PRODUCT PROTECTION DEVICE

Abstract

A cushion bumper may include a base member, a cavity sized to receive at least part of an object; and a protrusion extending from the base member into the cavity and having a geometric shape configured to deform in the X-, Y-, and Z-directions based on the application of a compressive force.

Description

FIELD OF THE INVENTION

This application relates generally to devices and assemblies for protecting products during shipping or moving, for example but not limited to cushion bumpers used during the shipment of products.

BACKGROUND OF THE INVENTION

Protective devices are often used when packaging objects for shipment. These devices may absorb vibration and noise and may stabilize the packaged objects. However, existing protective devices do not provide adequate protection for the packaged objects and expose the packaged objects to high G's during impact events, which can cause the packaged objects to be damaged or broken.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.

In some embodiments, a cushion bumper may include a base member; a cavity sized to receive at least part of an object; and a protrusion extending from the base member into the cavity and having a geometric shape configured to deform in the X-, Y-, and Z-directions based on the application of a compressive force

In certain embodiments, a method of using a cushion bumper that includes a base member, a cavity, and a protrusion, may include inserting at least part of an object into the cavity; exposing the cushion bumper to an external force; and deforming the protrusion in the X-, Y-, and Z-directions based on the application of a compressive force.

In some embodiments, a cushion bumper may include a base member; a cavity sized to receive at least part of an object; and a protrusion extending from the base member in the Z-direction and having a geometric shape configured to deform in the X-, Y-, and Z-directions based on the application of a compressive force.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label.

FIG. 1A is a perspective view of a protective device according to certain embodiments.

FIG. 1B is a cross-sectional view of the protective device of FIG. 1A taken along lines 1B.

FIG. 1C is a partial view of the projection of the protective device of FIG. 1B.

FIG. 2 is a front view of the protective device of FIG. 1A with an object received within the cavity.

FIG. 3 is a front view of the protective device of FIG. 2 during an impact event.

FIG. 4A is a partial perspective view of the protective device and object of FIG. 2.

FIG. 4B is a partial perspective view of the protective device and object of FIG. 4A during an impact event.

FIG. 5A is a perspective view of a protective device according to certain embodiments.

FIG. 5B is top view of the protective device of FIG. 5A.

FIG. 6A is a perspective view of a protective device according to certain embodiments.

FIG. 6B is top view of the protective device of FIG. 6A.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “upper,” “lower,” “down,” “top,” “left,” “right,” “bottom,” among others, are not intended to be limiting and are instead intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

Certain aspects and features of the present disclosure relate to a protective device for protecting a product during moving or shipping. The protective device may be a cushion bumper having a novel geometry within a projection sized and shaped to help aid in extending the deceleration event of an object/payload at least partially received within the cushion bumper during a drop or other impact event. The unique geometry of the projection structure may permit dynamic deformation of the projection during compression that offer benefits to the object/payload working against it, e.g., reducing the G's experienced by the object/payload during the drop/impact event.

According to certain aspects of the present disclosure, as shown in FIGS. 1A and 1B, a protective device (or cushion bumper) 100 may be sized and shaped to receive at least part of an object, e.g., a product, a payload, etc., within a hollow interior cavity 102 of the cushion bumper 100. One or more cushion bumpers 100 may be positioned on the object for protecting the object from damage during moving or shipping (e.g. from a drop event). For example, a cushion bumper 100 may be positioned on one end region of an object and another cushion bumper 100 may be positioned on another end region of an object. In some aspects, the object may be a server or other computing device. The cavity 102 may be defined on two opposing sides by a first wall member 104 and a second wall member 106. The cavity 102 may be further defined by two additional opposing sides by a base member 108 and a top member 110. In some aspects, the first wall member 104 and the second wall member 106 may connect the base member 108 and the top member 110.

Additionally, the cushion bumper 100 may include at least one end wall member 112 that further connects the base member 108 and the top member 110 and extends along a direction perpendicular to the first wall member 104 and the second wall member 106. The at least one end wall member 112 prevents an object received within the cavity 102 of the cushion bumper 100 from moving past the at least one end wall member 112. In some aspects, the cushion bumper 100 may include at least two end wall members 112 that are spaced apart from one another to form opening(s) between the at least two end wall members 112. In further aspects, the cushion bumper 100 may include a single end wall member 112 that completely encloses the cavity 102 along the side of the single end wall member 112.

The cushion bumper 100 may include one or more projections 114 extending from at least one of the base member 108 or the top member 110 of the cushion bumper 100. However, it is understood that the one or more projections 114 may extend from any suitable internal surface of the cushion bumper 100, e.g., an inner surface of the first wall member 104, the second wall member 106, and/or the at least one end wall member 112. In some aspects, the cushion bumper 100 may include multiple projections 114 with at least one projection 114 extending from the base member 108 and at least one projection 114 extending from the top member 110. One or more projections 114 extending from the base member 108 may align with or may be mis-aligned with one or more projections 114 extending from the top member 110.

As may be seen in more detail in FIG. 1C, the one or more projections 114 may extend from the base member 108 and/or the top member 110 such that the one or more projections 114 are angled with respect to the base member 108 and/or the top member 110. For example, first walls 116 of the projection 114 may extend at an angle θ with respect to the base member 108. The angle θ may be greater than 30 degrees, less than 90 degrees, or range from 40 degrees to 50 degrees, from 30 degrees to 60 degrees, from 20 degrees to 70 degrees, etc. Additionally, the one or more projections 114 may include second walls 117 that extend from the first walls 116 at an angle different than the angle θ.

In some aspects, the one or more projections 114 may define an optional recess 118, or in some instances a divot, an angled feature, a cut-out, etc., in the one or more projections 114. The recess 118 may extend into an object-abutting surface 120 of the projection 114 and may divide the projection 114 into at least two regions, e.g., a first region 122 and a second region 124. The recess 118 may define an angle Ω, which may be greater than 90 degrees, greater than 60 degrees, less than 90 degrees, or range from 10 degrees to 170 degrees, from 45 degrees to 135 degrees, from 60 degrees to 120 degrees, from 40 degrees to 50 degrees, from 30 degrees to 60 degrees, from 20 degrees to 70 degrees, etc. In certain aspects, the geometry of the recess may be shaped to permit flexure of the one or more projections 114 in the intended manner base on the material forming the one or more projections 114. The angle £2 may be determined at least in part based on the height of the projection 114.

The one or more projections 114 included in the cushion bumper 100 may all be the same shape or may have different shapes. For example, the projection(s) 114 that are positioned proximate the first wall member 104 and the second wall member 106 may be missing one or more areas such that these projection(s) 114 have an overall different shape than other projections included in the cushion bumper 100. The one or more projections 114 may aid in the deformation of the cushion bumper 100 during a drop event for improving the deceleration of the object positioned within the one or more cushion bumpers 100. For example, the one or more projections 114, including the angle θ, may provide appropriate cushioning, with optimized deceleration rates, tailored to the specific weight, geometry, and fragility of the object received in the one or more cushion bumpers 100.

In certain aspects, the base member 108 and/or the top member 110 may define an optional cut-out 126, or in some instances, a divot, a recess, an angled feature, etc., on an underside of the base member 108 and/or a topside of the top member 110. The cut-out 126 may at least partially overlap or align with the projection 114, and, in some instances, each projection 114 included in the cushion bumper 100 may align with a respective cut-out 126. The cut-out 126 may be a curved or arched shape, though any other suitable shape may be used and may be determined based on the object positioned within the one or more cushion bumpers 100 and the structural properties of the cushion bumpers 100. The cut-out 126 may aid in the deformation of the cushion bumper 100 during a drop event for improving the deceleration of the object positioned within the one or more cushion bumpers 100. For example, the cut-out 126 may provide added dynamic flexure for the corresponding projection 114 during a drop event.

Additionally, the underside of the base member 108 and/or the topside of the top member 110 may include one or more cut-outs 126 that do not overlap or align with a projection 114. In some aspect, the one or more cut-outs 126 that do not overlap or align with a projection 114 may correspond to, overlap, or align with an upwardly curved portion 128 or otherwise increased height area of the respective base member 108 and/or top member 110. Here, “upwardly curved” may be defined as an area of the base member 108 and/or the top member 110 extending centrally into the cavity 102 of the cushion bumper 100.

The cushion bumper 100 may be formed from foam (closed cell, open cell, etc.), blow molded plastics, thermoformed plastics, molded fiber, or any other suitable material. Further, the cushion bumper 100 may be formed using any suitable method. For example, a cushion bumper 100 formed of a plastics material may be formed by thermoforming, vacuum forming, vacuum casting, injection molding, blow molding, compression molding, rotational molding, extrusion, 3D printing, etc. In some aspects, a cushion bumper 100 formed of a fiber material and/or an alternative organic material may be formed by molding or injection molding the fibers. The various components of the cushion bumper 100, e.g., the base member 108, the top member 110, the projection(s) 114, etc. may be formed from the same or from different material. Further, the various components of the cushion bumper 100 may be integrally formed, e.g., formed together in a single mold, or may be separately formed then connected together.

As shown in FIG. 2, at least a part of the object 130, e.g., the outer edges, a first side, etc., may be received within the cavity 102 of the cushion bumper 100 such that the object abuts the object-abutting surface(s) 120 of the projection(s) 114 included in the cushion bumper 100. Further, in some instances, the entirety of the object 130 may be received within the cavity 102. Though the object 130, the cavity 102, and the cushion bumper 100 are shown having a substantially rectangular shape, it is understood that each of the object 130, the cavity 102, and the cushion bumper 100 may be any suitable size and shape. The size and shape of the cavity 102 and the cushion bumper 100 may be determined and adjusted based on the size and shape of the object 130.

FIG. 3 shows a movement of the object 130 and compression of the projections 114 during an impact event. For clarity purposes, FIG. 3 only illustrates the movement of the object 130 and the compression of the projections 114 during the impact event. The compression of other portions of the cushion bumper 100 is discussed in more detail below with respect to FIGS. 4A and 4B. The impact event may be dropping the object positioned within the cushion bumper 100, hitting the object positioned within the cushion bumper 100, etc. The shape of the projections 114 and corresponding cut-outs 126 permits the projections 114 to compress in the direction of the impact event. This compression of the projections extends the deceleration of the object 130 and provides improved reduced G's experienced by the object 130 during the impact event. By extending the deceleration of the object 130 the likelihood of damage to the object 130 (positioned within at least one cushion bumper 100) may be reduced. Further, extending the deceleration of the object 130 reduces the aggressiveness of the impact event transferred to the object 130 without increasing a cushioning distance.

Additionally, the angle θ and/or the angle Ω may be selected based on the required compression performance of the projections 114 depending on a rigidity and/or density of the material forming the cushion bumper 100 as well as the mass of the object 130. Additional dimensions of the projections 114, e.g., overall surface area of the projections 114, a height of one or more areas of the projections 114, a base length of the projections, etc. may similarly be selected based on the required compression performance of the projections 114 depending on a rigidity and/or density of the material forming the cushion bumper 100 as well as the mass of the object 130. In some aspects, selection of one dimension of the projections 114 may impact the selection of other dimensions. For example, selection of the angle θ may determine the overall height of the projections 114.

During the impact event, the compressed projections 114b may compress towards the base member 108 and thus extend the deceleration of the object 130. The compressed projections 114b dynamically deform and flex in the X-, Y-, and Z-directions due to the shape of the projections 114. In some instances, at least a portion of the first walls 116 may come into contact with the base member 108 as a result of the compression. The angle θ of the first walls 116 with respect to the base member 108 and/or the angle of the second walls 117 with respect to the first walls 116 may cause the compressed projections 114b to act as counteracting springs during the impact event to contribute to the extended deceleration of the object 130.

FIG. 4A shows the object 130 and portions of two cushion bumpers 100 in an uncompressed state. FIG. 4B shows the object 130 and the portions of the two cushion bumpers 100 of FIG. 4A in a compressed state during an impact event. As may be seen, additional areas of the cushion bumpers 100 besides just the projections 114 may move, flex, and/or compress during the impact event. Such movement, flexing, and/or compression of these additional areas may contribute to further extending the deceleration of the object 130 and providing improved reduced G's experienced by the object 130 during the impact event. For example, the cut-outs 126 in the base member 108 may permit the base member 108 to flex during the impact event to provide additional relief to the object 130 when the cushion bumpers 100 are in the compressed state during the impact event. In some aspects, the cushion bumpers 100 reduce the G force experienced by the object 130 during an impact event by between 10% and 35% when tested in a sequence drop test per the International Safe Transit Association (“ISTA”) test procedure 3A, which is compliant with ASTM D 5276.

According to certain aspects of the present disclosure, as shown in FIGS. 5A and 5B, a cushion bumper 500 may include a hollow interior cavity 502, a first wall member 504, a second wall member 506, a base member 508, a top member 510, an end wall member 512, and one or more projections 514. These components may be the same as or similar to the corresponding components described with respect to the cushion bumper 100 above in FIGS. 1-4B.

In some aspects, the end wall member 512 is connected to and/or integrally molded with the first wall member 504, the second wall member 506, the base member 508, and the top member 510. Additionally, the end wall member 512 may be connected to and/or integrally molded with one or more of the projections 514.

According to certain aspects of the present disclosure, as shown in FIGS. 6A and 6B, a cushion bumper 600 may include a hollow interior cavity 602, a first wall member 604, a second wall member 606, a base member 608, a top member 610, an end wall member 612, and one or more projections 614. These components may be the same as or similar to the corresponding components described with respect to the cushion bumper 100 above in FIGS. 1-5B.

In some aspects, the end wall member 612 is connected to and/or integrally molded with the first wall member 604, the second wall member 606, the base member 608, and the top member 610. The first wall member 604, the second wall member 606, the base member 608, and the top member 610 may extend from the end wall member 612 in a Z-direction. Additionally, the projections 614 may extend from the one or more of the first wall member 604, the second wall member 606, the base member 608, or the top member 610 in the Z-direction and may further define the cavity 602.

The projection 614 may include a first curved portion 640, a second curved portion 642, and a curved recess 644 positioned between the first curved portion 640 and the second curved portion 642. In certain aspects, the first curved portion 640 is positioned proximate to the cavity 602, and the second curved portion 642 extends farther in the Z-direction than the first curved portion 640. Additionally, the first curved portion 640 may extend into an object-abutting surface 620 of the projection 614.

Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Examples of the invention have been described for illustrative and not restrictive purposes, and alternative examples will become apparent to readers of this patent. Accordingly, the present invention is not limited to the examples described above or depicted in the drawings, and various examples and modifications may be made without departing from the scope of the claims.

It should be noted that the systems and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. Also, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are examples and should not be interpreted to limit the scope of the invention.

Claims

1. A cushion bumper comprising: a base member;a cavity sized to receive at least part of an object; anda protrusion extending from the base member into the cavity and comprising a geometric shape configured to deform in the X-, Y-, and Z-directions based on the application of a compressive force.

2. The cushion bumper of claim 1, wherein the protrusion comprises a first set of walls that each extend at an angle of less than 90 degrees from the base member.

3. The cushion bumper of claim 2, wherein the protrusion further comprises a second set of walls that each extend at a non-vertical angle from a respective wall of the first set of walls.

4. The cushion bumper of claim 3, wherein the protrusion comprises a first surface that defines a recess extending into the protrusion.

5. The cushion bumper of claim 3, wherein the base member defines a cut-out extending into the base member on a side of the base member opposite from the protrusion.

6. The cushion bumper of claim 5, wherein the cut-out aligns with the protrusion.

7. The cushion bumper of claim 1, further comprising an end wall member, wherein the protrusion extends from both the base member and the end wall member.

8. The cushion bumper of claim 1, wherein the cushion bumper is formed from at least one of a foam material, a blow molded plastic material, a thermoformed plastic material, or a molded fiber material.

9. A method of using a cushion bumper comprising a base member, a cavity, and a protrusion, the method comprising: inserting at least part of an object into the cavity;exposing the cushion bumper to an external force; anddeforming the protrusion in the X-, Y-, and Z-directions based on the application of a compressive force.

10. The method of claim 9, wherein the protrusion comprises a first surface against which at least a part of the object abuts.

11. The method of claim 9, wherein the protrusion comprises a first set of walls that each extend at an angle of less than 90 degrees from the base member.

12. The method of claim 11, wherein deforming the protrusion comprises flexing the first set of walls until at least a portion of the first set of walls contacts the base member.

13. The method of claim 9, wherein deforming the protrusion extends a deceleration event of the object.

13. The method of claim 9, wherein the base member defines a cut-out extending into the base member on a side of the base member opposite from the protrusion.

14. The method of claim 13, further comprising flexing the base member based on the application of the compressive force.

15. The method of claim 9, wherein the cushion bumper is formed from at least one of a foam material, a blow molded plastic material, a thermoformed plastic material, or a molded fiber material.

16. A cushion bumper comprising: a base member;a cavity sized to receive at least part of an object; anda protrusion extending from the base member in the Z-direction and comprising a geometric shape configured to deform in the X-, Y-, and Z-directions based on the application of a compressive force.

17. The cushion bumper of claim 16, wherein the protrusion comprises a first curved portion and a second curved portion.

18. The cushion bumper of claim 17, wherein the protrusion defines a curved recess between the first curved portion and the second curved portion.

19. The cushion bumper of claim 16, wherein the first curved portion is positioned proximate to the cavity, and the second curved portion extends farther in the Z-direction than the first curved portion.

20. The cushion bumper of claim 16, wherein the cushion bumper is formed from at least one of a foam material, a blow molded plastic material, a thermoformed plastic material, or a molded fiber material.