The described embodiments relate generally to packaging. More specifically, the present embodiments relate to packaging with integrated cushioning supports capable of providing contiguous support to a product inside the packaging.
Product packaging is used to store, transport, protect and/or present products to consumers or end users. For instance, shipping packaging is used to transport or ship a finished goods package containing a product. It is important to provide adequate protection to the product to the destination while maintaining the presentation of the product to the consumer or the end user.
Certain current packaging may use, e.g., a polymeric film to retain the finished goods package. Other shipping packaging may use expanded polystyrene cushions, or other less environmentally friendly cushioning systems (e.g., plastic bubble pack materials). These packaging systems can require different configurations for differently sized products, and therefore, existing shipping packaging systems may use separately designed and/or sized cushioning systems for shipping items.
Accordingly, there exists a need for a new and improved packaging system that can maintain packaging integrity and cushioning characteristics prior to being received by an end user, with high recyclability of the packaging while maintaining the flexibility of the supply chain by allowing various products or finished goods packaging to be received in a shipping packaging. Further, there is a need for a packaging system to promote simple and efficient handling for a shipper and easy and simple unboxing for an end user for easy opening and access to the product inside.
Some embodiments are directed to product packaging having a base box and a cover. The base box includes a base panel and cushioning cells. The cushioning cells include an upper cushioning cell disposed at an upper edge of the base panel and defining an upper side of the base box, a lower cushioning cell disposed at a lower edge of the base panel and defining a lower side of the base box, a left side cushioning cell disposed at a left side edge of the base panel and defining a left side of the base box, and a right side cushioning cell disposed at a right side edge of the base panel and defining a right side of the base box. The base panel and the cushioning cells together define a product-receiving space, and the base panel and the cushioning cells are integral and formed from a single blank. The cover is configured to cover the product-receiving space of the base box, and coupled to the left side cushioning cell and to the right side cushioning cell. The left side cushioning cell and the right side cushioning cell are hingedly coupled to the base panel.
In some embodiments, when the cover is intact and is coupled to the left side cushioning cell and the right side cushioning cell, the cover stops the left side cushioning cell and the right side cushioning cell from rotating relative to the base panel, and maintains the product packaging in a closed configuration. The cover is configured to be separated into a left cover panel coupled to the left side cushioning cell and a right cover panel coupled to the right side cushioning cell such that separating the cover into the left cover panel and the right cover panel transitions the packaging into an open configuration in which the left side cushioning cell and the right side cushioning cell rotate together with the left cover panel and the right cover panel, respectively, relative to the base panel to expose and expand the product-receiving space.
In some embodiments, the cover panel includes a ripcord extending between the left cover panel and the right cover panel. The left cover panel, the right cover panel, and the ripcord are integral and formed from a single blank. Tearing away the ripcord separates the left cover panel and the right cover panel, thereby allowing the left cover panel and the right cover panel to be rotated away from each other and exposing the product-receiving space. The left cover panel includes a left front cover panel and a left side cover panel, and the left side cover panel is adhered to an outer side of the left side cushioning cell. The right cover panel includes a right front cover panel and a right side cover panel, and the right side cover panel is adhered to an outer side of the right-side cushioning cell. When the left cover panel and the right cover panel are separated and rotated away from each other, the left side cover panel and the right side cover panel rotate together with the left side cushioning cell and the right side cushioning cell, respectively, to expand the product-receiving space.
In some embodiments, each of the cushioning cells includes four panels arranged to form a rectangular cross-section. Each of the left side cushioning cell and the right side cushioning cell further includes a fifth panel, the fifth panel being adhered to one of the four panels. In some embodiments, none of the panels of the left side cushioning cell or the right side cushioning cell are adhered to the base panel. Each of the upper and lower cushioning cells includes a fifth panel, the fifth panel forming a hypotenuse panel extending diagonally between interior corners of its respective cushioning cell.
In some embodiments, the hypotenuse panels extend upwardly toward the product-receiving space. Each hypotenuse panel has a length less than those of the other four panels of its respective cushioning cell. An adhesive is disposed on an outer side of a panel adjacent to the hypotenuse panel of the panels of each of the upper and lower cushioning cells, adhering its respective cushioning cell to the base panel.
Some embodiments are directed to a packaged product assembly having the product packaging and a product disposed within the product-receiving space. The product packaging is in a closed configuration in which the product is restrained from moving relative to the product packaging by contact with the base panel, the cushioning cells, and the cover.
In some embodiments, the product is a packaged product including retail packaging having an outer shape of a rectangular cuboid. The base panel, the cushioning cells, and the cover together define the product-receiving space as a rectangular cuboid matching that of the outer shape of the retail packaging, such that the retail packaging secured in the produce-receiving space.
Some embodiments are directed to a blank for forming product packaging. The blank includes a central base panel, a left panel, a right panel, an upper panel, and a lower panel. The left panel integrally extends outward from a left side of the central base panel and connected to the central base panel at an upward fold line. The right panel integrally extends outward from a right side of the central base panel and connected to the central base panel at an upward fold line. An upper panel integrally extends outward from an upper side of the central base panel and connected to the central base panel at an upward fold line. The lower panel integrally extends outward from a lower side of the central base panel and connected to the central base panel at an upward fold line. Each of the left panel and the right panel includes five sub-panels connected at parallel upward fold lines, and counting outward from the central base panel, their first and third sub-panels all have the same width, and their second and fourth sub-panels all have the same width. Each of the upper panel and the lower panel includes five sub-panels connected at parallel upward fold lines, and counting outward from the central base panel, their first and third sub-panels all have the same height, their second and fourth sub-panels all have the same height and their fifth sub-panels both have a height equal to a hypotenuse height, where the square of the hypotenuse height equals the sum of the squares of the heights of the third sub-panels and the fourth sub-panels. Each of the left panel, the right panel, the upper panel, and the lower panel is configured to be folded to form a cushioning cell disposed around a perimeter of the central base panel, thereby forming a base box.
Some embodiments are directed to a blank system that includes the blank and a cover blank. The blank is a base box blank, and the cover blank includes a central cover panel. The central cover panel has a width equal to a width of the central base panel. The central cover panel includes a ripcord extending vertically along its entire height, and the ripcord is disposed centrally along the width of the central cover panel.
In some embodiments, the cover blank includes: a left side panel integrally extending outward from a left side of the central cover panel and connected to the central cover panel at a downward fold line, and a right side panel integrally extending outward from a right side of the central cover panel and connected to the central cover panel at a downward fold line. The left side panel and the right side panel each has the same width as the width of the first sub-panels of the left panel and the right panel the base box blank.
The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims.
The following disclosure relates to a packaging system that reduces packaging materials and packaging processes while facilitating an end user unboxing and still providing a tamper-evident apparatus. In some existing packaging systems, shipping boxes are provided in flat blanks and assembled by a shipper, and separately provided cushioning materials are placed in the assembled boxes to protect products and minimize their movement within the shipping boxes. There is a burden for shippers to use adequate amount and/or size of the cushioning materials for each packaging to ensure adequate packaging protection, which can complicate assembly processes. Further, shippers may use separately provided tapes or the like to seal shipping boxes. Challenges in such packaging systems include securing a product in its originally packaged condition without damage to the product and its packaging, providing a tamper-evident seal, reducing the burden to the shipper and packaging manufacturer, and providing an easy user experience for opening the packaging and accessing the packaged product by the end user.
The packaging described herein relates to a product packaging providing a packaging solution utilizing environmentally friendly materials, and providing an improved cushioning system. Some embodiments include packaging including a base box with enhanced cushioning configurations integrated therein to surround a product, and a cover securely covering the packaging with a tamper-evident seal. Elements are described that achieve a structurally sound package, while allowing for easy manufacturing, assembly, and packing of the packaging, providing sufficient cushioning and support during transport, and providing for an improved opening experience.
Such product packaging may include two integral components: a base box integrally incorporating cushioning cells, and a cover. In some embodiments both the base box and the cover are formed of a unitary cardboard material, e.g., paperboard or cardboard corrugate, or any other environmentally friendly recyclable materials. In particular, the base box including the cushioning system may be formed from a continuous sheet (e.g., a cardboard blank), with the cushioning system provided formed from the perimeter portion thereof. The cover may similarly be formed from a continuous sheet. The base box and cover may be formed of the same material or different materials that are recyclable in the same fiber-recycling stream. Advantageously, this improves upon prior systems having, for example, plastic film retention elements.
In some embodiments, packaging that is constructed by assembling two parts (e.g., base box and cover) may be each scaled to various sizes to be used for various products. The cushioning dimension is adjusted according to cushion stiffness need, enabling the shipper to tune the cushioning parameters for different engineering performance requirements without changing the visual design and customer experience. The right-sized baseboards for packaging may be prepared prior to assembly. For instance, equipment to create the packaging may receive or be adjusted based on information about a product to be shipped (e.g., dimensions, weight, barcode, etc.), assign a pre-loaded die line, and create a right-sized packaging for the product by cutting and creasing corrugated material in a dynamic way.
Some embodiments discussed herein provide a cushioning system not only providing packaging protection but also inhibiting theft or other tampering from occurring during shipping. Cushioning cells are formed in a rectangular prism around a rectangular product (e.g., a finished goods box containing a product) as surrounding walls, two of which facing each other include hypotenuses inside the prism-formed cells for inhibiting them from flattening, thereby helping to inhibit surreptitious access to the product, helping to secure it from theft during the shipping process, and providing enhanced support to protect the product from damage. The other two walls of the cushioning cells may not include hypotenuses but are further protected by the cover being securely attached thereto.
In some embodiments, the packaging may have a ripcord on the cover to enable a user to easily tear open the packaging with a low amount of force. After the ripcord is torn away, and as the cover is opening, respective cushioning walls without hypotenuses rotate out to open up a space in which a product is placed. Once the ripcord is removed, the cushions can rotate out to expand the space, freeing the product and providing space for the user to grab and remove the product from the packaging. The packaging is then simply recycled without further material separation.
Packaging described in this document achieves these and other beneficial characteristics by balancing structural robustness, eco-friendly materials, and aesthetic elements. A product contained by the packaging may be, for example, an electronic device such as, for example, a desktop, monitor, laptop, tablet computer, or smartphone, smart watch, or it may be a non-electronic device. As used herein, the term “product” may include retail finished goods packaging for the article that it contains.
In some embodiments, the packaging may be shipping packaging (e.g., packaging used for shipping a retail finished goods package containing and conveying a product to a user).
The packaging described herein provides a shipping packaging solution utilizing integrated cushioning systems that promotes ease of packaging and opening thereof. Integrated cushions formed by layering panels can provide robust protection of a product being shipped. The cushioning systems disclosed herein provide a retention effect that is flexible to accommodate a variety of sizes of a particular product or products.
These and other embodiments are discussed below with reference to the accompanying figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting the scope of the disclosure in any way.
Packaging 10 further includes a cover 200 to cover product 11 within product-receiving space 400 (see also
As described above, cushioning cells 20, 30, 40, and 50 may be integrally formed from a continuous substrate, for example, panels integrally extending out from base panel 300 and folded in towards base panel 300, each forming a cuboid shape. In some embodiments, longitudinal lengths of upper and lower cushioning cells 20, 40 (i.e., in the x-direction of the axis of
Turning to
Referring to
Cover 200 is entirely separated into left cover panel 211 and right cover panel 221, exposing product 11 inside packaging 10. A user can then rotate left cover panel 211 and right cover panel 221 further out to the left and to the right, respectively, to completely open up packaging 10. As left cover panel 211 and right cover panel 221 rotate out, respective left cushioning cell 30 and right cushioning cell 50 rotate together with left cover panel 211 and right cover panel 221 in the same motion. More specifically, left side and right side of left cover panel 211 and right cover panel 221, respectively, to which left cover panel 211 and right cover panel 221 are respectively attached, rotate together as a user is opening up packaging 10. That is, as in the example shown in
Turning to
In some embodiments, first blank 110 may include a central base panel 111 and four side panels: a left panel 113, a right panel 115, an upper panel 112, and a lower panel 114 each extending out from central base panel 111 from a left side, a right side, an upper side, and a lower side, respectively, of central base panel 111. Each side panel is integrally connected to central base panel 111 at an upward fold line.
In some embodiments, each of left panel 113 and right panel 115 may be divided into five sub-panels. For instance, left panel 113 includes sub-panels 31, 32, 33, 34, 35 each integrally connected to each other at upward fold lines, and right panel 115 includes sub-panels 51, 52, 53, 54, 55 each integrally connected to each other at upward fold lines. The sub-panels of left panel 113 and right panel 115 can be folded inwardly to form respective cushioning cells (i.e., cushioning cells 30 and 50 forming a cuboid shape having a rectangular cross-section). In some embodiments, the outermost sub-panel of each of left panel 113 and right panel 115 may be provided with an adhesive. For example, sub-panel 31 of left panel 113 and sub-panel 51 of right panel 115 each has an adhesive on respective outer surfaces (the underside of blank 110 as it is shown in
In some embodiments, sub-panels 31, 33, 35 of left panel 113 and sub-panels 51, 53, 55 of right panel 115 may have the same width W1, and sub-panels 32, 34 of left panel 113 and sub-panels 52, 54 of right panel 115 may have the same width W2. In some embodiments, all of sub-panels of left panel 113 and right panel 115 may have the same width, that is, W1=W2, and in this case, left cushioning cell 30 and right cushioning cell 50 have a square cross-sectional shape. Alternatively, in some embodiments, W1 may be different from W2, in which left cushioning cell 30 and right cushioning cell 50 have a non-square rectangular cross-sectional shape.
Similarly, each of upper panel 112 and lower panel 114 comprises five sub-panels integrally connected at parallel upward fold lines. For example, upper panel 112 includes sub-panels 21, 22, 23, 24, 25, and lower panel 113 includes sub-panels 41, 42, 43, 44, 45. The sub-panels of upper panel 112 and lower panel 114 can be folded inwardly to form respective cushioning cells (i.e., cushioning cells 20 and 40 forming a cuboid shape having a rectangular cross-section). In some embodiments, sub-panels 22 and 42 (the second-from-outermost sub-panels of their respective panels) may be provided with an adhesive on their respective outer surfaces (the underside of blank 110 as it is shown in
To increase structural stability of cushioning cells 20 and 40, their outermost sub-panels (sub-panels 21 and 41, also referred to as hypotenuse panels) may have the greatest height of their sub-panels, and each may form a hypotenuse in its respective cushioning cell. To effect this configuration, each of outermost sub-panels 21 and 41 may be folded 135 degrees relative to its adjacent sub-panel, while the remaining folds between sub-panels may be at 90 degrees.
Accordingly, when folded, sub-panels 22 and 42 can be securely attached to an inner side of central base panel 111 only to portions on central base panel 111 (portions adjacent to sub-panels 25 and 45, respectively) by adhesives. Once folded and attached, upper panel 112 and lower panel 114 form upper cushioning cell 20 and lower cushioning cell 40, respectively, as shown in
In some embodiments, sub-panels 22 and 24 of upper panel 112 and sub-panels 42 and 44 of lower panel 114 may have the same height H1, and sub-panels 23 and 25 of upper panel 112 and sub-panels 43 and 45 of lower panel 114 may have the same height H2. In some embodiments, heights H1 and H2 may be the same or different from each other. In addition, sub-panels 21 and 41, which are the endmost sub-panels, may have a height H3 greater than other sub-panels of upper panel 112 and lower panel 114, that is, height H3 is greater than heights H1 and H2. More specifically, the square of height H3 may be equal to the sum of the squares of heights H1 and H2, to thereby serve as a supporting hypotenuse when formed into its respective cushioning cell, as described in more detail elsewhere herein. Accordingly, when sub-panels of upper panel 112 and sub-panels of lower panel 114 are folded to form cushioning cells, sub-panels 21 and 41 are positioned diagonally inside respective cushioning cells as shown in
Referring to
As described herein, each of left panel 113, right panel 115, upper panel 112, and lower panel 114 is configured to be folded to form a cushioning cell disposed around a perimeter of central base panel 111, thereby forming base box 100. In addition, certain dimensions of each of left panel 113, right panel 115, upper panel 112 may vary based on the product size and weight (e.g., cushioning considerations). For instance, a small product box containing a portable mobile device is suitable for a smaller packaging, and may not benefit from as much cushioning as would a larger, heavier product such as a tablet computer or a laptop.
For instance, certain dimensions of first blank 110 (and resulting base box 100) are determined by matching the shape of the product (i.e., the finished goods box containing a product) to be packaged therein. A length L1 of each of panels 113 and 115 match a height of the product box. Width W2 of each of sub-panels 33, 35 and 53, 55 match the depth of the product box. Height H2 of each of sub-panels 23, 25 and 43, 45 also match the depth of the product box. Widths and heights of sub-panels 32, 34, 52, 54, 22, 24, 42, 44 are not based on the product box dimensions, but on the degree of cushioning desired, which may be affected by the product box weight or expected shipping conditions. Greater dimensions for these panels equate to greater cushioning. Finally, a length L2 (or W3) of each of panels 112 and 114 are the width of the product box plus the width of left and right cushioning cells 30, 50 (i.e., the widths of sub-panels 32, 34 and 52, 52. In this way, upper and lower cushioning cells 20, 40 will cover the ends of left and right cushioning cells 30, 50.
Packaging 10 is completed with cover 200 which is formed by second blank 120. In some embodiments, second blank 120 includes a central cover panel 121 having the same width W3 and height H4 as central base panel 111. Central cover panel 121 integrally expends outward from a left side thereof to form left side cover panel 212, where central cover panel 121 and left side cover panel 212 are connected at a downward fold line 214. Central cover panel 121 further integrally expends outward from a right side thereof to form a right side cover panel 222, where central cover panel 121 and right side cover panel 222 are connected at a downward fold line 224. Left side cover panel 212 and right side cover panel 222 each has the same width as width W1 of sub-panels 31, 33, 35 of left panel 113 and sub-panels 51, 53, 55 of right panel 115. Each of left side cover panel 212 and right side cover panel 222 has an adhesive disposed on its inner surface (the underside of blank 120 as it is shown in
As described herein, second blank 120 forming cover 200 has height H4 that corresponds to height of central base panel 111. And, left and right panels 113, 115 have height H5 (or length L1) smaller than height H4 of second blank 120. By this way, when second blank 120 is folded to form cover 200, it can cover open ends of upper and lower cushioning cells 30, 50. That is, the exposed end portions of upper and lower cushioning cells 30, 50 shown in FIG. 10 are covered and protected by cover 200 when base box 100 and cover 200 are assembled (see also
In some embodiments, central cover panel 121 may further include a ripcord 230 extending vertically along its entire height and disposed centrally along the width of central cover panel 121. Various types of tear-away mechanism can be adapted as ripcord 230, for example, a perforation pattern cut through a cardboard, score lines, a line of serrations or weakened material, or other modes of separating portions of paperboard known in the art. Each panel of second blank 120 is integrally connected as a single blank and forms cover 200. Ripcord 230 provides a tamper-evident function. In some embodiments, ripcord 230 includes a grip portion 232 configured to be gripped by a user to tear away ripcord 230 through a breakable joint or breakable joints along central cover panel 121 between left front cover panel 211 and left side cover panel 212.
A user can fold and adhere first blank 110 at fold lines having the above-described configuration to form base box 100 of
Referring back to
Turning back to
As discussed herein, components of the packaging described may be formed from one or more blanks, e.g., cardboard or paper blanks. In some embodiments, the blank is formed of a single continuous substrate, such as, for example cellulose-based material like cardboard corrugate. Other cellulose-based materials are contemplated, such as paperboard, certain molded fiber components of sufficient construction, or grayboard.
Each of the components may be composed of recyclable materials including the shipping packaging, finished packaging, seals, and other related components. Thus, if and when the customer opts to dispose of the packaging, the packaging may simply be recycled without requiring material separation (e.g., in a single-stream recycling program).
Each of the components and their constituent parts, and other variations described herein may include corresponding features described with reference to each of the other components and features described without limitation.
Additionally, the packaging may be manufactured in a cost-effective and environmentally-friendly way. In some embodiments, the packaging components may be constructed of a single integrally-formed piece of material. The single integrally-formed piece of material may be a foldable material that is folded into a configuration that holds and secures a product, either alone or within a cavity of a packaging container. In some embodiments, the foldable material may be a single piece of material that is cut by a single operation (e.g., a single die-cutting operation). In some embodiments, the foldable material may be die cut from a stock material (e.g., a sheet of cardboard corrugate, or roll of material), or other fiber or cellulose based material. Single integrally-formed pieces of material that are cut by a single cutting operation may facilitate efficient and reproducible manufacturing. Moreover, such manufacturing may reduce waste by reducing waste material during manufacturing.
The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.
It is well understood that the use of personally identifiable information should follow privacy policies and practices that are generally recognized as meeting or exceeding industry or governmental requirements for maintaining the privacy of users. In particular, personally identifiable information data should be managed and handled so as to minimize risks of unintentional or unauthorized access or use, and the nature of authorized use should be clearly indicated to users.
This application claims the benefit of U.S. Provisional Patent Application No. 63/387,012, titled “PACKAGING WITH INTEGRATED CUSHIONING SUPPORTS” filed on Dec. 12, 2022, the disclosure of which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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63387012 | Dec 2022 | US |