Patent Application
20050241979
The present disclosure relates generally to the field of packaging, and, more particularly, to a reinforced packaging technique for the shipment of computer systems and other products.
Computer systems, as well as other products, are shipped worldwide to customers. These products must be packaged in a manner that insures that the products reach their destination without being damaged during the shipping process. Typically, the unit is enclosed for shipment within a protective foam frame. Once the unit is placed within the protective foam frame, the foam frame is slid into a cardboard box for shipment. The foam frame cushions the unit against the customary movement and jostling that is typical in the shipping process.
In the computer industry, the physical size of many computer systems is decreasing. In particular, many server systems are becoming thinner. Despite this decrease in physical size, the feature set of many computer systems continues to grow in complexity. As an example, a server system may have a size of 1U (1 3/4″ of thickness) and include within the case dual processors, multiple hard drives, and a backup power system. The placement of these features within a single server system leads to an increase in component density within the server unit. In addition, some server systems included parts that protrude externally from the chassis of the server system. As an example, some server systems may include an external power dongle or mounting flanges that are external to the chassis of the computer system. If a unit that includes an external component is dropped, depending on the angle of the drop and the shape of the external component, the external component may cut through the protective foam frame. If this occurs, the external component may encounter a hard stop once the external component reaches a hard surface, damaging the external component or the entire unit. The possibility of the unit cutting through the foam is exacerbated when the unit itself is heavy, as in the case of some server units. In the case of server units, protecting the server unit from damage is critical, as the server unit is often a vital piece of a computer network, as compared with a desktop or client computer.
In accordance with the present disclosure, a packaging system is provided that includes a foam frame. Within the foam frame, at a location that is susceptible to puncture, is a slit and an insert within the slit. The insert may be composed of a paper or plastic material. The insert cushions the shipped unit against a hard stop by prevent the shipped unit from puncturing through the foam frame. When the shipped unit contacts the insert, the insert transfers the force of the shipped unit across the surface area of the insert, which in turn transfers this force across the adjacent foam, preventing the unit from puncturing through the foam.
A technical advantage of the present disclosure is the structure of the disclosed packaging system provides a solution that can be localized to the weakest points of the foam frame. As such, it is not necessary to have an insert throughout the entire foam frame. Instead, the insert is placed in only those location that are know, whether through testing or otherwise, to be the most susceptible to puncture by the shipped unit. Another technical advantage of the present invention is a packaging system that prevents damage to the shipped unit without increasing the cost or shipping weight of the package. Because the insert is placed in the area or areas that are the most susceptible to puncture, the cost and weight of the packaging system is not significantly increased. Other technical advantages will be apparent to those of ordinary skill in the art in view of the following specification, claims, and drawings.
A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
The present disclosure concerns a foam fame for the packaging of computer systems, including server computer systems, and other products. Shown generally at 10 in
Shown generally in
In the event that the shipped unit is dropped such that the shipped unit or an external component of the shipped unit contacts insert 24, insert 24 will flex and will disperse the force upon insert 24 across the surface of insert 24 and across the foam that is behind insert 24. The ability of insert 24 to deform and spread the impact of the unit across insert 24 and the foam behind insert 24 decelerates the shipped unit and prevent a hard stop of the shipped unit against a hard surface. Insert 24 is sufficiently pliable that contact between the unit and insert 24 does not harm the unit or the surrounding foam. Insert 24 may, for example, be made of corrugated cardboard or a deformable plastic.
More than one slit 22 and accompanying insert 24 can be used in a single foam frame 10. The slit and an accompanying insert can be placed in all those locations of the foam frame in which the foam frame will encounter extraordinary stresses or the possibility of puncture because of the shape of the unit being shipped, including the shape of any external components on the unit being shipped. As such, the use of the slit and an accompanying insert can be localized to the weakest points of the foam frame. As compared with the option of having a reinforcing insert throughout the entire foam frame, the use of a slit and insert in only those areas in which the foam frame is the most vulnerable reduces the cost and weight of the foam frame. As such, because the weight of the foam frame is not markedly increased, the shipping weight, and therefore the shipping cost, of the unit is not markedly increased by the presence of one or more slits and accompanying inserts.
It should be recognized that the technique described herein may be used with foam frame of any size and shape, and the use of the technique described herein is not dependent on the presence of a foam frame having a certain size or configuration. Although the present disclosure has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereto without departing from the spirit and the scope of the invention as defined by the appended claims.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10437114 | May 2003 | US |
| Child | 11177023 | Jul 2005 | US |
