Patent Application
20250083888
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference in their entireties and made a part of the present disclosure.
The present inventions relate to packaging systems, for example, including packaging systems incorporating a capture feature and a cradle feature that can be formed without the use of plastics or foams.
Protective packaging devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact against the inner walls of the box which could be caused by shocks imparted to the box during loading, transit, and unloading.
In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is suspended or retained within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.
U.S. Pat. No. 11,124,348 discloses a number of inventions related to retention and suspension structures which incorporate a sheet of resilient material heat sealed to corrugated cardboard. In the designs disclosed in the 11,124,348 patent, the resilient sheet is attached to a piece of foldable cardboard so that the resilient material is tensioned by folding the cardboard, and for example, the resilient sheet material is stretched around the article.
At least one of the inventions disclosed herein includes the realization that certain additional efficiencies can be obtained in a packaging process incorporating structures that can support and/or constrict movement of an article within a shipping container, such as a box, without the use of additional foams or plastics, by incorporating structures that can capture a portion of an article in a position spaced away from the internal walls of the external container and/or form a cradle that can support the article in the position spaced away from the internal walls of the outer container.
In some embodiments, a shipping container can include one or more folding members that capture portions of an article so as to constrain movement in one or more directions of the article, within a container. For example, in some embodiments, the folding members can form at least an L-shaped portion having a slot extending through two sides of the L-shaped portion wherein the slot is sized to receive two different portions of the article. For example, a first part of the slot can be configured to straddle a lateral portion of the article and a second portion of the slot can be configured to straddle an axial end of the article. As such, the L-shaped portion can constrain movement of the article in several directions.
Some articles that can be packaged for shipping include projecting portions. One example of such an article would be a coffee mug. Coffee mugs typically include a handle which is a structural member of the mug itself. In other words, the handle is designed to support the entire weight of the mug, for example, when a user lifts the coffee mug, filled with coffee, in use. Thus, the handle of a coffee mug is sufficiently structural so as to withstand loads that may be applied to it during use and shipping.
In some embodiments, a shipping container can include one or more folding members that capture portions of the handle of a coffee mug so as to constrain movement of the coffee mug in a container in one or more directions. For example, in some embodiments, the foldable structure can form at least an L-shaped portion having a slot extending through two sides of the L-shaped portion wherein the slot is sized to receive two different portions of the handle. For example, a first part of the slot can be configured to straddle a laterally extended portion of the handle and a second portion of the slot can be configured to straddle an axial end of the handle. As such, the L-shaped portion can constrain movement of the mug in several directions, for example, including rotational movement, lateral movement, and axial movement.
In some embodiments, the container can include two L-shaped portions, each of which include a slot, and which engage four different portions of the handle. In some embodiments, the one or more L-shaped portions can be sized so as to maintain the handle and the coffee mug vessel portion in a position spaced away from an inner surface of the outer container.
In some embodiments, the L-shaped portions can be formed monolithically with the material forming the outer container. For example, in some embodiments, the packaging device can be made from corrugated cardboard with the L-shaped portions being formed monolithically therewith. Such a design can reduce costs by reducing the number of parts and the amount of attachment devices for the final packaging product (glue, tape, etc.).
Another aspect of at least one of the inventions disclosed herein includes the realization a packaging assembly can include the cradle member configured to contact an article to be packaged in limited areas so as to maintain an air gap between the article to be packaged and the inner walls of the outer container. For example, the cradle member can be formed with at least an M-shaped portion which is sized to make contact with an article along its inner slanted faces that are suspended by the structural shape of the M-shaped portion to be maintained in a position spaced away from the inner surfaces of the outer container. Additionally, this configuration can avoid contact between the article and a piled-up formation of packaging material that could create a more direct contact and force transmission between the article and the inner wall of the outer container.
In some embodiments, a cradle member can be formed monolithically with the material forming the outer container. For example, in some embodiments, an outer container can be formed of corrugated cardboard and a cradle member can be formed from the same piece of corrugated cardboard and provided with predefined bending lines or fold lines so that it can be preferentially folded into the M-configuration for use.
In some embodiments, the M-shaped portion can be configured like a hammock in which the center portion of the M-shaped structure does not make contact with the inner surface of the outer container. This can provide additional cushioning by maintaining a larger air gap between the article and the inner surface of the walls of the outer container.
In some embodiments, the container can include a U-shaped portion which can be formed monolithically with the material forming the outside of the container. Such a design can further reduce costs by reducing the amount of corrugated cardboard material the final packaging product and reducing the number of independent parts that are required to be manufactured, inventoried, tracked, and then assembled. Such a design can also simplify the assembly of the packaging product for the end user.
In some embodiments, the cradle portion can be configured with an end stop which acts as a locating feature for an end surface of an article, for example, more generically shaped articles. One such article could have a cylindrical shape such as a wine bottle or other type of beverage bottle. This added feature can optionally be configured to provide additional cushioning through buckling of the material, such as corrugated cardboard, against the walls of the outer container.
In some embodiments, the cradle portion can be configured with a stiffener which is derived from the center section of the M-shaped structure. The addition of the stiffener further strengthens the center portion of the M-shaped structure to further reduce contact with the inner surface of the outer container. This can provide additional cushioning by maintaining a larger air gap between the article and the inner surface of the walls of the outer container.
In some embodiments, the U-shaped portion can be configured to accept different sized articles while using the same packaging. These unique configuration provide all the appropriate impact mitigation properties without the need for different packaging containers which greatly simplifies the inventory needed and ensures the user has the appropriate shipping container for their product.
In some aspects, the techniques described herein relate to a packaging system for packaging an article and maintaining the article therein, the packaging system including: a first article including a generally cylindrical outer shape having a first height, a second article including a generally cylindrical outer shape having a second height that is less than the first height, and a third article including a generally cylindrical outer shape having a third height that is less than the first and second heights; a monolithic member configured to be folded into a container, the monolithic member including: a top, a bottom, and first, second, third and fourth sidewalls and an interior member; wherein the top is configured to be moved between opened and closed positions; wherein in the closed position, the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall form an enclosed interior space and in the opened position form an open interior space; wherein the top includes a first panel, a second panel and a latch panel that are foldable between the opened and closed positions; wherein the bottom includes a first, second, third and fourth bottom panels that are configured to fold into a predetermined bottom wall configuration; and an M-shaped cradle member including: a first angled panel portion connected to the first sidewall along a first fold so as to be foldable between a first unfolded orientation in which the first angled portion is generally parallel to the first sidewall and a second folded position in which the first angled portion extends into the open interior space at an angle relative to the first sidewall; a central panel portion connected to the first angled portion along a second fold and configured to be foldable into an orientation in which the central panel portion is approximately parallel to the bottom of the enclosed interior space; a second angled portion connected to the central portion and folded along a third fold and configured to be foldable into an orientation in which the second angled portion extends at an angle relative to the central panel portion and the second sidewall of the enclosed interior space; and a first leg panel portion connected to the second angled portion along a fourth fold and configured to be foldable into an orientation in which the first leg panel portion abuts the second sidewall of the enclosed interior space and contacts the bottom of the enclosed interior space; wherein the first angled panel portion, the central panel portion, and the second angled panel portion form a cradle configured to support the article, and wherein the first leg panel portion and the first sidewall support the first angled panel portion, the central panel portion, and the second angled panel portion at a position spaced above the bottom of the enclosed interior space so as to support the article at a position spaced above the bottom of the enclosed interior space, in use; wherein the top includes: a first foldable top panel portion connected to the third sidewall, the first foldable top panel having at least two first spacer folds configured to allow the first foldable top panel to be folded into a first spacer having a first thickness, wherein the first spacer is spaced at a first spacing from the central panel portion by a first height, in use; a second foldable top panel portion connected to the fourth sidewall, the second foldable top panel having at least two second spacer folds configured to allow the second foldable top panel to be folded into a second spacer having a second thickness that is greater than the first thickness, wherein the second spacer is spaced at a second spacing from the central panel portion by a second height that is shorter than the first height, in use; wherein the first and second foldable top panels, when they are not folded into the first and second spacers, are spaced from the central panel portion by a third height that is greater than the first and second height; wherein the at least two first spacer folds and the at least two second spacer folds are configured to cradle articles having three different heights by using the first and second foldable top panels in an unfolded state to cradle a first article having the first height, using the first foldable top panel folded to form the first spacer for cradling the second article having the second height that is less than the first height, and using the second top panel folded to form the second spacer for cradling the third article having the third height that is less than the first and second heights. a second foldable top panel portion connected to the fourth sidewall; wherein the first and second leg panel is sized and configured such that, when the M-shaped cradle is folded into the open interior space, an air gap is created between the central portion of the M-shaped cradle portion and the bottom; wherein the first leg panel portion is configured to deflect individually or in tandem without allowing the central portion of the M-shaped cradle to contact the bottom when the container is mishandled during transport.
In some aspects, the techniques described herein relate to a packaging system wherein the first foldable top panel portion includes a slot configured to engage a handle of a coffee mug.
In some aspects, the techniques described herein relate to a packaging system, wherein the container further includes a viewing hole located on a sidewall.
In some aspects, the techniques described herein relate to a packaging system for packaging an article and maintaining the article therein, the packaging system including: an outer container portion including a top, a bottom, and first, second, third and fourth sidewalls; wherein the top is configured to be moved between opened and closed positions; wherein in the closed position, the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall form an enclosed interior space and in the opened position form an open interior space; and a cradle portion including: a first angled panel portion connected to the first sidewall foldable between into an orientation in which the first angled portion extends into the open interior space at an angle relative to the first sidewall; a central panel portion connected to the first angled portion and configured to be foldable into an orientation in which the central panel portion is approximately parallel to the bottom of the enclosed interior space, in use; a second angled portion connected to the central portion and configured to be foldable into an orientation in which the second angled portion extends at an angle relative to the central panel portion and the second sidewall of the enclosed interior space; and a first leg panel portion connected to the second angled portion and configured to be foldable into an orientation in which the first leg panel portion abuts the second sidewall of the enclosed interior space and contacts the bottom of the enclosed interior space, in use; wherein the cradle portion is configured to support an article in a position spaced from the bottom, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the top is configured to be foldable into three different configurations which limit the enclosed interior space to three different heights, respectively.
In some aspects, the techniques described herein relate to a packaging system wherein the outer container portion and the cradle portion are made from a single monolithic piece of corrugated cardboard.
In some aspects, the techniques described herein relate to a packaging system wherein the top includes a first foldable top panel portion connected to the third sidewall, the first foldable top panel having at least two first spacer folds configured to allow the first foldable top panel to be folded into a first spacer having a first thickness, wherein the first spacer is spaced at a first spacing from the central panel portion by a first height, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the top further includes a second foldable top panel portion connected to the fourth sidewall, the second foldable top panel having at least two second spacer folds configured to allow the second foldable top panel to be folded into a second spacer having a second thickness that is greater than the first thickness, wherein the second spacer is spaced at a second spacing from the central panel portion by a second height that is shorter than the first height, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the first and second foldable top panels, when they are not folded into the first and second spacers, are spaced from the central panel portion by a third height that is greater than the first and second height, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the at least two first spacer folds and the at least two second spacer folds are configured to cradle articles having three different heights by using the first and second foldable top panels in an unfolded state to cradle a first article having the first height, using the first foldable top panel folded to form the first spacer for cradling the second article having the second height that is less than the first height, and using the second top panel folded to form the second spacer for cradling the third article having the third height that is less than the first and second heights.
In some aspects, the techniques described herein relate to a packaging system additionally including a first article including a generally cylindrical outer shape having a first height, a second article including a generally cylindrical outer shape having a second height that is less than the first height, and a third article including a generally cylindrical outer shape having a third height that is less than the first and second heights.
In some aspects, the techniques described herein relate to a packaging system wherein the first leg panel portion and the first sidewall support the first angled panel portion, the central panel portion, and the second angled panel portion at a position spaced above the bottom of the enclosed interior space so as to support the article at a position spaced above the bottom of the enclosed interior space, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the top includes at least one handle engaging panel connected to the third sidewall and including at least one aperture configured to engage a handle of a mug, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the at least one handle engaging panel is configured to engage an upper end and a lower end of the handle of a mug, in use.
In some aspects, the techniques described herein relate to a packaging system for packaging an article, the packaging system including: an outer container portion including a top, a bottom, and first, second, third and fourth sidewalls; a cradle portion including: a first panel portion connected to the first sidewall; a central panel portion connected to the first panel portion; a second panel portion connected to the central portion; and a first leg panel portion connected to the second panel portion and configured to be foldable into an orientation in which the first leg panel portion abuts the second sidewall and contacts the bottom, in use; wherein the first panel portion, the central panel portion and the second panel portion are configured to form a cradle and to support an article in a position spaced from the bottom, in use.
In some aspects, the techniques described herein relate to a packaging system, wherein the top is configured to be moved between opened and closed positions and wherein in the closed position, the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall form an enclosed interior space and in the opened position form an open interior space.
In some aspects, the techniques described herein relate to a packaging system wherein the top is configured to be foldable into three different configurations which limit an interior space of the outer container portion to three different heights, respectively.
In some aspects, the techniques described herein relate to a packaging system wherein the outer container portion and the cradle portion are made from a single monolithic piece of corrugated cardboard.
In some aspects, the techniques described herein relate to a packaging system wherein the top includes a first foldable top panel portion connected to the third sidewall, the first foldable top panel having at least two first spacer folds configured to allow the first foldable top panel to be folded into a first spacer having a first thickness, wherein the first spacer is spaced at a first spacing from the central panel portion by a first height, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the top further includes a second foldable top panel portion connected to the fourth sidewall, the second foldable top panel having at least two second spacer folds configured to allow the second foldable top panel to be folded into a second spacer having a second thickness that is greater than the first thickness, wherein the second spacer is spaced at a second spacing from the central panel portion by a second height that is shorter than the first height, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the first and second foldable top panels, when they are not folded into the first and second spacers, are spaced from the central panel portion by a third height that is greater than the first and second height, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the at least two first spacer folds and the at least two second spacer folds are configured to cradle articles having three different heights by using the first and second foldable top panels in an unfolded state to cradle a first article having the first height, using the first foldable top panel folded to form the first spacer for cradling the second article having the second height that is less than the first height, and using the second top panel folded to form the second spacer for cradling the third article having the third height that is less than the first and second heights.
In some aspects, the techniques described herein relate to a packaging system wherein the top includes at least one handle engaging panel connected to the third sidewall and including at least one aperture configured to engage a handle of a mug, in use.
In some aspects, the techniques described herein relate to a packaging system wherein the at least one handle engaging panel is configured to engage an upper end and a lower end of the handle of a mug, in use.
In some aspects, the techniques described herein relate to a packaging system for packaging an article and maintaining the article therein, the packaging system including: a monolithic member configured to be folded into a container including: a top, a bottom, and first, second, third and fourth sidewalls and an interior member; wherein the top is configured to be moved between opened and closed positions; wherein in the closed position, the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall form an enclosed interior space and in the opened position form an open interior space; wherein the top includes a first, second and latch top panels that are foldable between the opened and closed positions; wherein the bottom includes a first, second, third and fourth bottom panels that fold into a predetermined bottom; and an article including a cylindrical portion, a bottom portion, open top portion and a handle portion, wherein the confluence of the cylindrical and handle portions resides between the open top or bottom portions and is constructed of a fragile material; and an M-shaped structural member, configured to be in contact with the sidewalls which are perpendicular to the longer axis of said structural member and to engage the article on two or more sides of said structural member, including: a first and second leg panel connected to an M-cradle portion which are all created from the interior member, including: a first leg portion which is created from a portion of the interior wall of the monolithic member; an M-cradle portion sized and configured to resiliently support an article, including; a first angled portion which is connected to the first leg portion and folded along a fold line predetermined by the manufacturing process to an angle defined by the article, a central portion which is connected to the first angled portion and folded along a fold line predetermined by the manufacturing process to be parallel to the bottom of the container, a second angled portion which is connected to the central portion and folded along a fold line predetermined by the manufacturing process to an angle defined by the article, wherein the first, second and central portion dimensions dictated by the size, weight and shape of the article being supported, a second leg panel which is attached to the second angled portion of the M-cradle portion and folded along a fold line predetermined by the manufacturing process, wherein the M-cradle is sized and configured based on the dimensions dictated by the size, weight and shape of the article being supported, wherein the first and second leg panel is sized and configured such that, when the M-cradle is folded into the open interior space, an air gap is created between the central portion of the M-cradle portion and the bottom; wherein the first and second leg panel are configured to deflect individually or in tandem without allowing the central portion of the M-cradle to contact the bottom when the container is mishandled during transport; wherein the long axis length of the M-cradle is less than the length between the open top and bottom portions of the article, wherein the length of the first and second leg panel are less than the half of the diameter of the cylindrical portion of the article; and a U-shaped structural member configured to contact the sidewall from which it is created and the sidewall opposite of origin, contact the top, contact the handle and cylindrical portion of the of the article from a cutout said member, when the container is in the closed position, including: a first portion which is folded perpendicular and along a fold line predetermined by the manufacturing process from the sidewall, a central portion which is folded perpendicular to and along a fold line predetermined by the manufacturing process sized from the first portion and configured to engage the handle portion through a cutout in the member, a last portion which is folded perpendicular to and along a fold line predetermined by the manufacturing process from the central portion and sized and which contacts the opposite sidewall of the members origin, wherein the central portion is configured with sufficient structural strength to retain the article within the open interior space when the container mishandled during transport; wherein the first and last portions are parallel to the sidewall of origin, wherein the length of the first portion is equivalent to the length of the last portion, wherein the length of the central portion enables the last portion to contact the cylindrical portion of the article, wherein the cutout dimensions in the central portion are sized such that the edges of the cutout make contact with the handle on all sides of said cutout at the confluence of the handle and cylindrical portions of the article, wherein the minimum length of the central portion is equivalent to the air gap on either side of the article dictated by the size, weight and shape of the article plus the distance between the open top and bottom portions of the article plus the thickness of the monolithic member.
In some aspects, the techniques described herein relate to a packaging system, wherein the container further includes a viewing hole located on a sidewall.
In some aspects, the techniques described herein relate to a packaging system, wherein the container further includes a modified bottom to include a ‘snap lock base’.
In some aspects, the techniques described herein relate to a packaging system, wherein the container further includes a tab and latch configuration located on the top.
In some aspects, the techniques described herein relate to a packaging system for packaging an article and maintaining the article therein, the packaging system including: a monolithic member configured to be folded into a container including: a top, a bottom, and first, second, third and fourth sidewalls and an interior member; wherein the top is configured to be moved between opened and closed positions; wherein in the closed position, the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall form an enclosed interior space and in the opened position form an open interior space; wherein the top includes a first, second and latch top panels that are foldable between the opened and closed positions; wherein the bottom includes a first, second, third and fourth bottom panels that fold into a predetermined bottom; wherein the minimum thickness of the monolithic member is dictated by the structural needs of the largest article when sufficiently supported by three layers of said member without adhesive; and an article including a first side portion, a second side portion, rounded axial corners, top edge, bottom, and a cylindrical protrusion off the first side portion, wherein the article is positioned in the enclosed interior space, between the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall, with the first side portion juxtaposed to the M-cradle central portion, the second side portion juxtaposed to the U-shaped structure and the protrusion limiting the movement towards the top edge and bottom; and an M-shaped structural member, configured to be in contact with the sidewalls which are perpendicular to the longer axis of said structural member, includes a cutout hole and to engage the article on two or more sides of said structural member, including: a first and second leg panel connected to an M-cradle portion which are all created from the interior member, including: a first leg portion which is created from a portion of the interior wall of the monolithic member; an M-cradle portion sized and configured to resiliently support an article, including; a first angled portion which is connected to the first leg portion and folded along a fold line predetermined by the manufacturing process to an angle defined by the article, a central portion which is connected to the first angled portion and folded along a fold line predetermined by the manufacturing process to be parallel to the bottom of the container, a second angled portion which is connected to the central portion and folded along a fold line predetermined by the manufacturing process to an angle defined by the article, wherein the first, second and central portion dimensions dictated by the size, weight and shape of the article being supported, a second leg panel which is attached to the second angled portion of the M-cradle portion and folded along a fold line predetermined by the manufacturing process, wherein the M-cradle is sized and configured based on the dimensions dictated by the size, weight and shape of the article being supported, wherein the first and second leg panel is sized and configured such that, when the M-cradle is folded into the open interior space, an air gap is created between the central portion of the M-cradle portion and the bottom; wherein the first and second leg panel are configured to deflect individually or in tandem without allowing the central portion of the M-cradle to contact the bottom when the container is mishandled during transport; wherein the long axis length of the M-cradle is greater than or equal to the length between the top edge and bottom portions of the article, wherein the cutout hole is located to accept the cylindrical protrusion of the article and sized to limit the movement of the article from contacting the extents of the interior space; and at least one U-shaped structural member configured to contact the sidewall from which it is created, contact the top, contact the article and including a tab shaped cutout in the last portion which extends perpendicular to the last portion when the container is in the closed position, including: a first portion which is folded perpendicular and along a fold line predetermined by the manufacturing process from the sidewall, a central portion which is folded perpendicular to and along a fold line predetermined by the manufacturing process sized from the first portion and configured, a last portion which is folded perpendicular to and along a fold line predetermined by the manufacturing process from the central portion and sized and configured to be in contact with the article when the shipping container is closed, wherein the central portion is configured with sufficient structural strength to retain the article within the open interior space when the container mishandled during transport; wherein the additive length of the first, central and last portions is equal to or less than the largest length of the open interior space.
In some aspects, the techniques described herein relate to a packaging system, wherein the last portion contains a tab portion cutout from the last portion and perpendicular from the last portion when in use.
In some aspects, the techniques described herein relate to a packaging system, wherein the container further includes a modified bottom to include a ‘snap lock base’.
In some aspects, the techniques described herein relate to a packaging system, wherein the container further includes a tab and latch configuration located on the top.
In some aspects, the techniques described herein relate to a packaging structure for packaging an article and maintaining the article therein, the packaging system including: a monolithic member configured to be folded into a M-shaped structural member and residing in the open interior space of a shipping container including: a first and second leg panel, an M-cradle portion including at least one end support including: wherein the first and second leg panels are parallel to each other when assembled in the shipping container, an M-cradle portion, including at least one end support, sized and configured to resiliently support an article, including; a first angled portion which is connected to the first leg portion and folded at an angle dictated by shape of the article, a central portion which is connected to the first angled portion and is parallel to the bottom, a second angled portion which is connected to the central portion and folded at an angle dictated by the shape of the article, an end support including: a first angled panel which is connected to the first angled portion and the second angled panel which is connected to the second angled portion, wherein the first and second angled panels are sized and configured to deflect without allowing the article to contact the axial end of the shipping container when mishandled during transport, wherein the M-cradle is sized and configured based on the dimensions and weight of the article being supported such that when the M-cradle is in the open interior space of the shipping container an air gap is created between the central portion of the M-cradle portion and the bottom of the container; wherein the first and second leg panel are configured to deflect individually or in tandem without allowing the central portion of the M-cradle to contact the bottom when the container is mishandled during transport.
These and other features of the inventions disclosed herein are described below with reference to the drawings of several embodiments of the present packaging assembly kits which are intended to illustrate, but not to limit, the inventions. The drawings contain the following figures:
Embodiments of improved packaging systems are disclosed herein. The packaging systems include various combinations of one or more improved structures which can provide new alternatives to and advantages over known packaging systems.
In the following detailed description, terms of orientation such as “top,” “bottom,” “front,” “upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,” “midpoint,” and “end” may be used here to simplify the description in the context of the illustrated embodiments. Because other orientations are possible, however, the present inventions should not be limited to the illustrated orientations. Additionally, the term “suspension” is not intended to require that anything, such as an article to be packaged, is suspended above anything. Rather, the terms “suspended” as used herein, is only intended to reflect that such an article is held in a position spaced from another member, such as at least some of the walls of a container or box. Those skilled in the art will appreciate that other orientations of various components described herein are possible.
The packaging system 100 includes an outer container 130. The outer container 130 can include inner surfaces such as end surfaces 132, 134, side surface 138, an additional side surface (not shown), a bottom surface 140, and a top surface 142 formed by one or more top panel portion(s) 101.
The packaging system 100 also includes at least one L-shaped structure. The illustrated embodiment includes two L-shaped structures 150A, 150B. Parts, components, and features, and functions of the L-shaped portions 150A and 150B are described below what reference only to L-shaped structure 150A, but the descriptions apply to both L-shaped structures 150A, 150B.
The L-shaped structure 150A can be considered as including a first wall portion 152, a second wall portion 154 extending from the first wall portion 152, and a slot 160 extending through both the first wall portion 152 and the second wall portion 154. In the illustrated embodiment, the slot 160 is a single continuous opening extending through the thickness of both first and second wall portions 152, 154, however, other configurations can also be used.
In the illustrated embodiment, with the slot 160 spanning the first and second wall portions 152, 154, the slot 160 can be considered as including a first slot portion on the first wall portion 152 and a second slot portion on the second wall portion 154. In this configuration, the first slot portion includes three edges, top edge 161 and first and second lateral edges 162, 163.
The second slot portion 166 includes an end edge 156 and first and second lateral side edges 168, 169. Thus, when folded into the deployed state illustrated in
In some embodiments, the packaging system 100 can include additional cushioning structures for maintaining a gap between the bottom surface 120 of the article 110 and the bottom inner surface 140 of the container 130. For example, in some embodiments, the system 100 could include one or more additional L-shaped structures such as L-shaped structures 150A, 150B described above and optionally, monolithically formed with the material forming the outer container 130. Alternatively, other cushioning structures can also be used.
With reference to
Optionally, the walls 274, 276 can be sized with a suspended middle portion such that the lowermost extent of the middle portion 273 does not contact the bottom inner surface 240 thereby maintaining a gap between the lowermost portion of the middle portion 273 and the bottom inner surface 240. The suspended middle portion can be considered as forming a hammock. Optionally, additional wall portions, for example, a wall portion defined between middle walls 274, 276 can also be used.
With the generally V-shaped configuration of the middle portion 273, the contact patches 278, 279 between the article 210 and the middle walls 274, 276, respectively, are located along portions of the middle walls 274, 276 that are spaced away from the inner surfaces 238, 239, 240 such that an air gap is maintained there between. As such, shocks or loads imparted onto to the outer container 230 are not directly transmitted to the article 210 through piled-up material. This allows for bending or flexing of the middle wall portions 274, 276 during such shocks and thereby can provide optional additional shock absorption benefits.
In some embodiments, one or both of the end walls 271, 272 can be fixed to the outer container 230. In some embodiments, one of the end walls 271, 272 is fixed to the container 230 while the other can be left free. Where one of the end walls 271, 272 is not attached to the outer container 230, the article 210 itself and the structural configuration of the middle portion 273 presses outwardly against the end walls 271, 272, maintaining the arrangement illustrated in
Optionally, the M-shaped structure 270 can be formed monolithically with the outer container 230. In some embodiments, the L-shaped structures of the packaging system 100 can be combined with the M-shaped structure 270 of the embodiment 200.
With reference to
With continued reference to
Fold lines 306-309, as well as any other fold line described herein below can be made through a number of different techniques. One common technique is to crush the material, such as corrugated cardboard, with a standard cardboard processing machine. The crushed portion is a localized area of compromised the rigidity of the material, that provides the end user with preformed fold lines about which the material preferentially bends and folds for assembly. Score lines can also be used, for example, cuts that extent through only one of the outer layers, an outer layer and the corrugated middle layer, and/or completely through the material. Additionally, score lines can be made continuously or broken. The configuration of such fold lines can be chosen to provide the desired amount of remaining bias in the material, for example, bias towards a flat shape thereby providing some spring action, or more relief so that the material is easier to bend. Such different configurations of fold lines can also generate different amounts of shock absorption in the final product. Thus, such configurations of fold lines can also be chosen to provide the desired shock absorption which can be fine-tuned with well-known drop testing techniques in this art.
With continued reference to
Similar to the sidewall portion 301, the sidewall portion 302 includes a central sidewall portion 302a, a top panel portion 302b, and a bottom panel portion 302c. The central sidewall portion 302a includes an inner sidewall surface 339.
The top panel portions 301b, 302b are configured to be folded so as to form an outermost wall of the container 330. Similarly, the bottom panel portions 301c, 302c are configured to be folded so as to form an outermost bottom wall of the container 330, when fully assembled.
The end wall portion 303 includes a central end wall portion 303a, an upper panel portion 303b, and a lower panel portion 303c. The central end wall portion 303a includes a surface 332 which forms an inner end wall surface 332 of the container 330, when assembled.
In the illustrated embodiment, the upper panel portion 303b includes a portion that is configured to form an L-shaped structure 350A. In the illustrated embodiment, the upper panel portion 303b includes a first panel portion 351 attached to the central end wall portion 303a along the fold line. The L-shaped structured portion 350A includes a first wall portion 352 and a second wall portion 353 connected to each other along a fold line 355. A slot 360 is included in the first wall portion 352 and second wall portion 353. The L-shaped structure 350A can serve as a spacer, the dimension of which is defined by the spacing of the folds about which the panels 351, 352, 353 are folded. The fold lines, such as fold line 355 and other fold lines, can serve as spacer folds. In some embodiments, the slot 360 extends continuously across the fold line between the first and second wall portions 352, 353.
In the illustrated embodiment, the slot 360 is configured to fit over the handle of a coffee mug, illustrated in greater detail below with reference to
The end wall portion 304 includes a central wall portion 304a, upper wall portion 304b, and a lower wall portion 304c. Additionally, the end wall portion 304 includes an L-shaped structure portion 350B that is constructed essentially the same or similar to the construction of the L-shaped structure 350A.
The connector portion 305 includes a mounting portion 305a, and a cradle portion 370. The cradle portion 370 includes a first end wall portion 371, a second end wall portion 372, a first middle wall portion 374, and a second middle wall portion 376. The first end wall portion 371 and the second end wall portion 372 can be considered as serving as first and second leg panel portions of the cradle portion 370, which support the cradle above the bottom 340. In the illustrated embodiment, the cradle portion 370 includes an additional, optional middle wall portion 375. The first middle wall portion 374 and the second middle wall portion 376 can be considered as serving as first and second angled panel portions which extend into the interior space at an angle relative to the sidewalls. The optional middle wall portion 375 can be approximately parallel to the bottom 340. The wall portions 371-376 are connected to each other along fold lines, as shown in
With reference to
With reference to
With reference to
As shown in
In this configuration, the upper edge 361 of the slot 360 can be positioned so as to provide a space between the outer surface of the handle H and the upper edge 361. This allows the area near the fold line 355 of the second wall portion 353 to define the primary constraint of movement of the mug M in an upward direction (as viewed in
With reference to
Additionally, the sizes of the end wall portion 371, 372 and middle wall portions 374, 375, 376 of the cradle portion 370 can be sized such that the contact patches P between the outer surface of the mug M and the surfaces of the middle wall portion 374, 376 are in locations such that an air gap is maintained between the outer surfaces of the mug M and the inner surfaces of the container 330. As such, together, the L-shaped structures 350A, 350B and the cradle portion 370 can maintain the mug M in a location within the interior of the outer container 330 and spaced away from the internal surfaces of the outer container 330, and additionally, both of the L-shaped portions 350A, 350B and the cradle portion 370 can be made monolithically with the outer container 330 from a single piece of material.
The packaging system 500, like the other packaging systems, includes a top panel portion 501, two L-shaped structures 550A, 550B, as well as a cradle portion 570, all three of which are formed monolithically with the same material used for forming the exterior container 530. In the illustrated embodiment, the packaging system 500 includes an elongated top panel portion 493 including multiple panels attached by a fold line and a closure tab 494 configured to engage a closure slot 495. In the illustrated embodiment, the cradle portion 570 is cut from a portion of the sidewall panel 501a. As such, when folded into the assembled state, the cradle portion 570 leaves an open window W in the side panel 501a, thereby allowing the external container 530 to be side loaded.
Additionally, the packaging system 500 includes an “auto bottom” portion 596 which can be constructed monolithically with the L-shaped structures 550A, 550B, the cradle portion 570, and the other portions of the outer container 530, in a manner well-known in the art.
The packaging system 600, includes a M-shaped structure 670 and a U-shaped structure 696 which are formed monolithically with the same material used for forming the exterior container 630. In the illustrated embodiment, the packaging system 600 includes a U-shaped structure 696 constructed of side panel 697, handle support panel 698, and side support 699 panel. The handle support panel 698 can optionally include an aperture 698A.
In use, the U-shaped structure 696 can be folded into the exterior container 630, with the handle support slot 698A extending over and capturing the outer surfaces of handle H which can constrain the movement of the mug M.
The end stops 900a and 900b can be in the form of angle supports 901a, 901b, 902a and 902b. For example, the end stops 900a and 900b can be formed with score lines 903a and 903b, which allow the end stops to be folded partially independently from the panels 871, 872. When the cradle portion 870 is folded for engagement, the end stops 900a and 900b can be deployed by folding the angle supports 901a, 901b, 902a and 902b along the fold lines 904a, 904b, 905a, 905b, 906a and 906b. When deployed as such, the score lines 903a and 903b form edges that face inwardly along a longitudinal direction and are spaced away from the panels 871, 872, and 875 and thus be used to constrain movement of an article supported on the panels 821, 872, 875, in use. Further, the angle supports 901a, 901b, 902a and 902b can be configured to provide shock absorption, for example, by crushing, bending, or buckling of the material forming the angle supports 901a, 901b, 902a and 902b, which can be corrugated cardboard or other materials. Such crushing, bending, or buckling and thus the desired amount of shock absorption can be adjusted by changing the size of the angle supports 901a, 901b, 902a and 902b or by further compromising the material so as to crush, being or buckle more easily.
The opposing U-shaped structure 1001b can be constructed of angled panel 1002b, impact support panel 1003b, and tab support panel 1004b which can be bound by score lines 1006b and 1007b respectively. Optionally, support tab 1005b can be added to support panel 1004a with the addition of cutline 1008b.
The embodiments of
While several embodiments are presented in the foregoing detailed description, a vast number of variations exist. The embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description provides those skilled in the art with a convenient road map for implementing the described embodiments. Various changes can be made in the function and arrangement of elements without departing from the scope defined by any claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.
| Number | Date | Country | |
|---|---|---|---|
| 63581915 | Sep 2023 | US | |
| 63669333 | Jul 2024 | US |
