Boxes with internal resilient elements and insert therefor

Information

  • Patent Grant
  • 6206194
  • Patent Number
    6,206,194
  • Date Filed
    Wednesday, June 9, 1999
    26 years ago
  • Date Issued
    Tuesday, March 27, 2001
    24 years ago
Abstract
A resilient element for a box is provided, wherein the resilient element supports, suspends or holds down an item or items to be shipped. The resilient element may be a part of an insert for the box, wherein the insert comprises the resilient element film attached to one or more panels. The insert may comprise a plastic film glued to a sheet of corrugated cardboard, wherein the sheet of cardboard may be separated into two panels that may be positioned at opposite ends within the box. Alternatively, the resilient element may be directly attached to a box panel.
Description




BACKGROUND OF THE INVENTION




The invention relates to packaging in general, and, more particularly, to packaging boxes for accommodating an item or items in a secure manner.




Various packaging boxes are known, including boxes equipped for shipping items in a secure manner. For instance, sensitive items are often shipped in boxes with the items supported on blocks or on specially molded foamed polyurethane, or spaced from the side panels of the box by cardboard inserts, foamed polyurethane pellets or beads, or the so-called bubble-wrap sheets. These protective measures suppress the transmission to the items of impacts, shocks, vibrations and/or other forces to which the box itself may be subjected, but they sometimes are bulky, costly, difficult to handle, environmentally undesirable, and/or are non-compliant or do not conform to the items being shipped.




OBJECT AND SUMMARY OF THE INVENTION




An object of the invention is to provide alternative means for securing items being shipped in packaging boxes.




In accordance with an embodiment of the invention, a resilient element is provided within the box; the resilient element is capable of supporting, suspending and/or holding down an item or items being shipped. Because the resilient element is flexible, it acts as a shock absorber, such that forces on the box are absorbed in whole or in part to reduce or eliminate the transmission of such forces to the items being shipped.




The resilient element may be a part of an insert for placement within the box, wherein the insert provides for the resilient element to extend across a space within the box for supporting, suspending and/or holding down the item or items to be shipped. The insert may comprise one or more panels to which the resilient element is attached.




Alternatively, the resilient element may be directly attached to one or more of the panels of the box itself. For example, the resilient element may be attached to the inside of one or more side panels of the box. The resilient element may additionally be attached to a handle which may be used to twist or otherwise adjust the resilient element in order to secure the item or items in place. A cinching mechanism may also be used to secure the resilient element in place.




The resilient element may take many forms. For example, it may be in the form of a plastic film. Other suitable materials include fabrics, cellulose, rubbers, polymers, and any other material providing the desired pliability, elasticity, and/or flexibility. The shape of the resilient element may be in the form of a sheet, tube, pocket or any other suitable configuration. It may also have additional features, such as slits, holes, or punctures to allow the desired result with respect to the item or items to be secured. For example, a resilient element in the form of a mesh may be used to suspend an item like a hammock. As another example, the resilient element may have a central slit so that it may be looped around an object, with one end of the resilient element being passing through the slit to form the loop.




As a specific example of an insert in accordance with an embodiment of the invention, an insert may comprise a plastic film glued to a rigid sheet of corrugated cardboard or other relatively rigid material, wherein the sheet may be separated into two panels that may be positioned at opposite ends within the box. In such an embodiment, the plastic film extends between the two panels for supporting, suspending and/or holding down the item or items to be shipped.




In accordance with certain embodiments of the invention, the box and the insert may both be constructed so that they may be shipped to the user in a substantially flat condition. For example, the insert may be made of a single flat sheet of corrugated cardboard, with the plastic film glued in at least two places to the flat sheet. For use, the sheet of cardboard may be separated into two panels, with the plastic film glued to each of the panels so that it extends between them.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

shows a sheet portion of an insert in accordance with a first embodiment of the invention;





FIG. 2

shows the sheet of

FIG. 1

, with plastic film glued to the sheet, forming the completed insert;





FIG. 3

shows the insert of

FIG. 2

, with the sheet portion separated to form two panels;





FIG. 4

shows the insert of

FIG. 2

, with the plastic film being positioned;





FIG. 5

shows a cutaway view of a box with the insert of

FIG. 2

positioned within the box, showing one panel of the insert;





FIG. 6

shows a view similar to

FIG. 5

, with the lid of the box folded downward into slots in the insert to hold the insert in position;





FIG. 7

shows a top view of the box of

FIG. 5

with the insert in place and the lid of the box folded downward;





FIG. 8

shows a perspective view of the box of

FIG. 5

with the insert in place and the lid of the box folded downward, showing the inside of the box;





FIG. 9

shows a view similar to

FIG. 6

, with an item being supported by the plastic film;





FIG. 10

shows a view similar to

FIG. 6

, with an item being held down by the plastic film;





FIG. 10A

shows a view similar to

FIG. 10

, with an alternative configuration of a resilient element;





FIG. 10B

shows the box of

FIG. 10A

, with the resilient element being twisted to further support the item to be shipped;





FIG. 11

shows a sheet portion of an insert in accordance with a second embodiment of the invention;





FIG. 12

shows the sheet of

FIG. 11

, with plastic film glued to the sheet, forming the completed insert;





FIG. 13

shows the insert of

FIG. 12

, with the sheet portion separated to form two panels;





FIG. 14

shows the insert of

FIG. 12

, with the plastic film being positioned;





FIG. 15

shows a cutaway view of a box with the insert of

FIG. 12

positioned within the box, showing one panel of the insert;





FIG. 16

shows a top view of the box of

FIG. 15

with the insert in place;





FIG. 17

shows a perspective view of the box of

FIG. 15

with the insert in place, showing the inside of the box;





FIG. 18

shows a view similar to

FIG. 15

, with an item being supported by the plastic film;





FIG. 19

shows a view similar to

FIG. 15

, with an item being held down by the plastic film;





FIG. 20

shows a sheet portion of an insert in accordance with a third embodiment of the invention;





FIG. 21

shows the sheet of

FIG. 20

, with plastic film glued to the sheet, forming the completed insert;





FIG. 22

shows the insert of

FIG. 20

, with the sheet portion separated to form two panels, being inserted into a box;





FIG. 23

shows a top view of the box of

FIG. 22

with the insert in place;





FIG. 24

shows a perspective view of the box of

FIG. 22

with the insert in place, showing the inside of the box;





FIG. 25

shows a cutaway view of the box of

FIG. 22

with the insert in place, with an item being held down by the plastic film;





FIG. 25A

shows a view similar to

FIG. 23

, with the box having partitions;





FIG. 25B

shows the box of

FIG. 25A

, in a view similar to

FIG. 25

;





FIG. 26

shows a sheet portion of an insert in accordance with a fourth embodiment of the invention;





FIG. 27

shows the sheet of

FIG. 26

, with plastic film glued to the sheet, forming the completed insert;





FIG. 28

shows the insert of

FIG. 27

, with the sheet portion separated to form two panels;





FIG. 29

shows a cutaway view of a box with the insert of

FIG. 27

positioned within the box, showing one panel of the insert;





FIG. 30

shows a top view of the box of

FIG. 27

with the insert in place;





FIG. 31

shows a perspective view of the box of

FIG. 27

with the insert in place, showing the inside of the box;





FIG. 32

shows a sheet portion of an insert in accordance with a fifth embodiment of the invention;





FIG. 33

shows the sheet of

FIG. 32

, with plastic film glued to the sheet, forming the completed insert;





FIG. 34

shows a perspective view of the insert of

FIG. 33

;





FIG. 35

shows a perspective view of the insert of

FIG. 33

, with the sheet portion separated to form two panels;





FIG. 36

shows the insert of

FIG. 33

being inserted into a box;





FIG. 37

shows a top view of the box of

FIG. 36

with the insert in place;





FIG. 38

shows a perspective view of the box of

FIG. 36

with the insert in place, showing the inside of the box;





FIG. 39

shows a cutaway view of the box of

FIG. 22

with the insert in place, with an item being supported by the plastic film;





FIG. 40

shows a view similar to that of

FIG. 39

with the insert in place, with an item being held down by the plastic film;





FIG. 41

shows an alternative embodiment of an insert similar to that of

FIG. 33

positioned within a box;





FIG. 42

shows an initial stage of assembly of a box of an alternative embodiment of the invention;





FIG. 43

shows a further state of assembly of the box as shown in

FIG. 42

;





FIG. 44

shows a further stage of assembly of the box as shown in

FIG. 42

;





FIG. 45

shows the assembled box of

FIGS. 42 through 44

, showing the resilient element;





FIG. 46

shows a view similar to

FIG. 45

, with the resilient element being exposed by withdrawal of a handle;





FIG. 47

shows a view similar to

FIG. 46

, with an item being placed in the resilient element;





FIG. 48

shows a view similar to

FIG. 47

, with the resilient element being twisted to secure the item;





FIG. 49

shows a view similar to

FIG. 48

, with the resilient element being cinched;





FIG. 50

shows a view similar to

FIG. 49

, showing the closing of the box lid;





FIG. 51

shows an alterative embodiment in accordance with the invention;





FIG. 52

shows a perspective view of the box of

FIG. 51

, showing the inside of the box; and





FIG. 53

shows a top view of the box of FIG.


51


.











DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS





FIG. 1

shows a sheet


10


for an insert in accordance with a first embodiment of the invention. The sheet


10


may be constructed, for example, of corrugated cardboard of any other suitable material. The sheet has a score line


11


along which the sheet may be separated. The score line may be formed, for example, of a cut that extends completely through the material in all but a few places, and most of the way through the material in the remaining places, or in any other suitable manner as will be appreciated by persons of ordinary skill in the art.





FIG. 2

shows the sheet


10


of

FIG. 1

, with a resilient element


12


attached to the sheet


10


, forming the completed insert


13


. In this illustrated embodiment, the resilient element


12


is a plastic film, although any suitable material or configuration may be used. In this illustrated embodiment, the plastic film is attached to the sheet


10


by two glue beads or lines


14


,


15


, although attachment may be accomplished in any other suitable manner.





FIG. 3

shows the insert


13


of

FIG. 2

, with the sheet portion now separated along the score line


11


to form two panels


16


,


17


. The score line


11


facilitates easy separation of the sheet


10


into the panels


16


,


17


. Because the plastic film


12


is glued to each of the panels


16


,


17


, it extends between the panels


16


,


17


when they are separated.





FIG. 4

shows the insert


13


of

FIG. 2

, with the plastic film


12


being positioned, as well as tensioned, by the folding of flaps


18


,


19


. With the panels


16


,


17


facing each other, the flaps


18


,


19


to which the plastic film


12


is attached are folded outwardly, away from the central area between the two panels


16


,


17


. A tab


20


,


21


on each flap


18


,


19


, is then inserted into a respective slot


22


,


23


in the panels


16


,


17


. In this manner, the plastic film


12


may be tensioned between the two panels


16


,


17


.





FIG. 5

shows a cutaway view of a box


24


with the insert


13


of

FIG. 2

positioned within the box


24


, showing one panel


16


of the insert


13


. The panel


16


is wider than the box


24


, such that the side panels


25


and


26


must be folded at angles in order that the central portion of the panel


16


may be positioned against the side of the box. The side panels


25


,


26


help keep the panel


16


in position. The side panels


25


,


26


have lid receiving slots


27


,


28


for receiving a retaining flap


29


on the lid of the box


24


.

FIG. 6

shows a view similar to

FIG. 5

, with the retaining flap


29


of the lid of the box


24


shown folded downward into the receiving slots


27


,


28


of the insert


13


.




The other panel


17


is positioned at an opposite end of the box in a manner similar to panel


16


.

FIG. 7

shows a top view of the box


24


of

FIG. 5

with the insert


13


in place and the lid of the box folded downward. Lid flaps


30


and


32


are visible in this view and partially obstruct the view of the panels


16


,


17


of the insert


13


.

FIG. 8

shows a perspective view of the box of

FIG. 5

with the insert


13


in place and the lid of the box folded downward, showing the inside of the box.





FIGS. 9 and 10

show how the insert is used to support or hold down an item


33


to be shipped. As shown in

FIG. 9

, the insert


13


may be placed in the box


24


with the plastic film


12


extending across the box, near the bottom of the box but separated from the bottom of the box. The item


33


is placed in the box and is supported by the plastic film


12


, such that it is suspended from the bottom of the box. Alternatively or additionally, as shown in

FIG. 10

, the item


33


may be placed in the box and then insert


13


may be positioned in the box such that the plastic film


12


lies over the top of the item


33


to hold the item down. In this manner, the plastic film


12


secures the item


33


and keeps the item


33


distanced from the top of the box.




Persons of ordinary skill in the art will appreciate that using an insert in accordance with the invention, in which a resilient element is used to support, suspend and/or hold down an item being shipped, is useful in securing the item during shipping. The insert secures the item in place, and the resiliency of the resilient element helps absorb shock. The resilient element also distances the item away from sides of the box, which may be subject to puncture or other damage. In addition, because of the flexibility of the resilient element, it is able to conform substantially to the item or items being shipped, which is especially useful for items having odd-shaped configurations. Also, certain configurations of resilient elements in accordance with the invention, for example those with slits or holes or those in the form of a pocket, allow protrusions from the item to project and to be suspended, thereby protecting such protrusion, which may be fragile.





FIGS. 10A and 10B

show a view similar to

FIG. 10

, with an alternative configuration of a resilient element. In this embodiment, the resilient element


12


A may be in the form of a pocket or in the form of a tube with a slit in it, allowing an item


33


A to be placed inside the pocket or tube. This assists in securing the item for support and suspension. As shown in

FIG. 10B

, the item


33


A may be more tightly secured in the resilient element by twisting the resilient element


12


A. Tightening may be accomplished in other suitable ways, for example, by cinching the resilient element.





FIG. 11

shows a sheet


40


for an insert


43


in accordance with a second embodiment of the invention.

FIG. 12

shows the sheet


40


of

FIG. 11

, with plastic film


42


glued to the sheet, forming the completed insert


43


.





FIGS. 13 and 14

shows the insert


43


of

FIG. 12

, with the sheet


40


separated along score line


41


to form two panels


44


,


45


. The positioning of the plastic film


42


in this embodiment is similar to that described above with respect to the first embodiment.




The score line


41


is configured such that the panels


44


,


45


have projections


46


,


47


, respectively, when they are separated from each other. As shown in

FIGS. 15 through 17

, the box


49


has slots


48


for receiving and retaining the projections


46


,


47


when the lid of the box


49


is closed. In this manner, the lid of the box retains the insert


43


in place.





FIGS. 18 and 19

show this second illustrated embodiment in use to secure an item, by supporting, suspending, and/or holding down the item. This operation is similar to that described above with respect to the first illustrated embodiment.





FIG. 20

shows a sheet


50


for an insert in accordance with a third embodiment of the invention.

FIG. 21

shows the sheet


50


with plastic film


52


glued to the sheet


50


, forming the completed insert


53


.





FIG. 22

shows the insert


53


of

FIG. 20

, with the sheet


50


separated along score line


51


to form two panels


54


,


55


. The insert


53


is shown being inserted into a box


58


.




In this embodiment, the panels


54


,


55


have flaps


56


,


57


, respectively, which may be folded away from the central portion of the insert as shown. When placed in the box


58


, the flaps


56


,


57


are positioned between the respective side of the box and the main portion of the panel


54


,


55


, as shown in

FIGS. 23 through 25

. These flaps


56


,


57


help maintain the position of the panels


54


,


55


, providing additional protection in the form of cushion and support to the respective box sides. As shown in

FIG. 25

, the plastic film in this embodiment may be used to support, suspend, and/or hold down an item in a manner similar to that described above with respect to other embodiments.




As shown in

FIGS. 25A and 25B

, the box


58


may have dividers or partitions


59


within it. The resilient element


52


may serve to secure the partitions


59


as well as the individual items within the partitions. Of course, partitions may be used with other embodiments in accordance with the invention.





FIG. 26

shows a sheet


60


for an insert in accordance with a fourth embodiment of the invention.

FIG. 27

shows the sheet


60


of

FIG. 26

, with plastic film


62


glued to the sheet


60


, forming the completed insert


63


.





FIG. 28

shows the insert


63


of

FIG. 27

, with the sheet


60


separated along score line


61


to form two panels


64


,


65


. In this embodiment, each of the panels


64


,


65


comprises two side panels


66


,


67


and


68


,


69


, respectively. To fit the panels


64


,


65


against the appropriate sides of the box, the side panels


66


,


67


and


68


,


69


are folded, as shown in

FIGS. 28 through 31

. The plastic film


62


in this embodiment serves to support, suspend, and/or hold down an item in a manner similar to that described above with respect to other embodiments.





FIG. 32

shows a sheet


80


for an insert in accordance with a fifth embodiment of the invention.

FIG. 33

shows the sheet


80


of

FIG. 32

, with plastic film


82


glued to the sheet


80


, forming the completed insert


83


. The completed insert is also shown in FIG.


34


.





FIG. 35

shows the insert


83


with the sheet


80


separated along score line


81


to form two panels


84


,


85


. As shown in

FIGS. 36 through 40

, the panels


84


,


85


are positioned on the inside of opposite side panels of a box


86


, with the plastic film


82


extending between the panels. The insert


83


serves to support, suspend, and/or hold down an item in a manner similar to that described above.





FIG. 41

shows an alternative insert


93


similar to the insert


83


. In this embodiment, the panels


84


,


85


extend the full height of the box


36


, and may be themselves be taller than the box


6


so that they are angled when in use. The operation of the insert is similar to that described above. This configuration is especially adapted, for example, to the support and suspension of items having a larger base narrowing to a smaller top, as in tapered, tiered, or conical configurations.





FIG. 42

shows an initial stage of assembly of a box


100


for an alternative embodiment of the invention. Side panels


101


,


102


and


103


are folded with respect to bottom panel


105


to form three side of the box


100


. Subsequently, as shown in

FIG. 43

, side panel


104


is folded with respect to bottom panel


105


, and side flaps


106


,


107


are inserted within side panels


102


,


103


, respectively. Then, as shown in

FIG. 44

, side flaps


108


,


109


are folded inside of side panels


102


,


103


. Tabs


114


,


115


(labeled in

FIG. 42

) are inserted into slots


110


,


111


in flaps


112


,


113


, to secure the side panels


108


,


109


in place.




As shown in

FIGS. 45 through 50

, the box has a resilient element


122


within it, the resilient element


122


being in the form of a tube. A handle


120


, which may be formed by score liens in side panel


104


, is secured to one end of the resilient element


122


. The other end of the resilient element


122


is attached to the inside of the box


100


, for example by a glue strip


125


on the inside of the side panel


101


.




Withdrawing the handle


120


exposes an open end of the resilient element


122


. An item


123


to be secured may be placed in the opening in the resilient element


122


. As shown in

FIG. 48

, the handle


120


may be used to twist the resilient element


122


to tighten it around the item


123


.




Once the item is in place, the resilient element


122


may be cinched by a cinching element, for example, a slot


124


, as illustrated in

FIGS. 49 and 50

. Alternatively, a clip or other suitable cinching mechanism may be used. As will be appreciated by persons or ordinary skill in the art, as in previous embodiments, this embodiment suspends the item within the box to reduce or eliminate the transmission of outside forces to the item.





FIGS. 51 through 53

shown an alternative embodiment. The box


130


has within it a resilient element


131


in the form of a bag. The bag is secured to one or more sides of the box, for example at glue strips


132


,


133


,


134


and


135


. Again, this embodiment supports and suspends an item being shipped, to protect it from forces on the outside of the box.




The illustrated and described embodiments are examples only, as there are many other variations within the scope of the invention, as defined by the following claims.



Claims
  • 1. A box in combination with an insert for the box, wherein the insert comprises:(a) a relatively rigid sheet, separable into at least first and second panels; and (b) a resilient element attached to each of the first and second panels; wherein the insert is adapted to be positioned within the box so that at least the first panel of the relatively rigid sheet is at one end of the box and at least the second panel of the relatively rigid sheet is at an opposite end of the box, with the resilient element extending between the first and second panels across the inside of the box to secure an item within the box; wherein the insert further comprises means for maintaining the position of at least the first panel of the relatively rigid sheet within the box; and wherein the means for maintaining the position of at least the first panel within the box comprises a slot for receiving a lid flap of the box.
  • 2. A box in combination with an insert for the box, wherein the insert comprises:(a) a relatively rigid sheet, separable into at least first and second panels; and (b) a resilient element attached to each of the first and second panels; wherein the insert is adapted to be positioned within the box so that at least the first panel of the relatively rigid sheet is at one end of the box and at least the second panel of the relatively rigid sheet is at an opposite end of the box, with the resilient element extending between the first and second panels across the inside of the box to secure an item within the box; wherein the insert further comprises means for maintaining the position of at least the first panel of the relatively rigid sheet within the box; and wherein the means for maintaining the position of at least the first panel within the box comprises a projection that is received by a slot in a lid of the box.
  • 3. A method of assembling a packaging container comprising the steps of:(a) providing an insert comprising (i) an integral relatively rigid sheet comprising first and second panels, wherein the relatively rigid sheet is adapted to be separated along separating means such that the first and second panels are then spaced from each other, and (ii) a resilient element attached to each of the first and second panels; (b) separating the first and second panels of the relatively rigid sheet from each other; (c) placing the first and second panels inside a box, so that the first panel is positioned at a first end of the box and the second panel is positioned at an opposite end of the box, with the resilient element extending between the first and second panels across the inside of the box to secure an item within the box.
  • 4. The method of assembling a packaging container as recited in claim 3, wherein the first panel comprises means for maintaining the position of the first panel within the box.
  • 5. The method of assembling a packaging container as recited in claim 4, wherein the means for maintaining the position of the first panel within the box comprises a slot for receiving a lid flap of the box.
  • 6. The method of assembling a packaging container as recited in claim 4, wherein the means for maintaining the position of the first panel within the box comprises a projection that is received by a slot in a lid of the box.
  • 7. The method of assembling a packaging container as recited in claim 4, wherein the second panel comprises means for maintaining the position of the second panel within the box.
  • 8. The method of assembling a packaging container as recited in claim 7, wherein the means for maintaining the position of the second panel within the box comprises a slot for receiving a lid flap of the box.
  • 9. The method of assembling a packaging container as recited in claim 7, wherein the means for maintaining the position of the second panel within the box comprises a projection that is received by a slot in a lid of the box.
  • 10. The method of assembling a packaging container as recited in claim 3, wherein the step of placing the first and second panels inside a box further includes positioning the resilient element across the box adjacent to, but distanced from, the bottom of the box, to support an item to be shipped.
  • 11. The method of assembling a packaging container as recited in claim 3, wherein the step of placing the first and second panels inside a box further includes positioning the resilient element across the box adjacent to, but distanced from, the top of the box, to hold down an item to be shipped.
  • 12. The method of assembling a packaging container as recited in claim 3, wherein the integral relatively rigid sheet further comprises at least one side panel adapted to be folded with respect to the first panel and at least one side panel adapted to be folded with respect to the second panel.
  • 13. An insert for positioning inside a box comprising(i) an integral relatively rigid sheet comprising first and second panels, wherein the relatively rigid sheet is adapted to be separated along separating means such that the first and second panels are then spaced from each other, and (ii) a resilient element attached to each of the first and second panels.
  • 14. An insert as recited in claim 13, wherein the first panel comprises means for maintaining the position of the first panel within the box.
  • 15. An insert as recited in claim 14, wherein the means for maintaining the position of the first panel within the box comprises a slot for receiving a lid flap of the box.
  • 16. An insert as recited in claim 14, wherein the means for maintaining the position of the first panel within the box comprises a projection that is received by a slot in a lid of the box.
  • 17. An insert as recited in claim 14, wherein the second panel comprises means for maintaining the position of the second panel within the box.
  • 18. An insert as recited in claim 17, wherein the means for maintaining the position of the second panel within the box comprises a slot for receiving a lid flap of the box.
  • 19. An insert as recited in claim 17, wherein the means for maintaining the position of the second panel within the box comprises a projection that is received by a slot in a lid of the box.
  • 20. An insert as recited in claim 13, wherein the integral relatively rigid sheet further comprises at least one side panel adapted to be folded with respect to the first panel and at least one side panel adapted to be folded with respect to the second panel.
Parent Case Info

This application claims the benefit of U.S. Provisional Application No. 60/088,720, filed Jun. 10, 1998.

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Provisional Applications (1)
Number Date Country
60/088720 Jun 1998 US