CLAM SUSPENSION

FIELD OF THE INVENTION

Various embodiments of the present invention relate to frames useful in packaging assemblies for supporting a product in a box, and to the packaging assemblies incorporating those frames, for example, packaging assemblies used to protect a packaged product during shipment by supporting the product within a box.

BACKGROUND OF THE INVENTION

Protective packaging structures may be used to help protect a product during transport, for example, from physical shock, dust, and other contaminants. For example, a product may be enclosed in a box with additional packing materials (e.g., crumpled paper, air-filled plastic cushions, molded foam) to restrain the product movement inside the box and to cushion the product.

One type of packaging assembly is known as “suspension packaging.” In typical suspension packaging, the packaged product is suspended between two flexible sheets each attached to opposing rigid frames sized to fit within a corresponding box. Another type of packaging assembly is known as retention packaging. In typical retention packaging, a product is retained between a flexible sheet and a rigid backing frame to which the flexible sheet is attached. Examples of retention and suspension packaging are described in more detail in U.S. Pat. Nos. 4,852,743; 4,923,065; 5,071,009; 5,287,968; 5,388,701; 5,678,695; 5,893,462; 6,010,006; 6,148,590; 6,148,591; 6,289,655; 6,302,274; and 6,311,844, each of which is incorporated herein in its entirety by reference.

While existing suspension structures provide a level of protection for the packaged object, there is room for improvement, for example, by enhancing the protective qualities and/or reducing the cost of the structure.

SUMMARY

Generally, some embodiments provided herein include frames, packaging assemblies, and associated methods for supporting an object. In some embodiments, a frame may be provided that may include a first panel defining a first distal end and a first base end. The first distal end may be spaced from the first base end. The frame may include a second panel defining a second distal end and a second base end. The second distal end may be spaced from the second base end. The frame may include at least one pivot axis pivotally connecting the first base end of the first panel and the second base end of the second panel, such that the first panel and the second panel may be configured to rotate relative to one another about the at least one pivot axis. In some embodiments, a flexible support may extend between the first distal end and the second distal end. The first distal end may be configured to move relative to the second distal end. At least one of the first distal end of the first panel and the second distal end of the second panel may be configured to pivot towards an opposing one of the second distal end of the second panel or the first distal end of the first panel in response to application of a force from an object to the flexible support at least partially towards the first base end and the second base end.

In some embodiments, the first distal end may be configured to pivot towards the second distal end in response to the application of the force to the flexible support, and the second distal end may be configured to pivot towards the first distal end in response to the application of the force to the flexible support.

At least one of the first panel and the second panel may be configured to engage the object, such that at least a portion of the frame may be configured to apply a lateral force to the object when the force is applied. The first panel and the second panel may be configured to engage the object therebetween, such that the frame may be configured to apply lateral forces to the object when the force is applied.

In some embodiments, when the force is not applied to the flexible support, the first wall section may be substantially parallel to the second wall section.

In some embodiments, the first panel may further include a first wall section extending between the first distal end and the first base end. The first panel may further include a first flap connected to the first wall section at the first distal end by a first fold line. The second panel may include a second wall section extending between the second distal end and the second base end. The second panel may further include a second flap connected to the second wall section at the second distal end via a second fold line. In some embodiments, the first flap and the second flap may extend at least partially towards each other. The flexible support may be disposed adjacent the first flap and the second flap, and the first flap and the second flap may be configured to be disposed on an opposite side of the flexible support from the object.

In some embodiments, the first flap may be connected to the second flap, and the flexible support may comprise the first flap and the second flap. In some embodiments, the first flap may be connected to the second flap via a center fold line. The first flap may be attached to the second flap.

In some embodiments, the frame may include a flap connector. The flap connector may be generally planar. In some embodiments, the flap connector may be connected to the first flap at a first center fold line. The flap connector may be connected to the second flap at a second center fold line, such that the flap connector may pivotally connect the first flap and the second flap.

In some embodiments, the frame may include a flexible sheet of material connecting the first flap and the second flap. The flexible sheet of material may be configured to be disposed between the object and each of the first flap and the second flap. In some embodiments, each of the first flap and the second flap may be configured to be disposed between the object and the flexible sheet of material.

The flexible support may include a flexible film extending between the first distal end and the second distal end.

In some embodiments, the flexible support may be attached to the first distal end of the first panel. The flexible support may be attached to the second distal end of the second wall section.

In some embodiments, the flexible support may include a flexible sheet of material. The flexible sheet of material may be at least partially made of polyurethane.

In some embodiments, the first panel may further include a first wall section extending between the first distal end and the first base end. The second panel may further include a second wall section extending between the second distal end and the second base end. The first wall section may define an inner surface oriented towards the second panel, and the first wall section may define an outer surface oriented away from the second panel. The flexible support may be attached to the outer surface of the first wall section. In some embodiments, the second wall section may define an inner surface oriented towards the first panel, and the second wall section may define an outer surface oriented away from the first panel. The flexible support may be attached to the outer surface of the second wall section.

At least one of the first panel or the second panel may be made of at least one layer of cellulosic-based material. The at least one of the first panel or the second panel may be made of a plurality of layers of cellulosic-based material.

In some embodiments, the at least one pivot axis may comprise a common pivot axis connecting the first panel and the second panel, such that each of the first panel and the second panel may be configured to pivot with respect to one another about the common pivot axis. In some embodiments, the first panel and the second panel may be integrally connected, and at least one fold line may be disposed between the first panel and the second panel on the common pivot axis.

The first panel may further include a first wall section extending between the first distal end and the first base end, and may include a first hinge section extending from an inner surface of the first wall section at least partially perpendicular to the inner surface of the first wall section. The inner surface of the first wall section may extend between the first distal end and the first base end of the first wall section. The first hinge section may be disposed at least partially on the common pivot axis.

The second panel may further include a second wall section extending between the second distal end and the second base end, and may include a second hinge section extending from an inner surface of the second wall section at least partially perpendicular to the inner surface of the second wall section. The inner surface of the second wall section may extend between the second distal end and the second base end of the second wall section, and the second hinge section may be disposed at least partially on the common pivot axis.

In some embodiments, the first panel and the second panel may be integrally connected at an intersection of the first hinge section and second hinge section. At least one fold line may be disposed at the intersection of the first hinge section and the second hinge section on the common pivot axis. The first hinge section and the second hinge section may define a taper such that a height of the first hinge section and a height of the second hinge section decrease towards the at least one fold line, such that the at least one fold line may define the narrowest point of the first hinge section and the second hinge section.

The first hinge section may be disposed at a first lateral edge of the first wall section. The first lateral edge may be defined between the first distal end and the first base end, generally perpendicular to the first distal end and the first base end. The first panel may further include a third hinge section extending from the inner surface of the first wall section at least partially perpendicular to the inner surface of the first wall section. The third hinge section may be disposed at least partially on the common pivot axis. The third hinge section may be disposed at a third lateral edge of the first wall section, the third lateral edge being disposed opposite the first lateral edge, and the third lateral edge may be defined between the first distal end and the first base end, generally perpendicular to the first distal end and the first base end.

In some embodiments, the at least one pivot axis may include a first pivot axis and a second pivot axis. The first base end may be disposed at least partially on the first pivot axis, and the second base end may be disposed at least partially on the second pivot axis. In some embodiments, the frame may include a base section connecting the first base end of the first panel and the second base end of the second panel. At least a portion of the first panel and the base section may be integrally connected. At least one first fold line may be disposed between the first end of the first panel and the base section, and the at least one first fold line may be disposed on the first pivot axis. In some embodiments, at least a portion of the second panel and the base section may be integrally connected. At least one second fold line may be disposed between the second panel and the base section, and the at least one second fold line may be disposed on the second pivot axis.

At least one of the first panel and the second panel may be attached to the base section. The at least one of the first panel and the second panel may be attached to the base section via one or more tabs. The at least one of the first panel and the second panel may be attached to the base section via an adhesive.

In some embodiments, the base section may further include a central portion and a first upright portion. The first upright portion may extend from the central portion of the base section, and the first panel may be connected to the first upright portion of the base section. The base section may further include a second upright portion opposing the first upright portion. The second upright portion may extend from the central portion of the base section, and the second panel may be connected to the second upright portion of the base section.

In some embodiments, at least a portion of the first panel may be disposed flat against at least a portion of the first upright portion of the base section. The frame may further include at least one tab extending from the first base end, and the first panel may be configured to engage the first upright portion via the at least one tab.

In some embodiments, the first upright portion may define at least one slot at a junction of the first upright portion and the center portion of the base section, and the at least one tab may be configured to engage the at least one slot. The at least the portion of the first wall section may be disposed on an opposite side of the first upright portion relative to the second panel. The first upright portion of the base section may be configured to apply an outward force to the first panel in a direction opposite the second panel. The at least the portion of the first wall section may be disposed on a same side of the first upper portion relative to the second panel.

In some embodiments, the first panel may be attached to an inside of the first upright portion. The inside of the first upright portion may be disposed on a same side of the first upright portion as the second panel. The first wall section may be attached to the inside of the first upright portion. The first panel may further include a first fold line at a first base end. The first panel may further include a first wall section extending between the first distal end and the first base end. The first panel may further include an attachment flap extending from the first fold line opposite the first wall section, and the attachment flap may be attached to the first upright portion of the base section.

The first panel may be integral with the first upright portion. The attachment flap may further define a second fold line opposite the first fold line, and the attachment flap may be integral with the first upright portion such that the first upright portion may be connected to the attachment flap via the second fold line.

The first panel may be attached to the first upright portion proximate a base end of the first upright portion, and the base end of the first upright portion may be disposed adjacent the center portion. The first panel may be attached to the first upright portion proximate a distal end of the first upright portion, and the distal end of the first upright portion may be disposed opposite a junction between the first upright portion and the center portion. The first panel may be integral with the first upright portion.

The first panel may define a first pivot distance between the first distal end and the first pivot axis. The second panel may define a second pivot distance between the second distal end and the second pivot axis, and a sum of the first pivot distance and the second pivot distance may be greater than a distance between the first pivot axis and the second pivot axis.

In some embodiments, the first panel and the second panel may be disposed in a first support section. In such embodiments, the frame may further include a second support section that may include a third panel defining a third distal end and a third base end. The third distal end may be spaced from the third base end. The second support section may include a fourth panel defining a fourth distal end and a fourth base end. The fourth distal end may be spaced from the fourth base end. At least one second support pivot axis may pivotally connect the third base end of the third panel and the fourth base end of the fourth panel, such that the third panel and the fourth panel may be configured to rotate relative to one another about the at least one second support pivot axis. The second support section may include a second flexible support extending between the third distal end and the fourth distal end. The third distal end may be configured to move relative to the fourth distal end. At least one of the third distal end of the third panel and the fourth distal end of the fourth panel may be configured to pivot towards an opposing one of the fourth distal end of the fourth panel or the third distal end of the third panel in response to application of a force from the object to the second flexible support at least partially towards the third base end and the fourth base end. The first support section may be connected to the second support section. The first support section and the second support section may be configured to cooperate to support the object.

In some embodiments, the first panel and the third panel may be configured to engage a first side of the object, and the second panel and the fourth panel may be configured to engage a second side of the object opposite the first side of the object.

The first support section may be pivotally connected to the second support section, such that the first support section and the second support section are configured to rotate relative to one another. The first support section and the second support section may be configured to pivot generally perpendicular to the at least one pivot axis and the at least one second support pivot axis. In a first orientation, the at least one axis of the first support section may be disposed generally perpendicular to the at least one second support axis of the second support section, such that the first support section may be configured to engage a first edge of the object and the second support section may be configured to engage a second edge of the object. In a second orientation, the at least one axis of the first support section may be disposed parallel to the at least one second support axis of the second support section, such that both the first support section and the second support section may be configured to engage a same edge of the object. The first support section and the second support section may be integrally connected.

In some embodiments, the frame may include a connector attached to the first support section and the second support section, such that the connector may be configured to connect the first support section and the second support section.

In some embodiments, the frame may include a base section. The first support section may be connected to the base section, and the second support section may be connected to the base section. The base section may define a fold line between the first support section and the second support section, such that the first support section and the second support section may be pivotally connected via the fold line.

In some embodiments, the flexible support is configured to engage a flat-screen television, such that the frame is configured to support at least one side edge of the flat screen television.

Some embodiments of the frame may include a fifth panel defining a fifth distal end and a fifth base end. The fifth distal end may be spaced from the fifth base end. The frame may include sixth panel defining a sixth distal end and a sixth base end. The sixth distal end may be spaced from the sixth base end. At least one additional pivot axis may pivotally connect the fifth base end of the fifth panel and the sixth base end of the second panel, such that the fifth panel and the sixth panel may be configured to rotate relative to one another about the at least one additional pivot axis. The flexible support may extend between the fifth distal end and the second distal end. The fifth distal end may be configured to move relative to the sixth distal end. At least one of the fifth distal end of the fifth panel and the sixth distal end of the sixth panel may be configured to pivot towards an opposing one of the sixth distal end of the sixth panel or the fifth distal end of the fifth panel in response to application of the force from the object to the flexible support at least partially towards the fifth base end and the sixth base end. Each of the first panel, the second panel, the fifth panel, and the sixth panel may be configured to pivot relative to each other. The fifth panel and the sixth panel may extend between the first panel and the second panel, and the at least one pivot axis may be generally perpendicular to the at least one additional pivot axis.

In another embodiment, a packaging assembly for supporting an object may be provided. The packaging assembly may include a frame of any one of the frame embodiments detailed herein and in the claims for supporting an object. The packaging assembly may further include a box configured to enclose the frame and the object. The frame may be configured to be disposed between the object and at least one surface of the box.

In some embodiments of the packaging assembly, the box may define two opposing sides and four edges. The two opposing sides may define a larger surface area than the four edges. The frame may be disposed between the object and at least one of the four edges. At least a portion of the first panel may be disposed adjacent a first side of the two opposing sides, and at least a portion of the second panel may be disposed adjacent a second side of the two opposing sides.

The packaging assembly may further include a second frame. The second frame may be configured to be disposed between the object and at least one surface of the box. The second frame may be configured to be disposed between the object and a second surface of the box, and the frame may be configured to be disposed between the object and a first surface of the box. The second frame may be configured to be disposed between the object and the first surface of the box. The packaging assembly may further include a connector connecting the first frame and the second frame. In some embodiments, the flexible support may be configured to engage a flat-screen television, such that the frame is configured to support at least one side edge of the flat screen television.

In yet another embodiment, a packaging assembly for supporting an object may be provided. The packaging assembly may include a frame of any one of the frame embodiments detailed herein and in the claims supporting an object. The packaging assembly may further include a box enclosing the frame and the object. The frame may be disposed between the object and at least one surface of the box.

In another embodiment, a method of packaging an object may be provided. The method may include providing a box, and may include providing a frame of any one of the frame embodiments detailed herein and in the claims for supporting an object. The method may further include supporting an object with the frame so that the object applies a force to the flexible support to pivot at least one of the first distal end and the second distal end toward the other, and may include disposing the frame adjacent at least one surface of the box, such that the frame may be disposed between the at least one surface and a surface of the box.

Some embodiments of the method may further include providing a second frame, and may include disposing the second frame between the object and at least one surface of the box.

In some embodiments, disposing the second frame between the object and at least one surface of the box may include disposing the second frame between the object and a second surface of the box. Disposing the frame adjacent at least one surface of the box may include disposing the frame between the object and a first surface of the box.

Disposing the second frame between the object and at least one surface of the box may further include disposing the second frame between the object and the first surface of the box.

In some embodiments, the object may be a flat screen television, and the frame may be disposed between the at least one surface of the box and the flat screen television, such that the frame may be configured to support at least one side edge of the flat screen television.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 shows a perspective view of a frame in accordance with some embodiments detailed herein;

FIG. 2 shows a front view of the frame of FIG. 1;

FIG. 3 shows a perspective view of the frame of FIG. 1 engaging an object in a box in accordance with some embodiments detailed herein;

FIG. 4 shows a front view of the frame of FIG. 3;

FIG. 5 shows a bottom view of the frame of FIG. 1;

FIGS. 6-12 show assembly views of the frame of FIG. 1;

FIG. 13 shows a perspective view of another frame in accordance with some embodiments detailed herein;

FIG. 14 shows a front view of the frame of FIG. 13;

FIG. 15 shows a front view of the frame of FIG. 13 engaging an object in accordance with some embodiments detailed herein;

FIG. 16 shows a bottom view of the frame of FIG. 13;

FIGS. 17-21 show assembly views of the frame of FIG. 13;

FIG. 22 shows a perspective view of another frame in accordance with some embodiments detailed herein;

FIG. 23 shows a front view of the frame of FIG. 22;

FIG. 24 shows a front view of the frame of FIG. 22 engaging an object in accordance with some embodiments detailed herein;

FIG. 25 shows a bottom view of the frame of FIG. 22;

FIGS. 26-30 show assembly views of the frame of FIG. 22;

FIG. 31 shows a perspective view of a frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 32 shows a perspective view of the frame of FIG. 31 having a plurality of support sections in a perpendicular configuration in accordance with some embodiments detailed herein;

FIG. 33 shows a front view of the frame of FIG. 31;

FIG. 34 shows a front view of the frame of FIG. 31 engaging an object in accordance with some embodiments detailed herein;

FIGS. 35A-35B show two frames having a plurality of support sections in a perpendicular configuration supporting an object in accordance with some embodiments detailed herein;

FIG. 36 shows a bottom view of the frame of FIG. 31;

FIGS. 37-41 show assembly views of the frame of FIG. 31;

FIGS. 42-43 show the frame of FIG. 31 engaging a connector;

FIG. 44 shows a perspective view of another frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 45 shows a perspective view of the frame of FIG. 44 having a plurality of support sections in a perpendicular configuration in accordance with some embodiments detailed herein;

FIG. 46 shows an inclined rear view of the frame of FIG. 45;

FIG. 47 shows a bottom view of the frame of FIG. 44;

FIGS. 48-52 show assembly views of the frame of FIG. 44;

FIG. 53 shows a perspective view of another frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 54 shows a front view of the frame of FIG. 53;

FIG. 55 shows a front view of the frame of FIG. 53 engaging an object in accordance with some embodiments detailed herein;

FIGS. 56-57 show assembly views of the frame of FIG. 53;

FIG. 58 shows a perspective view of another frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 59 shows a front view of the frame of FIG. 58;

FIG. 60 shows a front view of the frame of FIG. 58 engaging an object in accordance with some embodiments detailed herein;

FIGS. 61-62 show assembly views of the frame of FIG. 58;

FIG. 63 shows a perspective view of another frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 64 shows a front view of the frame of FIG. 63;

FIG. 65 shows a front view of the frame of FIG. 63 engaging an object in accordance with some embodiments detailed herein;

FIGS. 66-67 show assembly views of the frame of FIG. 63;

FIG. 68 shows a perspective view of another frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 69 shows a perspective view of a frame having a plurality of panels attached to a box in accordance with some embodiments detailed herein;

FIG. 70 shows a front view of the frame of FIG. 68;

FIG. 71 shows a front view of the frame of FIG. 68 engaging an object in accordance with some embodiments detailed herein;

FIGS. 72-73 show assembly views of the frames of FIGS. 68 and 69;

FIG. 74 shows a perspective view of another frame having a plurality of support sections in a parallel configuration in accordance with some embodiments detailed herein;

FIG. 75 shows a perspective view of a frame having a plurality of panels attached to a box in accordance with some embodiments detailed herein;

FIG. 76 shows a front view of the frame of FIG. 74;

FIG. 77 shows a front view of the frame of FIG. 74 engaging an object in accordance with some embodiments detailed herein;

FIGS. 78-79 show assembly views of the frames of FIGS. 74 and 75;

FIGS. 80-81 show a perspective view of a frame having four panels positioned in a box in accordance with some embodiments detailed herein;

FIG. 82 shows a front view of a frame having a flexible sheet of material connecting the flaps in accordance with some embodiments detailed herein;

FIG. 83 shows a front view of a frame having a connector connecting the flaps in accordance with some embodiments detailed herein; and

FIG. 84 shows a front view of a frame having two flaps connected by a fold line in accordance with some embodiments detailed herein.

DETAILED DESCRIPTION

Exemplary embodiments of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. For purposes of simplicity, like numerals may be used to refer to like, similar, or corresponding elements of the various drawings. The invention may be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The intention is to cover all modifications, combinations, equivalents, and alternatives falling within the spirit and scope of the claimed subject matter.

In some instances, suspension and retention packaging systems require pre-loading to properly secure an object within the package. In particular, these systems may require a user or automated packaging apparatus to apply a force to the object and/or packaging system prior to securing the object in order to properly tension the system to protect the object. Moreover, these suspension and retention packaging systems may require precise alignment of the object in the system to provide the maximum protective effect. This additional alignment may increase the cost of packaging and slow automated packing systems.

Embodiments detailed herein include a frame and packaging assembly that may use the weight of an object being packaged to automatically center and hold the object within the packaging assembly. In various embodiments of the presently disclosed subject matter, a frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100) may be provided that includes at least a first panel (e.g., any of first panels 102, 202, 302, 402, 502, 602, 702, 802, 902, or 1002) and an opposing second panel (e.g., any of second panels 104, 204, 304, 404, 504, 604, 704, 804, 904, or 1004) having a flexible support 10 attached therebetween. In some embodiments, more than two panels may be arranged to support the object from a plurality of sides.

Panels (e.g., any of panels 102, 104, 202, 204, 302, 304, 402, 404, 502, 504, 602, 604, 702, 704, 802, 804, 902, 904, 1002, 1004, 1101, 1102, 1103, or 1104), and any of the panels and frames of the various embodiments described herein, may comprise a substantially rigid, lightweight, foldable material, for example, any of the panels, or any of the portions of panels, described herein, may be formed of one or more of any of the following materials: cellulosic-based materials (e.g., cardboard, corrugated cardboard, paperboard), plastic, and compressed foam. For example, the panels may comprise corrugated cardboard, for example, any of single-wall B-flute, C-flute, and/or E-flute corrugated cardboard, B/C double-wall corrugated cardboard, and/or E/B double-wall corrugated cardboard. The panel, and any of the panels and frames of the various embodiments described herein, may have an average thickness of, for example, at most about, and/or at least about, any of the following thicknesses: 0.03, 0.06, 0.12, 0.18, 0.25, 0.3, 0.4, and 0.5 inches.

In some embodiments, the frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100) or any portion thereof (e.g., any of panels 102, 104, 202, 204, 302, 304, 402, 404, 502, 504, 602, 604, 702, 704, 802, 804, 902, 904, 1002, 1004, 1101, 1102, 1103, or 1104 and/or flexible support 10) may be made of a recyclable material. In contrast to traditional polystyrene packaging materials, such embodiments may require minimal storage space and may break down after use.

The first panel (e.g., any of panels 102, 202, 302, 402, 502, 602, 702, 802, 902, or 1002) and the second panel (e.g., any of panels 104, 204, 304, 404, 504, 604, 704, 804, 904, or 1004) may be pivotally connected to one another, such that at least one of the first panel and the second panel pivots inwardly towards the other upon application of a force to the flexible support 10. As used herein, the term “pivotally connected” may refer to integrally connected components, connected by a single piece of material, or attached components, which may include glued, adhered, taped or otherwise joined pieces of material. In use, the object 20 may be pressed (e.g., by force or under its own weight) against the flexible support 10 to cause the first panel and the second panel to cooperate to grasp and center the product (e.g., as shown in FIGS. 3, 4, 15, 24, 34, 35A, 35B, 55, 60, 65, 71, and 77). One or more of the frames may be used to retain the object 20 (e.g., a product for shipping) by positioning the frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100), abutting the object, in a box, such that the frame is at least partially disposed between the object and the box. In some embodiments detailed herein, the frame may include multiple support sections to engage one or more sides of the object 20 simultaneously. In some embodiments, at least four panels may be used in a square or rectangular configuration around four sides of the object to center the object in four directions.

As used herein, the term “center,” when used to refer to the position of the object 20, does not require the object to be positioned in the mathematically precise center of a package (e.g., a box) and is meant to indicate that the object is within a moderate range of deviation from absolute center that is commonly acceptable as a level of accuracy for these terms within the packaging field. For example, in embodiments in which a single panel pivots towards an opposite, stationary panel, the resulting position of the object may be termed “center.”

A flexible support (e.g., flexible support 10 as shown in any of FIG. 1, 13, 22, 31, 44, 53, 58, 63, 68, 74, or 80-84) may span between at least the first panel (e.g., any of panels 102, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 1101, or 1102) and the second panel (e.g., any of panels 104, 204, 304, 404, 504, 604, 704, 804, 904, 1004, 1103, or 1104). The object 20 may engage the flexible support 10 downwardly into the frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100) to cause the first panel and the second panel to pivot inwardly towards one another, relative to one another. As used herein, the first panel and the second panel pivoting “relative” to one another allows either or both the first panel and second panel to physically move, so long as the panels are at least partially rotated with respect to each other. As also used herein, the term “downward” refers to the vertically downward direction shown in some embodiments having the flexible support 10 positioned at or proximate the top of the frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100); however, “downward” in this context will not change if the frame is repositioned, for example, to support a laterally left, right, front, or rear side of an object, or a top of the object instead.

The flexible support 10, the first panel (e.g., any of panels 102, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 1101, or 1102), and the second panel (e.g., any of panels 104, 204, 304, 404, 504, 604, 704, 804, 904, 1004, 1103, or 1104) may center the object 20 by using the inclined surfaces created by the flexible support 10 under the influence of the force from the object to direct the object towards the lowest point of the flexible support. Once a force from the weight of the object 20 is applied to the frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100), or a pushing force is applied, the first panel and the second panel may, either directly or indirectly, grip the object due to the inward force and rotation of the panels created by the interaction between the flexible support 10, the panels, and the object 20. Embodiments of the frame described herein may thereby center and maintain the object 20 for packaging.

One or more flaps (e.g., any of flaps 114, 214, 314, 414, 514, 614, 714, 814, 914, 1014, 1114, 1214, 1314, or 1414) may extend from respective distal ends (e.g., any of first distal ends 110, 210, 310, 410, 510, 610, 710, 810, 910, 1010, 1109, or 1110 or second distal ends 112, 212, 312, 412, 512, 612, 712, 812, 912, 1012, 1111, or 1112) of the panels (e.g., any of panels 102, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 104, 204, 304, 404, 504, 604, 704, 804, 904, 1004, 1101, 1102, 1103, or 1104). In some embodiments, the flaps may be pivotally connected to the respective distal ends via one or more fold lines (e.g., any of fold lines 116, 216, 316, 416, 516, 616, 716, 816, 916, or 1016). The flaps may extend beneath the flexible support 10 such that the flaps at least partially engage and support the flexible support and the object 20 via the flexible support. In some embodiments, the panels may not include flaps. A “fold line” as used herein (and as depicted in the drawings as a broken line, for example as in FIG. 6) represents a line along which a panel, frame, or other material may be creased, crimped, embossed, perforated, scored, or otherwise weakened so as to enhance the foldability of the panel, frame, or other material along the fold line.

In some embodiments, a distance between the pivot axis and the distal end of a panel (e.g., any of first distal ends 110, 210, 310, 410, 510, 610, 710, 810, 910, 1010, 1109, or 1110 and second distal ends 112, 212, 312, 412, 512, 612, 712, 812, 912, 1012, 1111, or 1112) may define a pivot distance of the respective panel. The pivot distance may be generally the same between the first panel (e.g., any of panels 102, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 1101, or 1102) and the second panel (e.g., any of panels 104, 204, 304, 404, 504, 604, 704, 804, 904, 1004, 1103, or 1104). In some embodiments, the panels may define different pivot distances.

In some embodiments, the distal ends (e.g., any of first distal ends 110, 210, 310, 410, 510, 610, 710, 810, 910, 1010, 1109, or 1110 or second distal ends 112, 212, 312, 412, 512, 612, 712, 812, 912, 1012, 1111, or 1112) of the panels (e.g., any of panels 102, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 104, 204, 304, 404, 504, 604, 704, 804, 904, 1004, 1101, 1102, 1103, or 1104) may be defined at an uppermost distal end of the respective wall sections (e.g., any of wall sections 106, 108, 206, 208, 306, 308, 406, 408, 506, 508, 606, 608, 706, 708, 806, 808, 906, 908, 1006, 1008, 1105, 1106, 1107, or 1108) of the panels. The distal ends may be spaced from corresponding base ends (e.g., any of first base ends 124, 224, 324, 424, 524, 624, 724, 824, 924, or 1024 or any of second base ends 126, 226, 326, 426, 526, 626, 726, 826, 926, or 1026). As used herein, the term “spaced” may be used to describe features that are separated from one another by more than a de minimis amount.

As used herein, the term “generally” when used in conjunction with terms such as “parallel” or “perpendicular” or “coplanar” is meant to indicate that the parallel or perpendicular or coplanar orientation does not require mathematical precision, but rather indicates a moderate range of deviation from absolute parallel or perpendicular or coplanar that is commonly acceptable as a level of accuracy for these terms within the container-folding field. As used herein, the terms “distal end” and “base end” refer generally to the respective end regions of the described components but does not require the mathematically precise “end point” of the component.

The frame (e.g., any of frame embodiments 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100) may be positioned in a box (e.g., box 30 shown in FIG. 3 or other shipping or storage container). The frame may be disposed between the object 20 and one or more sides of the box 30 to support the object within the box. In some embodiments, frames may be positioned circumferentially along at least four sides of the object 20 (e.g., a top, bottom, and laterally left and right sides), such that the frames support the object within a plane. In such embodiments, the centering function of the frames may maintain the remaining sides (e.g., a front and rear side) of the object 20 parallel to the plane in a spaced relationship with the surfaces of the box (e.g., as shown in FIGS. 3, 35A, and 35B) to protect the object in the direction perpendicular to the plane. In such embodiments, rectangular-prism-shaped objects (e.g., flat screen televisions or other objects having two sides with a substantially greater surface area than the remaining sides) may be supported on their respectively narrow edges without requiring separate, large cushioning devices on their larger faces.

Reference will now be made to several example embodiments of the frame. Although specific features may be described in connection with one or more embodiments, these features are disclosed for example purposes as describing all that they would reasonably convey to a person of ordinary skill in the art. One or more features of any embodiment described herein may be applied in a corresponding manner to any other embodiment.

First Example Embodiment

With reference to FIG. 1, an embodiment of the presently disclosed subject matter includes a frame 100 having a first panel 102 and a second panel 104. The first panel 102 may include a first wall section 106, and the first panel may define a first distal end 110 and a first base end 124. The second panel 104 may include a second wall section 108, and the first panel may define a second distal end 112 and a second base end 126. The first wall section 106 and the second wall section 108 may be hollow (e.g., include one or more voids between the inner and outer surfaces (e.g., inner surface 154 and outer surface 156 of the wall sections 106, 108 shown in FIG. 5). As described herein, the wall sections (e.g., any of wall sections 106, 108, 206, 208, 306, 308, 406, 408, 506, 508, 606, 608, 706, 708, 806, 808, 906, 908, 1006, 1008, 1105, 1106, 1107, or 1108) may include voids between their respective inner and outer surfaces, may include no void between surfaces, or may define a single piece or multiple pieces of material having an inner and outer surface.

In some embodiments, the first wall section 106 may include a first hinge section 128 extending therefrom. The second wall section 108 may additionally or alternatively include a second hinge section 130 extending therefrom. The hinge sections 128, 130 may extend from the respective first wall section 106 and second wall section 108 towards the opposite panel. For example, with continued reference to FIG. 1, the first hinge section 128 may extend from the first wall section 106 on a same side of the first panel 102 as the inner surface 154 (shown in FIG. 5), and may extend towards the second panel 104, such that the first hinge section is generally perpendicular to the inner surface of the first wall section. Similarly, the second hinge section 130 may extend from the second wall section 108 on a same side of the second panel 104 as the inner surface 154, and may extend towards the first panel 102, such that the second hinge section is generally perpendicular to the inner surface of the second wall section.

The first hinge section 128 may connect with the second hinge section 130 to define a hinge 131 of the frame 100. In some embodiments, the first hinge section or the second hinge section may extend to the respective, opposing wall section, such that the hinge is defined by only the first hinge section or the second hinge section. The hinge 131 may pivot about a pivot axis 118, such that the first panel 102 and/or the second panel 104 are configured to pivot about the pivot axis 118 relative to each other. In such embodiments, the first panel 102 and the second panel 104 may pivot about a common pivot axis (e.g., pivot axis 118). The fold line 132 may be disposed between the first hinge section 128 and the second hinge section 130.

In some embodiments, the first hinge section 128 and the second hinge section 130 may be integrally connected (e.g., such that the fold line 132 is part of a continuous piece of material connecting the hinge sections), such that the first panel 102 and the second panel 104 may be integrally connected. Additionally or alternatively, the first hinge section 128 and the second hinge section 130 may be attached to one another (e.g., via an adhesive or other bonding material or device).

In some embodiments, the hinge 131 may include a taper 158 having a narrowest section at the fold line 132 to allow the first hinge section 128 and the second hinge section 130 to pivot about the fold line while remaining generally rigid elsewhere. The taper 158 may increase the range of motion of the hinge 131, by reducing binding of the first hinge section 128 and the second hinge section 130. With reference to FIG. 1, the first hinge section 128 and the second hinge section 130 may include an outer frame member 184 and an inner frame member 186 at least partially connected by a base frame member 188 of the hinge 131. The fold line 132 may be disposed on the base frame member 188 spanning the outer frame member 184 and the inner frame member 186.

With reference to FIG. 5, in some embodiments, the frame 100 may include multiple hinges 131 spaced along a length of the frame between the first panel 102 and the second panel 104. In some embodiments, at least one hinge 131 may be positioned at a lateral edge 160 of the first wall section 106 and the second wall section 108. In some further embodiments, a hinge 131 may be disposed at each lateral edge 160 of the first wall section 106 and the second wall section 108. Additionally or alternatively, one or more hinges may be positioned between the lateral edges 160.

With reference to FIGS. 1-4, a flexible support 10 may be connected to the first distal end 110 of the first panel 102 and the second distal end 112 of the second wall panel 104, such that the flexible support may extend between and span the first panel 102 and the second panel 104. In some embodiments, the flexible support 10 may be attached to the first panel 102 and/or the second panel 104 via one or more adhesive strips 162 (e.g., glue, tape, or the like). The adhesive strips 162 may continue from the respective first distal end 110 or second distal end 112 to surfaces of the respective hinges 131 adjacent the lateral edges 160 of the first wall section 108 or the second wall section 110. In some embodiments, the flexible support 10 may extend along only the first distal end 110 and/or the second distal end 112. In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall sections, or may attach to or include the flaps.

With reference to FIGS. 3-4, an object 20 is shown loaded onto the frame 100, with the first panel 102 and the second panel 104 pivoted inwardly relative to one another. As noted above, either or both the first panel 102 and the second panel 104 may physically move (e.g., the first panel 102 is shown pivoted inward while the second panel 104 is stationary). The first panel 102 and the second panel 104 may pivot about a hinge fold line 132, which may lie on and define a common pivot axis 118 of the panels.

One or more flaps 114 may be connected to the respective first distal end 110 and the second distal end 112 by one or more fold lines 116 between the flaps and the respective first wall section 106 or second wall section 108. With reference to FIG. 1, at least two flaps 114 may be connected to the first distal end 110 and/or the second distal end 112 in a laterally spaced arrangement. With reference to FIGS. 3-4, the flaps 114 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

With continued reference to FIGS. 3-4, the frame 100 may be positioned in a box 30 for packaging the object 20. The frame 100 may support one or more sides of the object 20 within the box 30, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., as a corner section). As detailed above, such embodiments may support the object 20 in a plane and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 6-12, progressive assembly views of the frame embodiment 100 shown in FIGS. 1-5 are depicted. With reference to FIG. 6, a top-down view of a frame template 150 is shown. The frame template 150 may define a substantially flat portion of material with fold lines and cuts to allow the completed frame (e.g., frame 100 shown in FIGS. 1-5) to be assembled therefrom.

FIG. 7 shows a reverse side of the frame template 150 of FIG. 6. During assembly, the inner frame members 186, base frame members 188, and outer frame members 184 of the hinges 131 may fold inwardly along one or more fold lines 166 in a lengthwise direction of the frame template 150 (e.g., towards an opposite hinge), and side flaps 168 of the hinges 131 may fold inwardly along one or more fold lines 170 in a transverse direction towards one another. With reference to FIG. 8, the hinge 131 is shown with the inner frame member 186 and the base frame member 188 folded generally perpendicular at each fold line 166, such that the inner frame member is generally parallel to the outer frame member 184 to form the first hinge section 128 and the second hinge section 130. The hinge 131 including side flaps 168 may then fold inwardly in the longitudinal direction to position the final hinge. Similarly, the opposing end of the frame template 150 may also be folded to form a second hinge section.

With reference to FIGS. 9-10, the first wall section 106 and the second wall section 108 may then be folded into position via one or more fold lines 172. Corner tabs 176 on the inner surface 154 of the wall sections 154, 156 may engage respective receiving slots 174 in the hinges 131. The side flaps 168 of the frame template 150 may be encompassed by the surfaces (e.g., inner surface 154; outer surface 156; distal end 110, 112 of the panels; and base end 124, 126 of the panels) of the respective first wall section 106 and second wall section 108. Each of the fold lines 172 may be folded into a generally perpendicular angle to form the first wall section 106 and the second wall section 108.

With reference to FIGS. 11-12, one or more locking tabs 178 may be disposed between flaps 114 in the frame template 150 (shown in FIGS. 6-7). In some embodiments, one or more locking tabs 178 may engage corresponding slots 182 in the inner surfaces 154 of each of the respective first wall section 106 and the second wall section 108. The locking tabs 178 may include one or more fold lines 180 for pivoting a distal end of the locking tab 178 perpendicular to the respective first wall section 106 and the second wall section 108 to engage the slots 182.

Second Example Embodiment

With reference to FIG. 13, an embodiment of the presently disclosed subject matter includes a frame 200 having a first panel 202 and a second panel 204. The first panel 202 may include a first wall section 206 and the first panel may have a first distal end 210 and a first base end 224. The second panel 204 may include a second wall section 208 and the second panel may include a second distal end 212 and a second base end 226. The first wall section 206 and the second wall section 208 may be hollow (e.g., include one or more voids between the inner and outer surfaces (e.g., inner surface 254 and outer surface 256 of the wall sections 206, 208 shown in FIG. 16). With reference to FIG. 16, in some embodiments, inner surfaces 254 of the respective first wall section 206 and second wall section 208 may be angled from a narrower section proximate a respective first base end 224 and second base end 226 to a wider section proximate the respective first distal end 210 and the second distal end 212. As detailed below with respect to FIGS. 20-21, the inner surfaces 254 of the respective first wall section 206 and second wall section 208 may engage one or more slots 274 via corresponding tabs 276 to support the wall sections.

Turning back to FIG. 13, in some embodiments, the first wall section 206 may include a first hinge section 228 extending therefrom. The second wall section 208 may additionally or alternatively include a second hinge section 230 extending therefrom. The hinge sections 228, 230 may extend from respective wall sections (e.g., first wall section 206 or second wall section 206) towards the opposite panel. For example, with continued reference to FIG. 13, the first hinge section 228 may extend from the first wall section 206 on a same side of the first panel 202 as the inner surface 254, and may extend towards the second panel 204, such that the first hinge section is generally perpendicular to at least the outer surface 256 of the first wall section. Similarly, the second hinge section 230 may extend from the second wall section 208 on a same side of the second panel 204 as the inner surface 254, and may extend towards the first panel 202, such that the second hinge section is generally perpendicular to at least the outer surface 256 of the second wall section.

The first hinge section 228 may connect with the second hinge section 230 to define a hinge 231 of the frame 200. In some embodiments, the first hinge section or the second hinge section may extend to the respective, opposing wall section, such that the hinge is defined by only the first hinge section or the second hinge section. The hinge 231 may pivot about a pivot axis 218, such that the first panel 202 and/or the second panel 204 are configured to pivot about the pivot axis 218 relative to each other. In such embodiments, the first panel 202 and the second panel 204 may pivot about a common pivot axis (e.g., pivot axis 218). The fold line 232 may be disposed between the first hinge section 228 and the second hinge section 230.

In some embodiments, the first hinge section 228 and the second hinge section 230 may be integrally connected (e.g., such that the fold line 232 is part of a continuous piece of material connecting the hinge sections), such that the first panel 202 and the second panel 204 may be integrally connected. Additionally or alternatively, the first hinge section 228 and the second hinge section 230 may be attached to one another (e.g., via an adhesive or other bonding material or device).

In some embodiments, the hinge 231 may include a taper 258 having a narrowest section at the fold line 232 to allow the first hinge section 228 and the second hinge section 230 to pivot about the fold line while remaining generally rigid elsewhere. The taper 258 may increase the range of motion of the hinge 231, by reducing binding of the first hinge section 228 and the second hinge section 230. The first hinge section 228 and second hinge section 230 may include at least an outer frame member 278 and a base frame member 280, and the fold line 232 may be defined on the base frame member 280 at the taper 258 between the hinge sections.

With reference to FIG. 16, in some embodiments, the frame 200 may include multiple hinges 231 spaced along a length of the frame between the first panel 202 and the second panel 204. In some embodiments, at least one hinge 231 may be positioned at a lateral edge 260 of the first wall section 202 and the second wall section 204. In some further embodiments, a hinge 231 may be disposed at each lateral edge 260 of the first wall section 202 and the second wall section 204. Additionally or alternatively, one or more hinges may be positioned between the lateral edges 260.

With reference to FIGS. 13-15, a flexible support 10 may be connected to the first distal end 210 of the first panel 202 and the second distal end 212 of the second panel 204, such that the flexible support may extend between and span the first panel 202 and the second panel 204. In some embodiments, the flexible support 10 may be attached to the first panel 202 and/or the second panel 204 via one or more adhesive strips 262 (e.g., glue, tape, or the like). The adhesive strips 262 may extend along the first distal end 210 and/or the second distal end 212. In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall sections, or may attach to or include the flaps.

With reference to FIG. 15, an object 20 is shown loaded onto the frame 200, with the first panel 202 and the second panel 204 pivoted inwardly relative to one another. As noted above, either or both the first panel 202 and the second panel 204 may physically move (e.g., the first panel 202 is shown pivoted inward while the second panel 204 is stationary). The first panel 202 and the second panel 204 may pivot about a hinge fold line 232, which may lie on and define a common pivot axis 218 of the panels.

One or more flaps 214 may be connected to the respective first distal end 210 and the second distal end 212 by one or more fold lines 216 between the flaps and the respective first wall section 206 or second wall section 208. The slots 274, which may receive the tabs 276 (shown in FIGS. 20-21) of the inner surface 256 of the respective wall sections 206, 208, may be disposed in line with the one or more fold lines 216 such that the inner surface of the wall supports the pivot axis of the flaps. With reference to FIGS. 14-15, the flaps 214 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

The frame 200 may be positioned in a box for packaging the object 20 similar to the embodiment shown in FIGS. 3-4 above. The frame 200 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., as a corner section). As detailed above, such embodiments may support the object 20 in a plane and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 17-21, progressive assembly views of the frame embodiment 200 shown in FIGS. 13-16 are depicted. With reference to FIG. 17, a top-down view of a frame template 250 is shown. The frame template 250 may define a substantially flat material with fold lines and cuts to allow the completed frame (e.g., frame 200 shown in FIGS. 13-16) to be assembled therefrom.

FIG. 18 shows a reverse side of the frame template 250 of FIG. 17. During assembly, the hinges 231, including an outer frame member 278 and base frame member 280, may fold inwardly along one or more fold lines 266 in a lengthwise direction of the frame template 250 (e.g., towards an opposite hinge), and side flaps 268 of the hinges 231 may fold inwardly along one or more fold lines 270 in a transverse direction towards one another. In some embodiments, the base frame member 280 of the hinges 231 may remain coplanar with the remaining sections of the hinge 231 until the wall sections 206, 208 are folded into position, as detailed below. In some embodiments, the base frame member 280 of the hinges 231 may be folded perpendicular to the outer frame member 278 before the wall sections 206, 208 are folded into position. With reference to FIG. 19, the hinges 231 are shown with the respective base frame members 280 unfolded relative to the outer frame member 278, and the outer frame member 278 may be generally perpendicular to the distal ends 210, 212. In some embodiments, the side flaps 268 from opposing hinges 231 (e.g., side flaps of each respective first hinge section 228 or each respective second hinge section may overlap, for example, within the respective wall sections 206, 208.

With reference to FIGS. 19-20, the first wall section 206 and the second wall section 208 may then be folded into position via one or more fold lines 272. The tabs 276 on the inner surface 254 of the respective wall sections 206, 208 may engage the corresponding slots 274 at the distal ends 210, 212 of the panels 202, 204. The side flaps 268 of the frame template 250 (shown in FIGS. 17-18) may be encompassed by the surfaces (e.g., inner surface 254; outer surface 256; distal end 210, 212 of the panels; and base end 224, 226 of the panels) of the respective first wall section 206 and second wall section 208. Each of the fold lines 272 may be folded into a generally perpendicular angle to form the first wall section 206 and the second wall section 208. In some embodiments, as detailed above, the inner surfaces 254 may be angled, such that the first wall section 206 and/or the second wall section 208 is wider proximate the respective distal ends 210, 212 than at the respective base ends 224, 226.

With reference to FIG. 21, one or more retaining tabs 282 may project from the respective first base end 224 of the first panel 202 at a base end of the first wall section 206 and the second base end 226 of the second panel 204 at a base end of the second wall section 208. In some embodiments, the one or more retaining tabs 282 may project from the inner surfaces 254 generally perpendicular to the inner surface. In some embodiments, the one or more retaining tabs 282 may be coplanar with the first base end 224 and the second base end 226. The base frame member 280 of the hinges 231 may be folded on fold lines 266 to engage the retaining tabs 282. With reference to FIGS. 16 and 21, portions of the base frame members 280 and/or tabs 282 may be deflected to allow the base frame members to fold inwardly past the tabs and to rest against an upper surface of the retaining tabs. In some embodiments, the base frame members 280 may be generally perpendicular to the outer frame member 278 of the hinges 231.

Third Example Embodiment

With reference to FIG. 22, an embodiment of the presently disclosed subject matter includes a frame 300 having a first panel 302 and a second panel 304. The first panel 302 may include a first wall section 306, and the first panel may include a first distal end 310 and a first base end 324. The second panel 304 may include a second wall section 308, and the second panel may include a second distal end 312 and a second base end 326.

In some embodiments, the first wall section 306 may include a first hinge section 328 extending therefrom. The second wall section 308 may additionally or alternatively include a second hinge section 330 extending therefrom. The hinge sections 328, 330 may extend from respective wall sections (e.g., first wall section 306 or second wall section 306) towards the opposite panel. For example, with continued reference to FIG. 22, the first hinge section 328 may extend from the first wall section 306 on a same side of the first panel 302 as the inner surface 354, and may extend towards the second panel 304, such that the first hinge section is generally perpendicular to at least the outer surface 356 of the first wall section. Similarly, the second hinge section 330 may extend from the second wall section 308 on a same side of the second panel 304 as the inner surface 354, and may extend towards the first panel 302, such that the second hinge section is generally perpendicular to at least the outer surface 356 of the second wall section.

The first hinge section 328 may connect with the second hinge section 330 to define a hinge 331 of the frame 300. In some embodiments, the first hinge section or the second hinge section may extend to the respective, opposing wall section, such that the hinge is defined by only the first hinge section or the second hinge section. The hinge 331 may pivot about a pivot axis 318, such that the first panel 302 and/or the second panel 304 are configured to pivot about the pivot axis 318 relative to each other. In such embodiments, the first panel 302 and the second panel 304 may pivot about a common pivot axis (e.g., pivot axis 318). The fold line 332 may be disposed between the first hinge section 328 and the second hinge section 330.

In some embodiments, the first hinge section 328 and the second hinge section 330 may be integrally connected (e.g., such that the fold line 332 part of a continuous piece of material connecting the hinge sections), such that the first panel 302 and the second panel 304 may be integrally connected. Additionally or alternatively, the first hinge section 328 and the second hinge section 330 may be attached to one another (e.g., via an adhesive or other bonding material or device).

In some embodiments, the hinge 331 may include a taper 358 having a narrowest section at the fold line 332 to allow the first hinge section 328 and the second hinge section 330 to pivot about the fold line while remaining generally rigid elsewhere. In addition, the taper 358 may increase the range of motion of the hinge 331, by reducing binding of the first hinge section 328 and the second hinge section 330. The first hinge section 328 and second hinge section 330 may include at least an outer frame member 378 and a base frame member 380, and the fold line 332 may be defined on the base frame member 380 at the taper 358 between the hinge sections.

With reference to FIG. 25, in some embodiments, the frame 300 may include multiple hinges 331 spaced along a length of the frame between the first panel 302 and the second panel 304. In some embodiments, at least one hinge 331 may be positioned at a lateral edge 360 of the first wall section 302 and the second wall section 304. In some further embodiments, a hinge 331 may be disposed at each lateral edge 360 of the first wall section 302 and the second wall section 304. Additionally or alternatively, one or more hinges may be positioned between the lateral edges 360.

With reference to FIGS. 22-24, a flexible support 10 may be connected to the first distal end 310 and the second distal end 312, such that the flexible support may extend between and span the first panel 302 and the second panel 304. In some embodiments, the flexible support 10 may be attached to the first panel 302 and/or the second panel 304 via one or more adhesive strips 362 (e.g., glue, tape, or the like). The adhesive strips 362 may extend along the first distal end 310 and/or the second distal end 312. In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall sections, or may attach to or include the flaps.

With reference to FIG. 24, an object 20 is shown loaded onto the frame 300, with the first panel 302 and the second panel 304 pivoted inwardly relative to one another. As noted above, either or both the first panel 302 and the second panel 304 may physically move (e.g., the first panel 302 is shown pivoted inward while the second panel 304 is stationary). The first panel 302 and the second panel 304 may pivot about a hinge fold line 332, which may lie on and define a common pivot axis 318 of the panels.

One or more flaps 314 may be connected to the respective first distal end 310 and the second distal end 312 by one or more fold lines 316 between the flaps and the respective first wall section 306 or second wall section 308. With reference to FIGS. 23-24, the flaps 314 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

The frame 300 may be positioned in a box for packaging the object 20 similar to the embodiment shown in FIGS. 3-4 above. The frame 300 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., as a corner section). As detailed above, such embodiments may support the object 20 in a plane and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 26-30, progressive assembly views of the frame embodiment 300 shown in FIGS. 22-25 are depicted. With reference to FIG. 26, a top-down view of a frame template 350 is shown. The frame template 350 may define a substantially flat material with fold lines and cuts to allow the completed frame (e.g., frame 300 shown in FIGS. 22-25) to be assembled therefrom.

FIG. 27 shows a reverse side of the frame template 350 of FIG. 26. During assembly, the hinges 331, including base frame member 380 and outer frame member 378, may fold inwardly along one or more fold lines 366 in a lengthwise direction of the frame template 350 (e.g., towards an opposite hinge), and side flaps 368 of the hinges 331 may fold inwardly along one or more fold lines 370 in a transverse direction towards one another. In some embodiments, the base frame member 380 of the hinges 331 may remain coplanar with the remaining sections of the hinge 331 until the wall sections are folded into position, or the base frame member 380 of the hinges 331 may be folded perpendicular to the outer frame member 378 before the wall sections 306, 308 are folded into position. With reference to FIG. 28, the hinges 331 are shown with the respective base frame members 380 folded relative to the outer frame member 378, and the outer frame member 378 may be generally perpendicular to the distal ends 310, 312.

With reference to FIGS. 28-29, the outer surface 356 (shown in FIG. 26) of the first wall section 306 and the outer surface 356 (shown in FIG. 26) of the second wall section 308 may then be folded into position via one or more fold lines 372. The side flaps 268 of the frame template 350 may form a portion of the inner surface 354 of the respective first wall section 306 and second wall section 308. Each of the fold lines 372 may be folded into a generally perpendicular angle to form the first wall section 306 and the second wall section 308.

With reference to FIGS. 29-30, one or more retaining tabs 382 may fold from the outer surfaces 356 of the respective first base end 324 of the first panel 302 at a based end of the first wall section 306 and the second base end 326 of the second panel 304 at a based end of the second wall section 308 to engage corresponding receiving slots 384 in the side flaps 368 forming a portion of the inner surface 354. The retaining tabs 382 may provide rigidity to the frame 300 and may retain the base frame members 380 to strengthen the assembled frame 300. With reference to FIGS. 25 and 30, the base frame members 380 may rest against an upper surface of the retaining tabs 382. In some embodiments, the base frame members 280 may be angled relative to the outer frame member 278 of the hinges 231. In some embodiments the retaining tabs 382 may be wider than the receiving slots 384 to frictionally hold the tabs in position.

Fourth Example Embodiment

With reference to FIG. 31, an embodiment of the presently disclosed subject matter includes a frame 400 having a first support section 444 and a second support section 446. Each support section 444, 446 may include a first panel 402 and a second panel 404. The first panel 402 may include a first wall section 406, and the first panel may include a first distal end 410 and a first base end 424. The second panel 404 may include a second wall section 408, and the second panel may include a second distal end 412 and a second base end 426.

With reference to FIG. 32, the first support section 444 may be generally perpendicular to the second support section 446. In such embodiments, with reference to FIGS. 35A-B, the support sections 444, 446 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object).

With reference to FIGS. 31-35B, the frame 400 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 31) and a perpendicular configuration (e.g., as shown in FIG. 32). In a parallel configuration, the first pivot axis 420 of the first support section 444 may be generally collinear with the first pivot axis 420 of the second support section 446, and the second pivot axis 422 of the first support section 444 may be generally collinear with the second pivot axis 422 of the second support section. In a perpendicular configuration, the first pivot axis 420 of the first support section 444 may be generally perpendicular to the first pivot axis 420 of the second support section 446, and the second pivot axis 422 of the first support section 444 may be generally perpendicular to the second pivot axis 422 of the second support section. In such embodiments, the frame may include a fold line 448 between the first support section 444 and the second support section 446 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 448 may be generally perpendicular to the first pivot axis 420 of the first panel 402 and the second pivot axis 422 of the second panel 404 in both the parallel and perpendicular configurations. At least a portion of the frame may include a taper 474 having a narrowest portion at the center fold line 448. One or more frames (e.g., any of frames 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100) detailed herein may be connected to define multiple support sections as detailed above, in such embodiments, any number of fold lines may be disposed between the support sections to allow the support sections to engage two or more sides of an object 20.

With reference to FIG. 31, in some embodiments, the first panel 402 and the second panel 404 may pivot relative to one another about separate axes. For example, the first panel 402 may pivot about a first pivot axis 420 and a second panel 404 may pivot about a second pivot axis 422. In some embodiments, within a given support section (e.g., one of support sections 444, 446), the first pivot axis 420 may be generally parallel to the second pivot axis 422. In some embodiments, the first pivot axis 420 may be disposed at the first base end 424 of the first panel 402 and may be parallel to the first base end. The second pivot axis 422 may be disposed at the second base end 426 of the second panel 404 and may be parallel to the second base end.

With reference to FIGS. 31-36, in some embodiments, the first panel 402 and/or the second panel 404 may be connected to a base section 438. In some embodiments, the first panel and the second panel may be connected to the base section integrally, via one or more fold lines (e.g., as shown in FIG. 53). In some embodiments, the base section 438 may include a respective first upright portion 440 and second upright portion 442, which may support the respective first panel 402 and the second panel 404. The first wall section 406 may engage the first upright portion 440, such that the first upright portion pivotally supports the first wall section. The second wall section 408 may engage the second upright portion 442, such that the second upright portion pivotally supports the second wall section. The first upright portion 440 may include a first fold line 434 disposed on the first pivot axis 420, and the second upright portion 442 may include a second fold line 436 disposed on the second pivot axis 422.

With reference to FIG. 33, the first wall section 406 may include one or more tabs 476 that may engage the first upright portion 440, and the second wall section 408 may include one or more tabs 476 that may engage the second upright portion 442. The tabs 476 may engage corresponding slots 478 (e.g., shown in FIGS. 39-40) in the base section 438. In some embodiments, the slots 478 may be disposed on the respective first fold line 434 or second fold line 436. In some embodiments, each wall section 406, 408 may include two or more tabs 476.

With reference to FIGS. 31-35B, a flexible support 10 may be connected to the outer surface 456 of the first wall section 406 at the first distal end 410 and the outer surface 456 of the second wall section 408 at the second distal end 412, such that the flexible support spans between the first panel 402 and the second panel 404. In some embodiments, the flexible support 10 may be attached to the first panel 402 and/or the second panel 404 via one or more adhesive strips 462 (e.g., glue, tape, or the like). In some embodiments, as detailed herein, the flexible support 10 may attach to an inner surface of the wall section, may attach to or include the flaps (e.g., flaps 414), or may attach to one of the respective distal ends 410, 412.

With reference to FIGS. 31-35B, the first upright portion 440 and the second upright portion 442 may apply outward forces on the respective first panel 402 and second panel 404. In some embodiments, the first wall section 406 may be disposed on an outside of the first upright portion 440 (e.g., wherein an inner surface 454 of the first wall section abuts an outer surface of the first upright portion), such that the first upright portion applies outward force to the first wall section in a direction opposing the tension of the flexible support 10. The second wall section 408 may be disposed on an outside of the second upright portion 442 (e.g., wherein an inner surface 454 of the second wall section abuts an outer surface of the second upright portion), such that the second upright portion applies outward force to the second wall section in a direction opposing the tension of the flexible support 10. In such embodiments, the respective first upright portion 440 and second upright portion 442 may provide protection for the object by tensioning the flexible support 10, similar to a hinge (e.g., hinges 131, 231, 331, and 531).

With reference to FIGS. 34-35B, an object 20 is shown loaded onto one or more frames 400, with the first panels 402 and the second panels 404 pivoted inwardly relative to one another. As noted above, either or both the first panel 402 and the second panel 404 may physically move (e.g., the first panel 402 and second panel 404 are shown pivoted inward towards one another). The first panel 402 may pivot about a first fold line 434 on the first pivot axis 420, and the second panel 404 may pivot about the second fold line 436 on the second pivot axis 422. In some embodiments, the first panel 402 and the second panel 404 may facilitate centering the object 20 when the pivot distance of each panel (e.g., the distance from the pivot axis 420, 422 to the respective distal end 410, 412) is substantially the same. In embodiments having two pivot axes, the distance between the pivot axes may be less than the sum of the pivot distances of each opposing panel to cause the panels to contact one another.

Turning to FIG. 35B, one or more handles 488 having one or more hand holes 490 may be connected to the frames 400 to allow a user to remove the object 20 easily from the box. The handles may be attached to one or more of the support sections 444, 446 in a direction accessible by the user. In some embodiments, the handles may be integral with the support sections in the desired direction (e.g., as shown in FIG. 53). In some embodiments, the handles 488 may be attached to the support sections 444, 446 via one or more handle tabs 492. For example, as shown in FIG. 35B, two handles 488 may be oriented upward from the frames 400 on either lateral side of the object 20 such that a user may lift the object vertically. The handles 488 may be generally planar and parallel with the bottoms of the respective support sections 446, 448 so that the assembled frames fit within the box. In such embodiments, two or more of the frames 400 may be connected via the connector 484 so that the frames may be lifted as a single unit.

In some embodiments, support sections may be positioned on four or more sides of the object, and in such embodiments, the support sections may be connected (e.g., using a connector 484 as shown in FIGS. 35A-B) such that the object 20 and frames may be removed as a single unit. In such embodiments, the connector 484 and/or one or more of the frames 400 may include one or more handles (e.g., at the top, sides, or bottom of the assembled frames) for removing the object from the box.

One or more flaps 414 may be connected to the respective first distal end 410 and the second distal end 412 by one or more fold lines 416 between the flaps and the respective first wall section 406 or second wall section 408. With reference to FIGS. 34-35B, the flaps 414 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20. As detailed above, in some embodiments, the upright portions 440, 442 may apply an outward force on the respective panels 402, 404, which panels may then at least partially support the object 20. In some embodiments, the distal ends 410, 412 of the respective panels 402, 404 may contact the object, and in some embodiments, the outward force may hold the distal ends 410, 412 outwardly relative to the object.

With continued reference to FIGS. 34-35B, the frame 400 may be positioned in a box for packaging the object 20. The frame 400 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane (e.g., as shown in FIGS. 35A-B) and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 37-41, progressive assembly views of the frame embodiment 400 shown in FIGS. 31-36 are depicted. With reference to FIG. 37, a top-down view of a frame template 450 is shown. The frame template 450 may include a base section template 480 and one or more panel templates 482. The frame template 450 may define one or more substantially flat materials with fold lines and cuts to allow the completed frame (e.g., frame 400 shown in FIGS. 31-36) to be assembled therefrom.

FIG. 38 shows a reverse side of the frame template 450 of FIG. 37. During assembly, the first upright portions 440 and second upright portions 442 of each support section (e.g., first support section 444 and second support section 446 shown in FIG. 31) may be folded inward towards one another.

With reference to FIGS. 39-41, tabs 476 of the first wall section 406 may be inserted into the receiving slots 478 at the first upright portion 440. The panel template 482 may then be wrapped around the base section 438 such that the tabs 476 of the second wall section 408 may be inserted into the receiving slots 478 at the second upright portion 442 to form the final support section (e.g., first support section 444 and second support section 446 shown in FIG. 31). As shown in FIGS. 31-43, in some embodiments, two or more panel templates 482 may be attached to a common base section 438, such that the first support section 444 is connected to the section support section 446 via the common base section.

In some embodiments, a connector 484 may be used to connect separate frames and/or support sections. For example, FIGS. 42-43 depict the first support section 444 and the second support section 446 as separate frames. In the embodiment shown in FIGS. 42-43, the connector 484 engages one or more slots 486 in the first and second support sections 444, 446 to connect the respective support sections. Similarly, as shown in FIGS. 35A-B, the connector 484 may connect two frames 400 for supporting multiple sides and/or corners of an object 20. For example, a flat screen television may be engaged on two or more edges by multiple frames 400 connected via the connector 484, as shown in FIGS. 35A-B. The frames 400 may each include one or more support sections as described above. In some embodiments, the connector may be rigid, such that the connected frames may not pivot relative to one another. In some embodiments, the connector may include one or more pivot axes to allow the frames to pivot relative to one another (e.g., pivot as shown with respect to base section 438 shown in FIG. 31).

Fifth Example Embodiment

The embodiment of FIGS. 44-52 includes a frame 500 substantially similar to the frame 200 of FIGS. 13-21 having two support sections 544, 546. With reference to FIG. 44, an embodiment of the presently disclosed subject matter includes a frame 500 having a first support section 544 and a second support section 546. Each support section 544, 546 may include a first panel 502 and a second panel 504. The first panel 502 may include a first wall section 506, and the first panel may include a first distal end 510 and a first base end 524. The second panel 504 may include a second wall section 508, and the second panel may include a second distal end 512 and a second base end 526.

With reference to FIG. 45, the first support section 544 may be generally perpendicular to the second support section 546. In such embodiments, the support sections 544, 546 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object).

With reference to FIGS. 44-47, the frame 500 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 44) and a perpendicular configuration (e.g., as shown in FIG. 45). In a parallel configuration, the first pivot axis 520 of the first support section 544 may be generally collinear with the first pivot axis 520 of the second support section 546, and the second pivot axis 522 of the first support section 544 may be generally collinear with the second pivot axis 522 of the second support section. In a perpendicular configuration, the first pivot axis 520 of the first support section 544 may be generally perpendicular to the first pivot axis 520 of the second support section 546, and the second pivot axis 522 of the first support section 544 may be generally perpendicular to the second pivot axis 522 of the second support section. In such embodiments, the frame may include a fold line 548 between the first support section 544 and the second support section 546 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 548 may be generally perpendicular to the common pivot axis 518 of the first support section 544 and the second support section 546 in both the parallel and perpendicular configurations. At least a portion of the frame 500 may include a taper 584 having a narrowest portion at the center fold line 548. In some embodiments, the taper 584 may be formed by portions of the wall sections 506, 508 of each of the support sections 544, 546.

With continued reference to FIGS. 44-47, the first panels 502 include a first wall section 506, and the first panels may include a first distal end 510 and a first base end 524, and the second panels 504 include a second wall section 508 and the second panels may include a second distal end 512 and a second base end 526. The first wall section 506 and the second wall section 508 may be hollow (e.g., include one or more voids between the inner and outer surfaces (e.g., inner surface 554 and outer surface 556 of the wall sections 506, 508 shown in FIG. 47). With reference to FIG. 52, in some embodiments, an inner surface 554 of the respective first wall section 506 and second wall section 508 may be angled from a narrower section proximate a respective first base end 524 and second base end 526 to a wider section proximate the respective first distal end 510 and the second distal end 512. As detailed below with respect to FIGS. 49-52, the inner surfaces 554 of the respective first wall section 506 and second wall section 508 may engage one or more slots 574 via corresponding tabs 576 to support the wall sections.

Returning to FIG. 44, in some embodiments, the first wall section 506 may include a first hinge section 528 extending therefrom. The second wall section 508 may additionally or alternatively include a second hinge section 530 extending therefrom. The hinge sections 528, 530 may extend from respective wall sections (e.g., first wall section 506 or second wall section 508) towards the opposite panel. For example, with continued reference to FIG. 44, the first hinge section 528 may extend from the first wall section 506 on a same side of the first panel 502 as the second panel 504, and may extend towards the second panel 504, such that the first hinge section is generally perpendicular to at least the outer surface 556 of the first wall section. Similarly, the second hinge section 530 may extend from the second wall section 508 on a same side of the second panel 504 as the first panel 502, and may extend towards the first panel 502, such that the second hinge section is generally perpendicular to at least the outer surface 556 of the second wall section.

The first hinge section 528 may connect with the second hinge section 530 to define a hinge 531 of the frame 500. In some embodiments, the first hinge section or the second hinge section may extend to the respective, opposing wall section, such that the hinge may be defined by only the first hinge section or the second hinge section. The hinge 531 may pivot about the pivot axis 518, such that the first panel 502 and/or the second panel 504 are configured to pivot about the pivot axis 518 relative to each other. In such embodiments, the first panel 502 and the second panel 504 may pivot about a common pivot axis (e.g., pivot axis 518). The fold line 532 may be disposed between the first hinge section 528 and the second hinge section 530.

In some embodiments, the first hinge section 528 and the second hinge section 530 may be integrally connected (e.g., such that the fold line 532 is part of a continuous piece of material connecting the hinge sections), such that the first panel 502 and the second panel 504 may be integrally connected. Additionally or alternatively, the first hinge section 528 and the second hinge section 530 may be attached to one another (e.g., via an adhesive or other bonding material or device).

In some embodiments, the hinge 531 may include a taper 558 having a narrowest section at the fold line 532 to allow the first hinge section 528 and the second hinge section 530 to pivot about the fold line while remaining generally rigid elsewhere. In addition, the taper 558 may increase the range of motion of the hinge 531, by reducing binding of the first hinge section 528 and the second hinge section 530. The first hinge section 528 and second hinge section 530 may include at least an outer frame member 578 and a base frame member 580, and the fold line 532 may be defined on the base frame member 580 at the taper 558 between the hinge sections.

With reference to FIG. 47, in some embodiments, the frame 500 may include multiple hinges 531 spaced along a length of the frame between the first panel 502 and the second panel 504. In some embodiments, at least one hinge 531 may be positioned at a lateral edge 560 of the first wall section 502 and the second wall section 504. In some further embodiments, a hinge 531 may be disposed at each lateral edge 560 of the first wall section 502 and the second wall section 504. Additionally or alternatively, one or more hinges may be positioned between the lateral edges 560.

With continued reference to FIG. 46-47, in some embodiments, each support section (e.g., first support section 544 and second support section 546) may include one or more hinges 531 on outside ends (e.g., the ends opposite the center pivot 548). In such embodiments, a portion of the frame 500 between the first support section 544 and the second support section 546 may define one or more center pivot flaps 586. The center pivot flaps 586 may be generally perpendicular to the outer surfaces 556 of the respective first wall section 506 and second wall section 508. In some embodiments, a portion of the center pivot flaps 586 may be substantially coplanar with the first base end 524 and the second base end 526 of each of the respective first support section 544 and the second support section 556. The center pivot flaps 586 may each define a portion of the center pivot 548. In some embodiments, as shown in FIGS. 46-47, the frame 500 may include two center pivot flaps 586 opposingly extending from opposite edges of the frame. In some further embodiments, the two center pivot flaps 586 may be spaced from one another.

With reference to FIGS. 44-45, a flexible support 10 may be connected to the first distal end 510 and the second distal end 512, such that the flexible support may extend between and span the first panel 502 and the second panel 504. In some embodiments, the flexible support 10 may be attached to the first panel 502 and/or the second panel 504 via one or more adhesive strips 562 (e.g., glue, tape, or the like). The adhesive strips 562 may extend along the first distal end 510 and/or the second distal end 512. In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall sections, or may attach to or include the flaps.

As shown above with respect to FIG. 15, an object 20 may be loaded onto the frame 500, with the first panel 502 and the second panel 504 pivoted inwardly relative to one another. As noted above, either or both the first panel 502 and the second panel 504 may physically move (e.g., the first panel 502 may pivot inward while the second panel 504 may be flat against the floor). The first panel 502 and the second panel 504 may pivot about a hinge fold line 532, which may lie on and define a common pivot axis 518 of the panels.

One or more flaps 514 may be connected to the respective first distal end 510 of the first panel 502 and the second distal end 512 of the second panel 504 by one or more fold lines 516 between the flaps and the respective first wall section 506 or second wall section 508. The slots 574, which may receive the tabs 576 (shown in FIGS. 48-49) of the inner surface 554 of the respective wall sections 506, 508, may be disposed in line with the one or more fold lines 516 such that the inner surface of the wall supports the pivot axis of the flaps. With reference to FIGS. 44-45, the flaps 514 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

The frame 500 may be positioned in a box for packaging the object 20 similar to the embodiment shown in FIGS. 3-4 above. The frame 500 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 48-52, progressive assembly views of the frame embodiment 500 shown in FIGS. 44-47 are depicted. With reference to FIG. 48, a top-down view of a frame template 550 is shown. The frame template 550 may define a substantially flat material with fold lines and cuts to allow the completed frame (e.g., frame 500 shown in FIGS. 44-47) to be assembled therefrom.

FIG. 49 shows a reverse side of the frame template 550 of FIG. 48. During assembly, the hinges 531, including an outer frame member 578 and base frame member 580, may fold inwardly along one or more fold lines 566 in a lengthwise direction of the frame template 550 (e.g., towards an opposite hinge), and side flaps 568 of the hinges 531 may fold inwardly along one or more fold lines 570 in a transverse direction towards one another. In some embodiments, the base frame member 580 of the hinges 531 may remain coplanar with the remaining sections of the hinge 531 until the wall sections 506, 508 are folded into position, as detailed below. In some embodiments, the base frame member 580 of the hinges 531 may be folded perpendicular to the outer frame member 578 before the wall sections 506, 508 are folded into position. With reference to FIG. 50, the hinges 531 are shown with the respective base frame members 580 unfolded relative to the outer frame members 578, and the outer frame members 578 may be generally perpendicular to the distal ends 510, 512.

With reference to FIGS. 50-51, the first wall section 506 and the second wall section 508 may then be folded into position via one or more fold lines 572. The tabs 576 on the inner surface 554 of the respective wall sections 506, 508 may engage the corresponding slots 574 at the distal ends 510, 512 of the panels. The side flaps 568 of the frame template 550 (shown in FIGS. 48-49) may be encompassed by the surfaces (e.g., inner surface 554; outer surface 556; distal end 510, 512 of the panels; and base end 524, 526 of the panels) of the respective first wall section 506 and second wall section 508. Each of the fold lines 572 may be folded into a generally perpendicular angle to form the first wall section 506 and the second wall section 508. In some embodiments, as detailed above, the inner surfaces 554 may be angled, such that the first wall section 506 and/or the second wall section 508 is wider proximate the respective distal ends 510, 512 than at the respective base ends 524, 526. In some embodiments, portions of the inner surface 554 of the first wall section 506 and the second wall section 508 proximate the center fold line 448 between support sections 544, 546 may be substantially the same shape as the taper 584 at the center of the frame 500.

With reference to FIG. 52, one or more retaining tabs 582 and the center pivot flaps 586 may project from the of the respective first base end 524 of the first panel 502 at a base end of the first wall section 506 and the second base end 526 of the second panel 504 at a base end of the second wall section 508. In some embodiments, the one or more retaining tabs 582 may project from the inner surfaces 554 generally perpendicular to at least the outer surface 556. In some embodiments, the one or more retaining tabs 582 may be coplanar with the first base end 524 and the second base end 526. The base frame member 580 of the hinges 531 may be folded on fold lines 566 to engage the retaining tabs 282. With reference to FIGS. 47 and 52, portions of the base frame members 580 and/or tabs 582 may be deflected to allow the base frame members to fold inwardly past the tabs and to rest against an upper surface of the retaining tabs. In some embodiments, the base frame members 580 may be generally perpendicular to the outer frame member 578 of the hinges 531.

Sixth Example Embodiment

With reference to FIG. 53, an embodiment of the presently disclosed subject matter includes a frame 600 having a first support section 644 and a second support section 646. Each support section 644, 646 may include a first panel 602 and a second panel 604. The first panel 602 may include a first wall section 606, and the first panel may include a first distal end 610 and a first base end 624. The second panel 604 may include a second wall section 608, and the second panel may include a second distal end 612 and a second base end 626.

The support sections may be formed separately, as independent supporting devices (e.g., similar to the frames of the embodiments shown in FIGS. 1-30), or the support sections 644, 646 may be parts of a single frame 600. In embodiments of a frame 600 having multiple support sections 644, 646, the support sections may be attached and/or integrally connected to one another. With reference to FIG. 53, the frame 600 may include the first support section 644 disposed generally parallel to the second support section 646. In some embodiments, the first support section 644 may be spaced from the second support section 646. In some embodiments, the first support section 644 may be generally perpendicular to the second support section 646. In such embodiments, the support sections 644, 646 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object) as shown and described above with respect to FIGS. 32, 45.

With reference to FIGS. 53-55, the frame 600 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 53) and a perpendicular configuration. In a parallel configuration, the first pivot axis 620 of the first support section 644 may be generally collinear with the first pivot axis 620 of the second support section 646, and the second pivot axis 622 of the first support section 644 may be generally collinear with the second pivot axis 622 of the second support section. In a perpendicular configuration, the first pivot axis 620 of the first support section 644 may be generally perpendicular to the first pivot axis 620 of the second support section 446, and the second pivot axis 622 of the first support section 644 may be generally perpendicular to the second pivot axis 622 of the second support section. In such embodiments, the frame may include a center pivot 648 (e.g., a fold line) between the first support section 644 and the second support section 646 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 648 may be generally perpendicular to the first pivot axis 620 of the first panel 602 and the second pivot axis 622 of the second panel 604 in both the parallel and perpendicular configurations. At least a portion of the frame may include a taper 674 having a narrowest portion at the center pivot 648. In some embodiments, the taper 674 may be formed by portions of the wall sections 606, 608 of each of the support sections 644, 646.

With reference to FIG. 53, in some embodiments, the first panel 602 and the second panel 604 may pivot relative to one another about separate axes. For example, the first panel 602 may pivot about a first pivot axis 620 and a second panel 604 may pivot about a second pivot axis 622. In some embodiments, within a given support section (e.g., one of support sections 644, 646), the first pivot axis 620 may be generally parallel to the second pivot axis 622. In some embodiments, the first pivot axis 620 may be disposed at the first base end 624 of the first panel 602 at a base end of the first wall section 606 and may be parallel to the first base end. The second pivot axis 622 may be disposed at the second base end 626 of the second panel 604 at a base end of the second wall section 608 and may be parallel to the second base end.

With reference to FIGS. 53-55, in some embodiments, the first panel 602 and/or the second panel 604 may be connected to a base section 638. In some embodiments, the first panel 602 and the second panel 604 may be connected to the base section integrally, via respective first fold line 634 and second fold line 636. The first fold line 634 may be defined on the first pivot axis 620 between the first wall section 606 and the base section 638, and the second fold line 636 may be defined on the second pivot axis 622 between the second wall section 608 and the base section 638. In some embodiments, the base section may include a respective first upright portion and second upright portion, which may support the respective first panel and the second panel.

In some embodiments, the base section 638 may include one or more handle sections 676 for forming a handle as shown with respect to FIG. 35B. In such embodiments, the handle section 676 may be integral with the base section, and may be defined at either or both lateral ends of the frame, such that one or more handles on one or more cooperating frames may allow a user to remove the object from a box.

With reference to FIGS. 53-55, a flexible support 10 may be connected to the first panel 602 at the flaps 614 proximate the first distal end 610 of the first and proximate the second panel 604 near the second distal end 612, such that the flexible support may extend between and span the first panel 602 and the second panel 604. In some embodiments, the flexible support 10 may be attached to the first panel 602 and/or the second panel 604 via one or more adhesive strips 662 (e.g., glue, tape, or the like). In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall section, may attach to or include the flaps (e.g., flaps 614), or may attach to one of the respective distal ends 610, 612.

With reference to FIG. 55, an object 20 is shown loaded onto the frame 600, with the first panels 602 and the second panels 604 pivoted inwardly relative to one another. As noted above, either or both the first panel 602 and the second panel 604 may physically move (e.g., the first panel 602 and second panel 604 are shown pivoted inward towards one another). The first panel 602 may pivot about a first fold line 634 on the first pivot axis 620, and the second panel 604 may pivot about the second fold line 636 on the second pivot axis 622. In some embodiments, the first panel 602 and the second panel 604 may facilitate centering the object 20 when the pivot distance of each panel (e.g., the distance from the pivot axis 620, 622 to the respective distal end 610, 612) is substantially the same. In some embodiments, the respective wall sections 606, 608 may apply an outward force (e.g., via a restorative force from the respective first fold line 634 and second fold line 636) to at least partially support the object 20. In some embodiments, the distal ends 610, 612 of the respective panels 602, 604 may contact the object 20, and in some embodiments, the outward force may hold the distal ends 610, 612 outwardly relative to the object. In embodiments having two pivot axes, the distance between the pivot axes may be less than the sum of the pivot distances of each opposing panel to cause the panels to contact one another.

One or more flaps 614 may be connected to the respective first distal end 610 of the first panel 602 and the second distal end 612 of the second panel 604 by one or more fold lines 616 between the flaps and the respective first wall section 606 or second wall section 608. With reference to FIGS. 54-55, the flaps 614 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20. In some embodiments, one or more of the flaps 614 may be attached to the respective first wall section 606 and/or second wall section 608 via one or more attachment flaps 652. The one or more flaps 614 may include a fold line 616 at the attachment flap 652 for maintaining the attachment flap 652 adjacent and parallel the respective first wall section 606 and/or second wall section 608. In some embodiments, more than one of the flaps 614 may be attached to the first wall section 606 and/or second wall section 608 with an attachment flap.

The frame 600 may be positioned in a box for packaging the object 20. The frame 600 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane (e.g., as shown in FIGS. 35A-B) and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 56-57, progressive assembly views of the frame embodiment 600 shown in FIGS. 53-55 are depicted. With reference to FIG. 56, a top-down view of a frame template 650 is shown. The frame template 650 may define one or more substantially flat materials with fold lines and cuts to allow the completed frame (e.g., frame 600 shown in FIGS. 53-55) to be assembled therefrom.

FIG. 57 shows a partial reverse side of the frame template 650 of FIG. 56. During assembly, the flaps 614, coupled via the flexible support 10, may be integral with one of the first wall section 606 and the second wall section 608 (e.g., second wall section 608 shown in FIG. 57). The flaps 614 may be folded at the fold line 616 connecting one of the flaps 614 to the one of the first wall section 606 and the second wall section 608. The attachment flap 652 may engage the other of the wall sections 606, 608 (e.g., first wall section 606 shown in FIG. 57). In some embodiments the first wall section 606 and/or the second wall section 608 may be at least partially folded at the respective first fold line 634 and second fold line 636 to allow the attachment flap 652 to engage the wall section 606, 608.

Seventh Example Embodiment

With reference to FIG. 58, an embodiment of the presently disclosed subject matter includes a frame 700 having a first support section 744 and a second support section 746. Each support section 744, 746 may include a first panel 702 and a second panel 704. The first panel 702 may include a first wall section 706, and the first panel may include a first distal end 710 and a first base end 724. The second panel 704 may include a second wall section 708, and the second panel may include a second distal end 712 and a second base end 726.

The support sections may be formed separately, as independent supporting devices (e.g., similar to the frames of the embodiments shown in FIGS. 1-30), or the support sections 744, 746 may be parts of a single frame 700. In embodiments of a frame 700 having multiple support sections 744, 746, the support sections may be attached and/or integrally connected to one another. With reference to FIG. 58, the frame 700 may include the first support section 744 disposed generally parallel to the second support section 746. In some embodiments, the first support section 744 may be spaced from the second support section 746. In some embodiments, the first support section 744 may be generally perpendicular to the second support section 746. In such embodiments, the support sections 744, 746 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object) as shown and described above with respect to FIGS. 32, 45.

With reference to FIGS. 58-60, the frame 700 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 58) and a perpendicular configuration. In a parallel configuration, the first pivot axis 720 of the first support section 744 may be generally collinear with the first pivot axis 720 of the second support section 746, and the second pivot axis 722 of the first support section 744 may be generally collinear with the second pivot axis 722 of the second support section. In a perpendicular configuration, the first pivot axis 720 of the first support section 744 may be generally perpendicular to the first pivot axis 720 of the second support section 746, and the second pivot axis 722 of the first support section 744 may be generally perpendicular to the second pivot axis 722 of the second support section. In such embodiments, the frame may include a center pivot 748 (e.g., a fold line) between the first support section 744 and the second support section 746 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 748 may be generally perpendicular to the first pivot axis 720 of the first panel 702 and the second pivot axis 722 of the second panel 704 in both the parallel and perpendicular configurations. At least a portion of the frame may include a taper 774 having a narrowest portion at the center pivot 748.

With reference to FIG. 58, in some embodiments, the first panel 702 and the second panel 704 may pivot relative to one another about separate axes. For example, the first panel 702 may pivot about a first pivot axis 720 and a second panel 704 may pivot about a second pivot axis 722. In some embodiments, within a given support section (e.g., one of support sections 744, 746), the first pivot axis 720 may be generally parallel to the second pivot axis 722. In some embodiments, the first pivot axis 720 may be disposed at the first base end 724 of the first panel 702 at a base end of the first wall section 706 and may be parallel to the first base end. The second pivot axis 722 may be disposed at the second base end 726 of the second panel 704 at a base end of the second wall section 708 and may be parallel to the second base end.

With reference to FIGS. 58-60, in some embodiments, the first panel 702 and/or the second panel 704 may be connected to a base section 738. In some embodiments, the first panel and the second panel may be connected to the base section integrally. In some embodiments, the base section 738 may include a respective first upright portion 740 and second upright portion 742, which may support the respective first panel 702 and the second panel 704. The first wall section 706 may engage the first upright portion 740, such that the first upright portion pivotally supports the first wall section. The second wall section 708 may engage the second upright portion 742, such that the second upright portion pivotally supports the second wall section.

In some embodiments, the base section 738 may include one or more handle sections 778 for forming a handle as shown with respect to FIG. 35B. In such embodiments, the handle section 778 may be integral with the base section, and may be defined at either or both lateral ends of the frame, such that one or more handles on one or more cooperating frames may allow a user to remove the object from a box.

In some embodiments, the first wall section 706 may be integral with the first upright portion 740, and the first wall section 706 may pivot relative to the first upright portion 740 via a first fold line 734 connecting the first wall section at the first base end 724 and the first upright portion. In such embodiments, the first pivot axis 720 may be disposed on the first fold line 734. In an unloaded position, the first wall section 706 may be substantially coplanar with the first upright portion 740.

The second wall section 708 may be attached to the second upright portion 742 via one or more attachment flaps 752. The attachment flap 752 may be integral with the second wall section 708 via a second fold line 736 defined on the second pivot axis. In some embodiments, the second fold line 736 may be bent at a generally 180 degree angle when the frame 700 is unloaded, such that the attachment flap 752 and second wall section 708 both extend upwardly from the fold line 736 at the second base end 726 of the second panel 704. Alternatively, the attachment flap 752 may extend downwardly from the fold line 736 such that the attachment flap and second wall section 708 are substantially coplanar in an unloaded position.

Additionally or alternatively, the first upright portion 740 and the second upright portion 742 may be connected the center portion of the base section 738 via one or more base fold lines 776. The base fold lines 776 may allow the first panel 702 and the second panel 704 to pivot relative to one another in addition to or as an alternative to the first fold line 734 and the second fold line 736. In some embodiments, the first panel 702 and second panel 704 may pivot relative to one another about both the respective pivot axes 720, 722 and the base fold lines 776, such that the pivot distance may include the distance between the base fold lines 776 and the respective distal ends 710, 712. In embodiments having two pivot axes, the distance between the pivot axes may be less than the sum of the pivot distances of each opposing panel to cause the panels to contact one another.

With reference to FIGS. 58-60, a flexible support 10 may be connected to the outer surface 756 of the first wall section 706 proximate the first distal end 710 of the first panel 702, and the flexible support may be connected to the outer surface 756 of the second wall section 708 proximate the second distal end 712 of the second panel 704, such that the flexible support spans between the first panel 702 and the second panel 704. In some embodiments, the flexible support 10 may be attached to the first panel 702 and/or the second panel 704 via one or more adhesive strips 762 (e.g., glue, tape, or the like). In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall section, may attach to or include the flaps (e.g., flaps 714), or may attach to one of the respective distal ends 710, 712.

With reference to FIG. 60, an object 20 is shown loaded onto the frame 700, with the first panels 702 and the second panels 704 pivoted inwardly relative to one another. As noted above, either or both the first panel 702 and the second panel 704 may physically move (e.g., the first panel 702 and second panel 704 are shown pivoted inward towards one another). The first panel 702 may pivot about a first fold line 734 on the first pivot axis 720, and the second panel 704 may pivot about the second fold line 736 on the second pivot axis 722. In some embodiments, the first panel 702 and the second panel 704 may facilitate centering the object 20 when the pivot distance of each panel (e.g., the distance from the pivot axis 720, 722 to the respective distal end 710, 712) is substantially the same. In some embodiments, the respective wall sections 706, 708 and/or upright portions 740, 742 may apply an outward force (e.g., via a restorative force from the respective first fold line 734 and second fold line 736) to at least partially support the object 20 on the flexible support 10. In some embodiments, the distal ends 710, 712 of the respective panels 702, 704 may contact the object 20, and in some embodiments, the outward force may hold the distal ends 710, 712 outwardly relative to the object.

One or more flaps 714 may be connected to the respective first distal end 710 of the first panel 702 and the second distal end 712 of the second panel 704 by one or more fold lines 716 between the flaps and the respective first wall section 706 or second wall section 708. With reference to FIGS. 59-60, the flaps 714 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

The frame 700 may be positioned in a box for packaging the object 20. The frame 700 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane (e.g., as shown in FIGS. 35A-B) and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 61-62, progressive assembly views of the frame embodiment 700 shown in FIGS. 58-60 are depicted. With reference to FIG. 61, a top-down view of a frame template 750 is shown. The frame template 750 may define one or more substantially flat materials with fold lines and cuts to allow the completed frame (e.g., frame 700 shown in FIGS. 61-62) to be assembled therefrom.

FIG. 62 shows a reverse side of the frame template 750 of FIG. 61. During assembly, the flaps 714, coupled via the flexible support 10, may be integral with one of the first wall section 706 and the second wall section 708 (e.g., first wall section 706 shown in FIG. 61). The wall sections 706, 708 may be folded at the first fold line 734 connecting the first wall section 706 to the first upright portion 740. The attachment flap 752 may engage the second upright portion 742. In some embodiments the first wall section 706, the second wall section 708, and/or the respective base fold lines 776 of the first upright portion 740 and the second upright portion 742 may be folded at the respective first fold line 734, second fold line 736, and/or base fold line 776 to allow the attachment flap 752 to engage the second upright portion. The first upright portion 740 and the second upright portion 742 may then be substantially perpendicular to the center of the base section 738 (e.g., by folding or by placing the frame 700 in a box), such that the first panel 702 and second panel 704 are positioned upright.

Eighth Example Embodiment

With reference to FIG. 63, an embodiment of the presently disclosed subject matter includes a frame 800 having a first support section 844 and a second support section 846. Each support section 844, 846 may include a first panel 802 and a second panel 804. The first panel 802 may include a first wall section 806, and the first panel may include a first distal end 810 and a first base end 824. The second panel 804 may include a second wall section 808, and the second panel may include a second distal end 812 and a second base end 826.

The support sections may be formed separately, as independent supporting devices (e.g., similar to the frames of the embodiments shown in FIGS. 1-30), or the support sections 844, 846 may be parts of a single frame 800. In embodiments of a frame 800 having multiple support sections 844, 846, the support sections may be attached and/or integrally connected to one another. With reference to FIG. 63, the frame 800 may include the first support section 844 disposed generally parallel to the second support section 846. In some embodiments, the first support section 844 may be spaced from the second support section 846. In some embodiments, the first support section 844 may be generally perpendicular to the second support section 846. In such embodiments, the support sections 844, 846 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object) as shown and described above with respect to FIGS. 32, 45.

With reference to FIGS. 63-65, the frame 800 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 63) and a perpendicular configuration. In a parallel configuration, the first pivot axis 820 of the first support section 844 may be generally collinear with the first pivot axis 820 of the second support section 846, and the second pivot axis 822 of the first support section 844 may be generally collinear with the second pivot axis 822 of the second support section. In a perpendicular configuration, the first pivot axis 820 of the first support section 844 may be generally perpendicular to the first pivot axis 820 of the second support section 846, and the second pivot axis 822 of the first support section 844 may be generally perpendicular to the second pivot axis 822 of the second support section. In such embodiments, the frame may include a center pivot 848 (e.g., a fold line) between the first support section 844 and the second support section 846 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 848 may be generally perpendicular to the first pivot axis 820 of the first panel 802 and the second pivot axis 822 of the second panel 804 in both the parallel and perpendicular configurations. At least a portion of the frame may include a taper 874 having a narrowest portion at the center pivot 848.

With reference to FIGS. 63-64, in some embodiments, the first panel 802 and the second panel 804 may pivot relative to one another about separate axes. For example, the first panel 802 may pivot about a first pivot axis 820 and a second panel 804 may pivot about a second pivot axis 822. In some embodiments, within a given support section (e.g., one of support sections 844, 846), the first pivot axis 820 may be generally parallel to the second pivot axis 822. In some embodiments, the first pivot axis 820 may be disposed at the first base end 824 of the first panel 802 at a base end of the first wall section 806 and may be parallel to the first base end. The second pivot axis 822 may be disposed at the second base end 826 of the second panel 804 at a base end of the second wall section 808 and may be parallel to the second base end.

With reference to FIGS. 63-65, in some embodiments, the first panel 802 and/or the second panel 804 may be connected to a base section 838. In some embodiments, the first panel and the second panel may be connected to the base section integrally. In some embodiments, the base section 838 may include a respective first upright portion 840 and second upright portion 842, which may support the respective first panel 802 and the second panel 804. The first wall section 806 may engage the first upright portion 840, such that the first upright portion pivotally supports the first wall section. The second wall section 808 may engage the second upright portion 842, such that the second upright portion pivotally supports the second wall section.

In some embodiments, the base section 838 may include one or more handle sections 880 for forming a handle as shown with respect to FIG. 35B. In such embodiments, the handle section 880 may be integral with the base section, and may be defined at either or both lateral ends of the frame, such that one or more handles on one or more cooperating frames may allow a user to remove the object from a box.

In some embodiments, the first wall section 806 may be attached to the first upright portion 840 via one or more attachment flaps 852. The attachment flap 852 may be integral with the first wall section 806 via a first fold line 834 defined on the first pivot axis 820. In some embodiments, the first fold line 834 may be bent at a generally 180 degree angle when the frame 800 is unloaded, such that the attachment flap 852 and first wall section 806 both extend upwardly from the first fold line 834 at the first base end 824 of the first panel 802. Alternatively, the attachment flap 852 may extend downwardly from the first fold line 834 such that the attachment flap and first wall section 806 are substantially coplanar in an unloaded position.

In addition, as shown in FIGS. 63-65, the second wall section 808 may be attached to the second upright portion 842 via one or more attachment flaps 852. The attachment flap 852 may be integral with the second wall section 808 via a second fold line 836 defined on the second pivot axis 822. In some embodiments, the second fold line 836 may be bent at a generally 180 degree angle when the frame 800 is unloaded, such that the attachment flap 852 and second wall section 808 both extend upwardly from the fold line 836 at the second base end 826 of the second panel 804. Alternatively, the attachment flap 852 may extend downwardly from the fold line 836 such that the attachment flap and second wall section 808 are substantially coplanar in an unloaded position.

In some embodiments, at least one of the attachment flaps 852 of the respective first wall section 806 or the second wall section 808 may additionally be integral with the respective first upright portion 840 or second upright portion 842. For example, with reference to FIGS. 63-65, the first upright portion 840 is integrally connected to the attachment flap 852 of the first panel 802 via integral fold line 878. In some further embodiments, as also shown in FIGS. 63-65, the first upright portion 840 may be integrally connected to the first wall section 706 via the first fold line 834, the integral fold line 878, and the attachment flap 852.

The first upright portion 840 and the second upright portion 842 may be connected to the center portion of the base section 838 via one or more base fold lines 876. The base fold lines 876 may allow the first panel 802 and the second panel 804 to pivot relative to one another in addition to or as an alternative to the first fold line 834 and the second fold line 836. In some embodiments, the first panel 802 and second panel 804 may pivot relative to one another about both the respective pivot axes 820, 822 and the base fold lines 876, such that the pivot distance may include the distance between the base fold lines 876 and the respective distal ends 810, 812. In embodiments having two pivot axes, the distance between the pivot axes may be less than the sum of the pivot distances of each opposing panel to cause the panels to contact one another.

With reference to FIGS. 63-65, a flexible support 10 may be connected to the outer surface 856 of the first wall section 806 proximate the first distal end 810 of the first panel 802, and the flexible support may be connected to the outer surface 856 of the second wall section 808 proximate the second distal end 812 of the second panel 804, such that the flexible support may extend between and span the first panel 802 and the second panel 804. In some embodiments, the flexible support 10 may be attached to the first panel 802 and/or the second panel 804 via one or more adhesive strips 862 (e.g., glue, tape, or the like). In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall section, may attach to or include the flaps (e.g., flaps 814), or may attach to one of the respective distal ends 810, 812.

With reference to FIG. 65, an object 20 is shown loaded onto the frame 800, with the first panels 802 and the second panels 804 pivoted inwardly relative to one another. As noted above, either or both the first panel 802 and the second panel 804 may physically move (e.g., the first panel 802 and second panel 804 are shown pivoted inward towards one another). The first panel 802 may pivot about a first fold line 834 on the first pivot axis 820, and the second panel 804 may pivot about the second fold line 836 on the second pivot axis 822. In some embodiments, the first panel 802 and the second panel 804 may facilitate centering the object 20 when the pivot distance of each panel (e.g., the distance from the pivot axis 820, 822 to the respective distal end 810, 812) is substantially the same. In some embodiments, the respective wall sections 806, 808 and/or upright portions 840, 842 may apply an outward force (e.g., via a restorative force from the respective first fold line 834 and second fold line 836) to at least partially support the object 20 on the flexible support 10. In some embodiments, the distal ends 810, 812 of the respective panels 802, 804 may contact the object 20, and in some embodiments, the outward force may hold the distal ends 810, 812 outwardly relative to the object.

One or more flaps 814 may be connected to the respective first distal end 810 of the first panel 802 and the second distal end 812 of the second panel 804 by one or more fold lines 816 between the flaps and the respective first wall section 806 or second wall section 808. With reference to FIGS. 64-65, the flaps 814 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

The frame 800 may be positioned in a box for packaging the object 20. The frame 800 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane (e.g., as shown in FIGS. 35A-B) and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 66-67, progressive assembly views of the frame embodiment 800 shown in FIGS. 63-65 are depicted. With reference to FIG. 66, a top-down view of a frame template 850 is shown. The frame template 850 may define one or more substantially flat materials with fold lines and cuts to allow the completed frame (e.g., frame 800 shown in FIGS. 63-65) to be assembled therefrom.

FIG. 67 shows a reverse side of the frame template 850 of FIG. 66. During assembly, at least one of the first panel 802 and the second panel 804 may be integral with the respective first upright portion 840 and second upright portion 842 (e.g., first panel 802 and first upright portion 840 shown in FIGS. 63-65). The wall sections 806, 808 and attachment flap 852 may be folded at the integral fold line 878 connecting the attachment flap 852 and the first upright portion 740. The attachment flap 852 of the first panel 802 may be rotated approximately 180 degrees to also engage the first upright portion 840 via an adhesive or other bonding or attachment mechanism (e.g., adhesive strip 862).

The attachment flap 852 of the second panel 804 may engage the second upright portion 842. In some embodiments the first wall section 806, the second wall section 808, and/or the respective base fold lines 876 of the first upright portion 840 and the second upright portion 842 may be folded at the respective first fold line 834, second fold line 836, and/or base fold line 876 to allow the attachment flap 852 of the second panel 806 to engage the second upright portion. The first upright portion 834 and the second upright portion 836 may then be substantially perpendicular to the center of the base section 838 (e.g., by folding or by placing the frame 800 in a box), and the first panel 802 and second panel 804 are positioned upright by folding the respective first fold line 834 and second fold line 836 approximately 180 degrees with respect to the adjacent attachment flap 852. For example, with reference to FIG. 64, the first upright portion 840, the attachment flap 852 of the first panel 802, and the first wall section 806 substantially overlap one another. With continued reference to FIG. 64, the second upright portion 842, the attachment flap 852 of the second panel 804, and the second wall section 808 may substantially overlap one another.

Ninth Example Embodiment

The embodiment shown in FIGS. 68-73 includes a frame 900 having similar features to the embodiment shown in FIGS. 63-67 with the panels 902, 904 separate from and attached to either upright portion of the base section 938. With reference to FIG. 68, an embodiment of the presently disclosed subject matter includes a frame 900 having a first support section 944 and a second support section 946. Each support section 944, 946 may include a first panel 902 and a second panel 904. The first panel 902 may include a first wall section 906, and the first panel may include a first distal end 910 and a first base end 924. The second panel 904 may include a second wall section 908, and the second panel may include a second distal end 912 and a second base end 926.

The support sections 944, 946 may be formed separately, as independent supporting devices (e.g., similar to the frames of the embodiments shown in FIGS. 1-30), or the support sections 944, 946 may be parts of a single frame 900. In embodiments of a frame 900 having multiple support sections 944, 946, the support sections may be attached and/or integrally connected to one another. With reference to FIG. 68, the frame 900 may include the first support section 944 disposed generally parallel to the second support section 946. In some embodiments, the first support section 944 may be spaced from the second support section 946. In some embodiments, the first support section 944 may be generally perpendicular to the second support section 946. In such embodiments, the support sections 944, 946 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object) as shown and described above with respect to FIGS. 32, 45.

With reference to FIGS. 68, 70, and 71 the frame 900 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 68) and a perpendicular configuration. In a parallel configuration, the first pivot axis 920 of the first support section 944 may be generally collinear with the first pivot axis 920 of the second support section 946, and the second pivot axis 922 of the first support section 944 may be generally collinear with the second pivot axis 922 of the second support section. In a perpendicular configuration, the first pivot axis 920 of the first support section 944 may be generally perpendicular to the first pivot axis 920 of the second support section 946, and the second pivot axis 922 of the first support section 944 may be generally perpendicular to the second pivot axis 922 of the second support section. In such embodiments, the frame may include a center pivot 948 (e.g., a fold line) between the first support section 944 and the second support section 946 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 948 may be generally perpendicular to the first pivot axis 920 of the first panel 902 and the second pivot axis 922 of the second panel 904 in both the parallel and perpendicular configurations. At least a portion of the frame may include a taper 974 having a narrowest portion at the center pivot 948.

In some embodiments, as shown in FIG. 69, the first panel 902 and the second panel 904 may be attached directly to an inner wall 982 of a box (e.g., box 30) or a rectangular prism-shaped insert for a box (e.g., a partial box configured for insertion into a box) without a base section 938 or center fold line 948. In such embodiments, a fixed configuration (e.g., the parallel configuration) of the first support section 944 and the second support section 946 may be used. The box may be generally rigid, such that in some embodiments, the panels 902, 904 may pivot only about the first pivot axis 920 and the second pivot axis 904, respectively. As detailed below, one or more adhesive strips 962 may attach the first panel 902 and/or second panel 904 to the box.

In some embodiments, the base section 938 may include one or more handle sections 988 for forming a handle as shown with respect to FIG. 35B. In such embodiments, the handle section 988 may be integral with the base section, and may be defined at either or both lateral ends of the frame, such that one or more handles on one or more cooperating frames may allow a user to remove the object from a box.

With reference to FIG. 68, in some embodiments, the first panel 902 and the second panel 904 may pivot relative to one another about separate axes. For example, the first panel 902 may pivot about a first pivot axis 920 and a second panel 904 may pivot about a second pivot axis 922. In some embodiments, within a given support section (e.g., one of support sections 944, 946), the first pivot axis 920 may be generally parallel to the second pivot axis 922. In some embodiments, the first pivot axis 920 may be disposed at the first base end 924 of the first panel 902 at a base end of the first wall section 906 and may be parallel to the first base end. The second pivot axis 922 may be disposed at the second base end 926 of the second panel 904 at a base end of the second wall section 908 and may be parallel to the second base end.

With reference to FIGS. 68, 70, and 71, in some embodiments, the first panel 902 and/or the second panel 904 may be connected to a base section 938. In some embodiments, the first panel and the second panel may be connected to the base section integrally. In some embodiments, the base section 938 may include a respective first upright portion 940 and second upright portion 942, which may support the respective first panel 902 and the second panel 904. The first wall section 906 may engage the first upright portion 940, such that the first upright portion pivotally supports the first wall section. The second wall section 908 may engage the second upright portion 942, such that the second upright portion pivotally supports the second wall section.

In some embodiments, the first wall section 906 may be attached to the first upright portion 940 via one or more attachment flaps 952. The attachment flap 952 may be integral with the first wall section 906 via a first fold line 934 defined on the first pivot axis 920. In some embodiments, the first fold line 934 may be bent at a generally 180 degree angle when the frame 900 is unloaded, such that the attachment flap 952 and first wall section 906 both extend upwardly from the first fold line 934 at the first base end 924 of the first panel 902. Alternatively, the attachment flap 952 may extend downwardly from the first fold line 934 such that the attachment flap and first wall section 906 are substantially coplanar in an unloaded position.

In addition, as shown in FIGS. 68, 70, and 71, the second wall section 908 may be attached to the second upright portion 942 via one or more attachment flaps 952. The attachment flap 952 may be integral with the second wall section 908 via a second fold line 936 defined on the second pivot axis 922. In some embodiments, the second fold line 936 may be bent at a generally 180 degree angle when the frame 900 is unloaded, such that the attachment flap 952 and second wall section 908 both extend upwardly from the fold line 936 at the second base end 926 of the second panel 904. Alternatively, the attachment flap 952 may extend downwardly from the fold line 936 such that the attachment flap and second wall section 908 are substantially coplanar in an unloaded position. In the embodiments shown in FIG. 68-73, the attachment flaps 952 of the first panel 902 and the second panel 904 may be attached to the respective first upright portion 940 and second upright portion 942 at a respective first distal end 984 and second distal end 986.

Additionally or alternatively, the first upright portion 940 and the second upright portion 942 may be connected to the center portion of the base section 938 via one or more base fold lines 976. The base fold lines 976 may allow the first panel 902 and the second panel 904 to pivot relative to one another in addition to or as an alternative to the first fold line 934 and the second fold line 936. In some embodiments, the first panel 902 and second panel 904 may pivot relative to one another about both the respective pivot axes 920, 922 and the base fold lines 976, such that the pivot distance may include the distance between the base fold lines 976 and the respective distal ends 910, 912. In embodiments having two pivot axes, the distance between the pivot axes may be less than the sum of the pivot distances of each opposing panel to cause the panels to contact one another.

With reference to FIGS. 68-71, a flexible support 10 may be connected to the outer surface 956 of the first wall section 906 proximate the first distal end 910 of the first panel 902, and the flexible support may be connected to the outer surface 956 of the second wall section 908 proximate the second distal end 912 of the second panel 904, such that the flexible support may extend between and span the first panel 902 and the second panel 904. In some embodiments, the flexible support 10 may be attached to the first panel 902 and/or the second panel 904 via one or more adhesive strips 962 (e.g., glue, tape, or the like). In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall section, may attach to or include the flaps (e.g., flaps 914), or may attach to one of the respective distal ends 910, 912.

With reference to FIG. 71, an object 20 is shown loaded onto the frame 900, with the first panels 902 and the second panels 904 pivoted inwardly relative to one another. As noted above, either or both the first panel 902 and the second panel 904 may physically move (e.g., the first panel 902 and the second panel 904 are shown pivoted inward towards one another). The first panel 902 may pivot about a first fold line 934 on the first pivot axis 920, and the second panel 904 may pivot about the second fold line 936 on the second pivot axis 922. In some embodiments, the first panel 902 and the second panel 904 may facilitate centering the object 20 when the pivot distance of each panel (e.g., the distance from the pivot axis 920, 922 to the respective distal end 910, 912) is substantially the same. In some embodiments, the respective wall sections 906, 908 and/or upright portions 940, 942 may apply an outward force (e.g., via a restorative force from the respective first fold line 934 and second fold line 936) to at least partially support the object 20 on the flexible support 10. In some embodiments, the distal ends 910, 912 of the respective panels 902, 904 may contact the object 20, and in some embodiments, the outward force may hold the distal ends 910, 912 outwardly relative to the object.

One or more flaps 914 may be connected to the respective first distal end 910 of the first panel 902 and the second distal end 912 of the second panel 904 by one or more fold lines 916 between the flaps and the respective first wall section 906 or second wall section 908. With reference to FIGS. 68-71, the flaps 914 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

As detailed herein, the frame 900 may be positioned in a box for packaging the object 20. The frame 900 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane (e.g., as shown in FIGS. 35A-B) and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 72-73, progressive assembly views of the frame embodiment 900 shown in FIGS. 68-71 are depicted. With reference to FIG. 72, a top-down view of a frame template 950 is shown, including a base section template 978 and a plurality of panel section templates 980. The frame template 950 may define one or more substantially flat materials with fold lines and cuts to allow the completed frame (e.g., frame 900 shown in FIGS. 68, 70, and 71) to be assembled therefrom.

FIG. 73 shows a reverse side of the frame template 950 of FIG. 72. During assembly, the panel section templates 980, including at least one of the first panel 902 and the second panel 904 may be attached to with the respective first upright portion 940 and second upright portion 942 (e.g., first panel 902 and first upright portion 940 shown in FIGS. 68, 70, and 71) via one or more attachment flaps 952 having one or more adhesive strips 962 thereon. The attachment flap 952 of the first panel 902 may be attached proximate a first distal end 984 of the first upright portion 940, and the attachment flap 952 of the second panel 904 may be attached proximate a second distal end 986 of the second upright portion 942.

The first upright portion 934 and the second upright portion 936 may then be substantially perpendicular to the center of the base section 938 (e.g., by folding or by placing the frame 900 in a box), and the first panel 902 and second panel 904 may be positioned upright by folding the respective first fold line 934 and second fold line 936 approximately 180 degrees with respect to the adjacent attachment flap 952. For example, with reference to FIG. 70, the first upright portion 940, the attachment flap 952 of the first panel 902, and the first wall section 906 substantially overlap one another. With continued reference to FIG. 70, the second upright portion 942, the attachment flap 952 of the second panel 904, and the second wall section 908 may additionally or alternatively, substantially overlap one another.

Alternatively one or more panel section templates 980 may be inserted into a box or partial box, as detailed above, to form the frame 900 (e.g., as shown in FIG. 69). In such embodiments, the attachment flaps 952 may be attached substantially equal heights from a bottom of the box, approximately at a same height as a distal end 984 of the first upright portion 940 and a distal end 984 of the second upright portion 942 of the base section 938.

Tenth Example Embodiment

FIGS. 74-79 include a frame 1000 having substantially similar features to the frame 900 shown in FIGS. 68-73 with the attachment flaps 1052 attached to the base section 1038 or box (e.g., box 30) adjacent a respective first base end 1088 of the first upright portion 1040 or second base end 1090 of the second upright portion 1042. With reference to FIG. 74, an embodiment of the presently disclosed subject matter includes a frame 1000 having a first support section 1044 and a second support section 1046. Each support section 1044, 1046 may include a first panel 1002 and a second panel 1004. The first panel 1002 may include a first wall section 1006, and the first panel 1002 may include a first distal end 1010 and a first base end 1024. The second panel 1004 may include a second wall section 1008, and the second panel may include a second distal end 1012 and a second base end 1026.

The support sections 1044, 1046 may be formed separately, as independent supporting devices (e.g., similar to the frames of the embodiments shown in FIGS. 1-30), or the support sections 1044, 1046 may be parts of a single frame 1000. In embodiments of a frame 1000 having multiple support sections 1044, 1046, the support sections may be attached and/or integrally connected to one another. With reference to FIG. 74, the frame 1000 may include the first support section 1044 disposed generally parallel to the second support section 1046. In some embodiments, the first support section 1044 may be spaced from the second support section 1046. In some embodiments, the first support section 1044 may be generally perpendicular to the second support section 1046. In such embodiments, the support sections 1044, 1046 may support a corner of the object 20 (e.g., supporting two adjacent sides of the object) as shown and described above with respect to FIGS. 32, 45.

With reference to FIGS. 74, 76, and 77 the frame 1000 may be convertible between at least a parallel configuration (e.g., as shown in FIG. 74) and a perpendicular configuration. In a parallel configuration, the first pivot axis 1020 of the first support section 1044 may be generally collinear with the first pivot axis 1020 of the second support section 1046, and the second pivot axis 1022 of the first support section 1044 may be generally collinear with the second pivot axis 1022 of the second support section. In a perpendicular configuration, the first pivot axis 1020 of the first support section 1044 may be generally perpendicular to the first pivot axis 1020 of the second support section 1046, and the second pivot axis 1022 of the first support section 1044 may be generally perpendicular to the second pivot axis 1022 of the second support section. In such embodiments, the frame may include a center pivot 1048 (e.g., a fold line) between the first support section 1044 and the second support section 1046 allowing the first support section and the second support section to pivot relative to one another. The axis of the center fold line 1048 may be generally perpendicular to the first pivot axis 1020 of the first panel 1002 and the second pivot axis 1022 of the second panel 1004 in both the parallel and perpendicular configurations. At least a portion of the frame may include a taper 1074 having a narrowest portion at the center pivot 1048.

In some embodiments, as shown in FIG. 75, the first panel 1002 and the second panel 1004 may be attached directly to an inner wall 1082 of a box (e.g., box 30) or a rectangular prism-shaped insert for a box (e.g., a partial box configured for insertion into a box) without a base section 1038 or center fold line 1048. In such embodiments, a fixed configuration (e.g., the parallel configuration) of the first support section 1044 and the second support section 1046 may be used. As detailed below, one or more adhesive strips 1062 may attach the first panel 1002 and/or second panel 1004 to the box. The box may be generally rigid, such that in some embodiments, the panels 1002, 1004 may pivot only about the first pivot axis 1020 and the second pivot axis 1004, respectively.

With reference to FIG. 74, in some embodiments, the first panel 1002 and the second panel 1004 may pivot relative to one another about separate axes. For example, the first panel 1002 may pivot about a first pivot axis 1020 and a second panel 1004 may pivot about a second pivot axis 1022. In some embodiments, within a given support section (e.g., one of support sections 1044, 1046), the first pivot axis 1020 may be generally parallel to the second pivot axis 1022. In some embodiments, the first pivot axis 1020 may be disposed at the first base end 1024 of the first panel 1002 at a base end of the first wall section 1006 and may be parallel to the first base end. The second pivot axis 1022 may be disposed at the second base end 1026 of the second panel 1004 at a base end of the second wall section 908 and may be parallel to the second base end.

With reference to FIGS. 74, 76, and 77, in some embodiments, the first panel 1002 and/or the second panel 1004 may be connected to a base section 1038. In some embodiments, the first panel and the second panel may be connected to the base section integrally. In some embodiments, the base section 1038 may include a respective first upright portion 1040 and second upright portion 1042, which may support the respective first panel 1002 and the second panel 1004. The first wall section 1006 may engage the first upright portion 1040, such that the first upright portion pivotally supports the first wall section. The second wall section 1008 may engage the second upright portion 1042, such that the second upright portion pivotally supports the second wall section.

In some embodiments, the base section 1038 may include one or more handle sections 1092 for forming a handle as shown with respect to FIG. 35B. In such embodiments, the handle section 1092 may be integral with the base section, and may be defined at either or both lateral ends of the frame, such that one or more handles on one or more cooperating frames may allow a user to remove the object from a box.

In some embodiments, the first wall section 1006 may be attached to the first upright portion 1040 via one or more attachment flaps 1052. The attachment flap 1052 may be integral with the first wall section 1006 via a first fold line 1034 defined on the first pivot axis 1020. In some embodiments, the first fold line 1034 may be bent at a generally 180 degree angle when the frame 1000 is unloaded, such that the attachment flap 1052 and first wall section 1006 both extend upwardly from the first fold line 1034 at the first base end 1024 of the first panel 1002. Alternatively, the attachment flap 1052 may extend downwardly from the first fold line 1034 such that the attachment flap and first wall section 1006 are substantially coplanar in an unloaded position.

In addition, as shown in FIGS. 74, 76, and 77, the second wall section 1008 may be attached to the second upright portion 1042 via one or more attachment flaps 1052. The attachment flap 1052 may be integral with the second wall section 1008 via a second fold line 1036 defined on the second pivot axis 1022. In some embodiments, the second fold line 1036 may be bent at a generally 180 degree angle when the frame 1000 is unloaded, such that the attachment flap 1052 and second wall section 1008 both extend upwardly from the fold line 1036 at the second base end 1026 of the second panel 1004. Alternatively, the attachment flap 1052 may extend downwardly from the fold line 1036 such that the attachment flap and second wall section 1008 are substantially coplanar in an unloaded position. In the embodiments shown in FIG. 74-79, the attachment flaps 1052 of the first panel 1002 and the second panel 1004 may be attached to the respective first upright portion 1040 and second upright portion 1042 at a respective first base end 1088 and second base end 1090.

Additionally or alternatively, the first upright portion 1040 and the second upright portion 1042 may be connected to the center portion of the base section 1038 via one or more base fold lines 1076. The base fold lines 1076 may allow the first panel 1002 and the second panel 1004 to pivot relative to one another in addition to or as an alternative to the first fold line 1034 and the second fold line 1036. In some embodiments, the first panel 1002 and second panel 1004 may pivot relative to one another about both the respective pivot axes 1020, 1022 and the base fold lines 1076, such that the pivot distance may include the distance between the base fold lines 1076 and the respective distal ends 1010, 1012. In embodiments having two pivot axes, the distance between the pivot axes may be less than the sum of the pivot distances of each opposing panel to cause the panels to contact one another.

With reference to FIGS. 74, 76, and 77, a flexible support 10 may be connected to the outer surface 1056 of the first wall section 1006 proximate the first distal end 1010 of the first panel 1002, and the flexible support may be connected to the outer surface 1056 of the second wall section 1008 proximate the second distal end 1012 of the second panel 1004, such that the flexible support spans between the first panel 1002 and the second panel 1004. In some embodiments, the flexible support 10 may be attached to the first panel 1002 and/or the second panel 1004 via one or more adhesive strips 1062 (e.g., glue, tape, or the like). In some embodiments, as detailed herein, the flexible support 10 may attach to an inner or outer surface of the wall section, may attach to or include the flaps (e.g., flaps 1014), or may attach to one of the respective distal ends 1010, 1012.

With reference to FIG. 77, an object 20 is shown loaded onto the frame 1000, with the first panels 1002 and the second panels 1004 pivoted inwardly relative to one another. As noted above, either or both the first panel 1002 and the second panel 1004 may physically move (e.g., the first panel 1002 and the second panel 1004 are shown pivoted inward towards one another). The first panel 1002 may pivot about a first fold line 1034 on the first pivot axis 920, and the second panel 1004 may pivot about the second fold line 1036 on the second pivot axis 1022. In some embodiments, the first panel 1002 and the second panel 1004 may facilitate centering the object 20 when the pivot distance of each panel (e.g., the distance from the pivot axis 1020, 1022 to the respective distal end 1010, 1012) is substantially the same. In some embodiments, the respective wall sections 1006, 1008 and/or upright portions 1040, 1042 may apply an outward force (e.g., via a restorative force from the respective first fold line 1034 and second fold line 1036) to at least partially support the object 20 on the flexible support 10. In some embodiments, the distal ends 1010, 1012 of the respective panels 1002, 1004 may contact the object 20, and in some embodiments, the outward force may hold the distal ends 1010, 1012 outwardly relative to the object.

One or more flaps 1014 may be connected to the respective first distal end 1010 of the first panel 1002 and the second distal end 1012 of the second panel 1004 by one or more fold lines 1016. With reference to FIGS. 74-77, the flaps 1014 may provide support for the flexible support 10 from beneath the flexible support and may at least partially facilitate the centered positioning of the object 20.

As detailed herein, the frame 1000 may be positioned in a box for packaging the object 20. The frame 1000 may support one or more sides of the object 20 within the box, including a top, bottom, left, right, front, or rear surface of the object or combinations thereof (e.g., in the parallel or perpendicular configurations). As detailed above, such embodiments may support the object 20 in a plane (e.g., as shown in FIGS. 35A-B) and the centering function of the frames may protect the object in the direction perpendicular to the plane.

Turning to FIGS. 78-79, progressive assembly views of the frame embodiment 1000 shown in FIGS. 74-77 are depicted. With reference to FIG. 78, a top-down view of a frame template 1050 is shown, including a base section template 1078 and a plurality of panel section templates 1080. The frame template 1050 may define one or more substantially flat materials with fold lines and cuts to allow the completed frame (e.g., frame 1000 shown in FIGS. 74, 76, and 77) to be assembled therefrom.

FIG. 79 shows a reverse side of the frame template 1050 of FIG. 78. During assembly, the panel section templates 1080, including at least one of the first panel 1002 and the second panel 1004 may be attached to with the respective first upright portion 1040 and second upright portion 1042 (e.g., first panel 1002 and first upright portion 1040 shown in FIGS. 74, 76, and 77) via one or more attachment flaps 1052 having one or more adhesive strips 1062 thereon. The attachment flap 1052 of the first panel 1002 may be attached proximate a first base end 1088 of the first upright portion 1040, and the attachment flap 1052 of the second panel 1004 may be attached proximate a second base end 1090 of the second upright portion 1042. In some embodiments, the upright portions 1040, 1042 may define any length, and may be substantially a same length as the respective attachment flaps 1052. In some embodiments, the attachment flaps 1052 of the respective first panel 1002 and second panel 1004 may attach directly to the center portion of the base section 1038 with or without upright portions 1040, 1042.

The first upright portion 1034 and the second upright portion 1036 may then be substantially perpendicular to the center of the base section 1038 (e.g., by folding or by placing the frame 1000 in a box), and the first panel 1002 and second panel 1004 may be positioned upright by folding the respective first fold line 1034 and second fold line 1036 approximately 180 degrees with respect to the adjacent attachment flap 1052, such that the flap is disposed adjacent the outer surface 1056 of the respective wall sections 1006, 1008. For example, with reference to FIG. 76, the first upright portion 1040, the attachment flap 1052 of the first panel 1002, and the first wall section 1006 substantially overlap one another. With continued reference to FIG. 76, the second upright portion 1042, the attachment flap 1052 of the second panel 1004, and the second wall section 1008 may additionally or alternatively, substantially overlap one another.

Alternatively one or more panel section templates 1080 may be inserted into a box or partial box, as detailed above, to form the frame 1000 (e.g., as shown in FIG. 75). In such embodiments, the attachment flaps 1052 may be attached substantially equal heights from a bottom of the box, approximately at a same height as a distal end of the base section 1038.

In the embodiments shown in FIGS. 74 and 76, the support structure may be directly glued to the box 30, which reduces the number of parts and assembly time of the devices.

Eleventh Embodiment

Any of the frames detailed herein may be arranged in a configuration of three, four, five, or more panels configured to rotate inwardly to hold and maintain an object. In such embodiments, the panels may face the object receiving area to pivot towards the object when rotated by the flexible support.

With reference to FIGS. 80-81, an embodiment is shown having four panels 1101, 1102, 1103, 1104 pivotally connected to one another and positioned in a box. Each of the panels 1101, 1102, 1103, 1104 may include base ends; distal ends 1109, 1110, 1111, 1112; wall sections 1105, 1106, 1107, 1108; flaps 1114, and other components as detailed in each of the above embodiments. With reference to FIG. 81, each of the distal ends 1109, 1110, 1111, 1112 of the respective panels 1101, 1102, 1103, 1104 may pivot inwardly to receive and support an object 20.

In the embodiment shown in FIGS. 80-81, the flexible support 10 includes a flexible sheet of material 1176 connected to the flaps 1114 such that the flexible support extends between each of the panels 1101, 1102, 1103, 1104. In some embodiments, multiple flexible supports may connect different pairs of panels.

Each of the panels 1101, 1102, 1103, 1104 may be connected by one or more connectors 1174, which may hinge in their center to allow relative motion between the distal ends 1109, 1110, 1111, 1112.

In some embodiments, the frame 1100 may include a base section as described in the embodiments above and to which the panels 1101, 1102, 1103, 1104 are connected. In some embodiments, the frame 1100 may be connected to the walls and/or base of a box 30. The box 30 and/or frame 1100 may be designed to define complementary shapes, such that the panels 1101, 1102, 1103, 1104 are supported by the box. In some embodiments, the frame 1100 may rest inside the box 30 without requiring physical attachment by resting the base ends of the wall sections 1105, 1106, 1107, 1108 against the box.

With reference to FIG. 81, the frame 1100 may be designed to hold a generally tubular or longitudinal object 20 such as a post or rod. As detailed above, any number of panels may be arranged to support the sides of the object 20 based on the shape of the object. For example, two panel frames may support generally flat, rectangular objects, while four panel frames may support elongated rectangular prisms, in which one dimension is substantially greater than the other dimensions. In this manner, the frame 1100 shown in FIG. 81 may support any length object 20. For example, a second frame 1100 may support the opposite end of the object 20 while each of the panels 1101, 1102, 1103, 1104 provides a two-dimensional centering effect on the object 20 to support the remaining sides.

Example Flexible Support Structure

In the drawings, flexible support 10 is shown attached to the panel (e.g., any of panels 102, 104, 202, 204, 302, 304, 402, 404, 502, 504, 602, 604, 702, 704, 802, 804, 902, 904, 1002, 1004, 1101, 1102, 1103, or 1104) by adhering with adhesive applied in various strips as detailed above; however, in any embodiment detailed herein, the flexible support 10 may be attached to the panel, for example, by one or more of any of the following: adhering (e.g., with hot melt adhesive), gluing, heat welding, ultrasonic welding, stapling, tacking, taping, fastening, clipping (see, e.g., U.S. Pat. No. 5,694,744 to Jones, which is incorporated herein in its entirety by reference), tab/slot engagement (see, e.g., U.S. Pat. No. 6,073,761 to Jones, which is incorporated herein in its entirety by reference), anchoring, retaining and/or securing (see, e.g., U.S. Patent Application Publication 2004/0108239 A1 to McDonald et al. published Jun. 10, 2004, which is incorporated herein in its entirety by reference, and which discloses a sleeve having pockets or pouches for receiving a flap). The flexible supports of any embodiments described herein may be attached by one or more of any of the ways of attachment described herein.

Useful types of adhesives for attaching flexible supports to frames are known to those of skill in the art, and depend on the composition of the materials to be adhered. For example, a polyurethane-based flexible support may be adhered with a polyurethane-based adhesive, such as a water-borne aliphatic polyurethane dispersion.

Flexible support 10, including any of the sheets of the various embodiments described herein, may comprise any of the materials, compositions, and polymers set forth herein with respect to flexible supports, and may have any thickness, properties, treatments, additives, and other characteristics (e.g., flexibility, elasticity, optics, strength, elastic recovery, transparency, load tear resistance, puncture resistance) as set forth herein with respect to flexible supports.

Flexible support 10 may have a composition and thickness providing acceptable performance properties (e.g., flexibility, elasticity, optics, strength) for the given packaging application of expected use. The flexible support may have a thickness of at most any of the following: 10 mils, 6 mils, 5 mils, 4 mils, 3 mils, 2 mils, 1.5 mils, and 1 mil. (A “mil” is equal to 0.001 inch.) The flexible support may also have a thickness of at least any of the following: 0.5 mils, 1 mil, 1.5 mils, 2 mils, and 3 mils.

The flexible support 10 may have an elastic recovery in either or both of the transverse and longitudinal directions of at least any of the following values: 60%, 65%, 70%, 75%, 80%, and 85%, measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time.

The flexible support 10 may have a maximum load tear resistance in either or both of the transverse and longitudinal directions of at least any of the following values: 400, 450, 500, 550, and 600 grams force, measured according to ASTM D1004.

The flexible support 10 may have a slow puncture maximum load of at least any of the following values: 4, 4.5, 5, 5.5, 6, 6.5, and 7 pounds force, measured according to ASTM F1306 using a crosshead speed of 5 inches per minute.

The flexible support 10 may have a Young's modulus sufficient to withstand the expected handling and use conditions, yet may provide a “soft” feel that may be desirable for a packaging application. The flexible support may have a Young's modulus of at least any of the following values: 2,000; 2,500; 3,000; 3,500; and 4,000 pounds/square inch. The flexible support may have a Young's modulus of no more than about any of the following values: 8,000; 10,000; 15,000; 20,000; 30,000; and 40,000 pounds/square inch. The Young's modulus is measured in accordance with ASTM D882, measured at a temperature of 73° F.

The flexible support 10 may be a transparent sheet so that the packaged article (e.g., product 126) may be visible through the flexible support. “Transparent” as used herein means that the material transmits incident light with negligible scattering and little absorption, enabling objects to be seen clearly through the material under typical unaided viewing conditions (i.e., the expected use conditions of the material). The transparency (i.e., clarity) of the retention flexible support may be at least any of the following values: 65%, 70%, 75%, 80%, 85%, and 90%, measured in accordance with ASTM D1746.

The flexible support 10 may comprise, for example, one or more fabrics, such as one or more of the following: wovens, knits, nonwovens, and openwork meshes (e.g., netting), spandex, including Lycra® brand spandex, and elastic fabrics.

The flexible support 10 may comprise one or more polymers, for example, one or more of any of the following polymers: thermoplastic polymers, polyolefins, polyethylene homopolymers (e.g., low density polyethylene), polyethylene copolymers (e.g., ethylene/alpha-olefin copolymers (“EAOs”), ethylene/unsaturated ester copolymers, and ethylene/(meth)acrylic acid), polypropylene homopolymers, polypropylene copolymers, polyvinyl chloride, various types of natural or synthetic rubber (e.g., styrene-butadiene rubber, polybutadiene, neoprene rubber, polyisoprene rubber, ethylene-propylene diene monomer (EPDM) rubber, polysiloxane, nitrile rubber, and butyl rubber), and polyurethane (i.e., any one or more of polyurethane, polyether polyurethane, polyester polyurethane, and polycarbonate polyurethane, any of which may be aliphatic and/or aromatic). The flexible support may also comprise thermoplastic polyolefin elastomers (TPOs), which are two-component elastomer systems comprising an elastomer (such as EPDM) finely dispersed in a thermoplastic polyolefin (such as polypropylene or polyethylene). “Copolymer” as used in this application means a polymer derived from two or more types of monomers, and includes terpolymers, etc.

A flexible support comprising polyolefin (e.g., polyethylene), polyvinyl chloride, and/or polyurethane may be useful for lightweight applications, for example, where a flexible support thickness of from 2 to 4 mils may be desirable. A flexible support comprising polyurethane may provide desirable elastomeric, puncture resistance, temperature resistance, and tackiness characteristics.

The flexible support may comprise effective amounts of one or more of tackifiers, antiblocking agents, and slip agents—or may be essentially free of any of these components. Tackifiers, antiblocking agents, and slip agents, and their effective amounts, are known to those of ordinary skill in the art.

The flexible support may be manufactured by thermoplastic film-forming processes known in the art (e.g., tubular or blown-film extrusion, coextrusion, extrusion coating, and flat or cast film extrusion). A combination of these processes may also be employed.

At least one side of the flexible support may be corona and/or plasma treated to change the surface energy of the flexible support, for example, to increase the ability of the flexible support to adhere to a panel or frame.

In some embodiments, the flexible support may be an inelastic material. For example, a cloth or other non-elastic or minimally elastic material may be used as the flexible support to support the object 20. In such embodiments, the movement of the panels may allow the flexible support to cushion the object without requiring the flexible support itself to be elastic. In some embodiments, the flexible support may be made partially or entirely of cellulosic material, such as the same material as the panels.

Films that may be useful as flexible supports are described in U.S. Pat. No. 6,913,147 issued Jul. 5, 2005 and entitled “Packaging Structure Having a Frame and Film,” which is incorporated herein in its entirety by reference.

In some embodiments, the flexible support may comprise a plurality of components that collectively define a flexible support. For example, the flexible support may include all or a portion of the flaps (e.g., any of flaps 114, 214, 314, 414, 514, 614, 714, 814, 914, 1014, 1114, 1214, 1314, 1414). With reference to FIGS. 80-81, the flexible support 10 may include the flexible sheet of material supporting the object and the flaps 1114 to which the flexible sheet of material is attached. In such embodiments, the flexible support 10 may be said to extend between the distal ends of the panels 1101, 1102, 1103, 1104.

In each of the embodiments detailed herein, the flexible support may include combinations of flexible sheets of material, flaps, and/or other structures in the panel to support the object 20. In such embodiments, the flexible sheet of material may comprise any of the materials detailed above with respect to the flexible support (e.g., flexible and inflexible films, sheets, cloths, or other materials).

With reference to FIG. 82, an embodiment of the flexible support 10 is shown having a flexible sheet of material 1274 connecting the flaps 1214 beneath the flaps. In such embodiments, the flaps 1214 may directly engage the object 20 while the flexible sheet of material 1274 supports and connects the flaps. With reference to FIG. 83, an embodiment of the flexible support 10 is shown in which the flaps 1314 may be connected by a flap connector 1376. The connector 1376 may be connected to the flaps 1314 by one or more center fold lines 1374, and the connector may be integral with the flaps. In some alternative embodiments, the connector may be separately attached to the flaps. With reference to FIG. 84, in some embodiments, the flaps 1414 may be directly connected via a fold line 1474 and/or additional attachment mechanisms detailed herein. In such embodiments, the flaps 1414 may define the flexible support 10. The flaps of any of the embodiments detailed herein may be connected with one or more of the connections shown in FIGS. 82-84.

Manufacture

By using types of machinery known to those of skill in the field, panels may be cut to the desired shapes and provided with fold lines and/or lines of detachability, using the known types of machinery, for example, to slit, crease, crimp, emboss, perforate, score, or otherwise weaken the panel in desired regions. Adhesive may be applied to the panel (e.g., any of panels 102, 104, 202, 204, 302, 304, 402, 404, 502, 504, 602, 604, 702, 704, 802, 804, 902, 904, 1002, 1004, 1101, 1102, 1103, or 1104) in selected areas, for example, at any of the adhesive strips shown and described herein (e.g., any of adhesive strips 162, 262, 362, 462, 562, 662, 762, 862, 962, 1062, or 1162). The flexible support 10 may be attached to the panel by laminating or adhering the flexible support with adhesive to the panel, or by other ways as discussed herein. The flexible support material may be provided in roll form, unrolled, and then cut to the desired length and width either before or after attachment to the panel. The frames (e.g., any of frames 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, or 1100 detailed herein) may be assembled by hand or by one or more automated packaging apparatus following the assembly steps detailed herein, as would be understood by a person of ordinary in the art based upon Applicant's disclosure.

Any numerical value ranges recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable (e.g., temperature, pressure, time) may range from any of 1 to 90, 20 to 80, or 30 to 70, or be any of at least 1, 20, or 30 and/or at most 90, 80, or 70, then it is intended that values such as 15 to 85, 22 to 68, 43 to 51, and 30 to 32, as well as at least 15, at least 22, and at most 32, are expressly enumerated in this specification. For values that are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these embodiments of the invention pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Except in the claims and the specific examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material, reaction conditions, use conditions, molecular weights, and/or number of carbon atoms, and the like, are to be understood as modified by the word “about” in describing the broadest scope of the invention. Therefore, it is to be understood that the embodiments of the invention are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

Any reference to an item in the disclosure or to an element in the claim in the singular using the articles “a,” “an,” “the,” or “said” is not to be construed as limiting the item or element to the singular unless expressly so stated. The definitions and disclosures set forth in the present Application control over any inconsistent definitions and disclosures that may exist in an incorporated reference. All references to ASTM tests are to the most recent, currently approved, and published version of the ASTM test identified, as of the priority filing date of this application. Each such published ASTM test method is incorporated herein in its entirety by this reference.

While some drawings and description may omit features described elsewhere for simplicity of explanation, it is understood that these features may nonetheless be present in any of the embodiments in any combination or configuration, as detailed above. As described herein, features of any embodiment may be combined or substituted to produce any combination of features in a given apparatus. For example, the frame 100 shown in FIG. 1 may be lengthened to include multiple support sections (e.g., as shown in FIGS. 4-5), or the attachment flap 752 and panels 702 and/or 704 of the embodiment of FIG. 58 may be extended to the base of the respective upright portion (e.g., as shown in FIG. 74). Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

CLAM SUSPENSION

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