four minor sides 13, 14 extending between of the two major sides (only one of the major sides and two of the minor sides being visible in this view). The shorter of the minor sides 13 is here shown in a partially assembled state. In the assembled state the side sections 13’ will extend perpendicular to the major side 11. In this embodiment the cardboard box is configured for being opened as illustrated by the arrows P. This type of cardboard box is typically used for heavy products such as roof windows with glass panes.

It is to be understood that the cardboard box 1 shown in Fig 1 is merely an example, and that the cardboard box may have another shape to better fit the shape and dimensions of the roof window product and/or be configured for being opened in a different way.

Furthermore, it is to be understood that in the following the same reference numbers will be used for elements having substantially the same function, even if not identical. Figs 2 and 3 show how packaging material components in the form of blocks 42-47 of shock absorbing material are arranged around and on a roof window 5 to protect it from damage, before being arranged in a cardboard box as the one shown in Fig. 1.

Rectangular blocks 42, 43 of shock absorbing material extend along side frame members 51 and a top frame member of the window frame of the roof window 5, and liners 61 made from cardboard compensate for irregularities in the shape of the sides of the roof window. A block 44 of a 9 more complex shape extends along a bottom frame member 52 and makes room for a cardboard carton 62 containing smaller product components, such as mounting brackets and/or fasteners. These four blocks 42-44 of shock absorbing material will be arranged at the four minor sides of the cardboard box 1 in the packed state of the roof window 5.

The pane 53 is protected by two elongate blocks 45 of shock absorbing material, which are arranged on the pane, so that they will be located between the roof window 5 and the major side 11 of the cardboard box 1 in the packed state. A paper liner (not shown) may be provided between the elongate blocks 45 and the pane 53 to protect the pane from scratching.

In Fig. 3 the pane has been shown as transparent so that additional blocks 46, 47 of shock absorbing material arranged on a handlebar 54 of the roof window product are seen. These blocks 46, 47 serve to retain the handle bar, keeping it in an intended position in relation to the pane 53 and to the cardboard box in the packed state. One or both blocks 46, 47 could be replace by a carton or box, and may then be used for containing smaller product components, such as wires and/or a remote control.

Fig. 4 shows an example of paper ribbons 7 being used to retain packaging material components in relation to a roof window product. The window related product is here embodied by the roof window 5 and the packaging material components retained thereto are the shock absorbing blocks 45. The blocks 45 of shock absorbing material arranged on the pane 53 is attached to the side liners 61 by paper ribbons 7, thereby retaining the blocks 45 in relation to the roof window 5. The paper ribbons 7 are in this embodiment a paper tape, which adheres to the blocks 45 and liners 61. It is to be understood that similar paper ribbons may also be used for attaching or retaining other blocks of shock absorbing material, for example at the corners where the blocks 42, 43, 44 extending along the sides, top and bottom of the window, meet or other packaging material components. One of the paper ribbons of Fig. 4 further retains an installation guide in between the block 45 and the window pane 53. In this embodiment, the shock absorbing blocks 42- 10

45 are made from paper and comprise honeycomb structures, to provide shock absorption.

Fig. 5 shows a lower end of a roof window 5 with packaging material components 44, 45, 61 corresponding substantially to the roof window shown in Fig. 3. Like in Fig. 4, a paper ribbon 7 in the form of a paper tape retains the block 45 relative to the roof window 5 and to the liners 61. Furthermore, additional paper ribbons 7 connect liners 61 and block 44 to each other, thereby retaining them in the shown positions relative to the roof window 5.

Fig. 6 shows an upper end of a roof window 5 corresponding to substantially to the roof window shown in Fig. 3. As can be seen a paper ribbon 7 is here used to retain shock absorbing block 45 to the roof window 5 and at the same time it retains a carton 63. The paper ribbon 7 retains the block 45 in the same manner as in Fig. 5. The carton 63 is positioned on the window pane 53 and contains a collection of product components for use in installing the roof window, such as a vapour barrier collar or flashing components. The carton 63 is made from cardboard and has a lid 63a which is longer than the remaining sides of the carton 63, allowing the lid 63a to extend across the block 45 and in between the roof window 5 and block 43. The paper ribbon 7 attaches the lid 63a to the block 45, thereby retaining the carton 63 in relation to the roof window 5.

Another cardboard box 2 packed with another roof window related product, namely a flashing assembly 3, which is typically less heavy than a roof window and consists of a large number of product components, is shown in Fig. 7. This cardboard box is also of a rectangular configuration having two major sides 21 , 22 and four minor sides 23, 24 extending between of the two major sides.

Two blocks 41 of a shock absorbing material are arranged at component 31 of the roof window product 3 to protect it from damage, which might result from the product component moving violently around in the cardboard box during handling or transportation. Flashing assemblies are particularly sensitive to damages caused by deformation but should also be protected from scratching as it might make the product aesthetically 11 unacceptable.

Another component 32 of the roof window product 3 is retained by a paper ribbon 7, which retains the product component 32 in relation to the cardboard box 2. This is achieved by the paper ribbon 7 being attached at both ends by means of an adhesive to the major side 22 forming the bottom of the cardboard box 2.

Fig. 8 shows an example of a folded product component being retained by a paper ribbon 7, preventing the product component from unfolding. The folded product component is here embodied by the cable 64 of a rain-sensor. The paper ribbon 7 is here a strip of paper or cardboard arranged around the folded cable as a loop.

Fig. 9 shows a paper ribbon 7 being used for retaining an underroof collar 66 in a folded state. The paper ribbon is here provided with printed information 71 informing for example about the intended use of the underroof collar. Furthermore, the ribbon here has a weakening 72 in the form of perforations allowing the ribbon to be more easily broken at this place, thus facilitating unfolding of the underroof collar in the intended way.

Fig. 10 shows the detail marked C in Fig. 7 from a slightly different angle. Flere a paper ribbon 7 is used for retaining a tool 67 for use in the installation of a roof window product in relation to the cardboard box 2, here to a minor side 23 of the cardboard box. In this case the tool 67 is a torque bit, but other tools may be attached in the same way.

Fig. 11 and 12 show examples of collections of fasteners 65 each being retained by a paper ribbon 7. In Fig. 11 the fasteners 65 are three screws and the paper ribbon 7 a strip of cardboard, and in Fig. 12 the paper ribbon is paper tape. In both cases the screws are interconnected by the paper ribbon 7.

The embodiment of Fig. 11 has the advantage that the paper ribbon 7 can also be used as a holder by an installer as shown in Fig. 13, where one of the screws is used for attaching a mounting bracket.

In the embodiment of Fig. 12 the fasteners 65 are retained in between two pieces of paper tape. In an alternative embodiment, a single 12 piece of paper tape interconnecting the collection of fasteners can be attached to the cardboard box or to another item.

13

List of reference numerals

1 Cardboard box

11 Major side

13 Minor side

13’ Section of minor side

14 Minor side

2 Cardboard box

21 Major side

22 Major side

23 Minor side

24 Minor side

3 Flashing assembly

31 Component

32 Component

41 -49 Blocks of a shock absorbing material 5 Roof window

51 Side frame member

52 Bottom frame member

53 Pane

54 Handle bar

55 Top frame member

56 Top sash member

61 Side liner

62 Carton

63 Carton

63a Lid

64 Rain sensor

65 Fastener

66 Underroof collar

67 Tool

7 Paper ribbon

71 Printed information

72 Weakening

P Opening of box