Patent Application
20110108450
1. Field of Invention
The present invention relates generally to a collapsible shipping container utilizing standard box making equipment manufactured from material such as paper, corrugated board, and corrugated plastic, and in particular, to a package that employs a tensioned film system, that holds a product hammock style, between two layers of film and/or between a film and a wall of the package.
2. Brief Description of Prior Art
The prior art includes numerous variations of boxes that employ a hammock like structure to cradle a product within the box. However, there is still a need to design a box that provides the combination of low cost, ease of manufacture, ease of transport to an end user, ease of use from the end user's standpoint, and which provides a required level of cushioning.
The present invention relates to a typical box having four sides and bottom and top flaps when erected.
In accordance with an embodiment of the invention, a box comprises a first blank having a first center panel with four edges and four flap panels. Each of the four flap panels is contiguous with one of the center panel four edges and separated therefrom by a flap panel fold line. The center panel has a first central fold line extending parallel to the flap panel fold line separating the opposing first and third panels. The central fold line extends from an edge of the center panel to an outer edge of at least one contiguous opposing flap panel. The second flap panel is divided into two sub-panels by a slot and the fourth panel is divided into two sub-panels by a fold line. The first and third opposing flap panels have an elongated slot that are parallel to one another and to the center panel central fold line.
A second blank is dimensioned to coordinate with the first blank when the two blanks are in their folded configuration with the second blank overlying the first blank. The second blank has a second center panel with four edges and four flap panels contiguous with each edge that are separated from the center panel by an edge fold line. A first and a third of the flap panel have a contiguous pair of opposing end flaps that are separated from a neighboring flap panel by a slot.
A second central fold line of the second blank extends parallel to the central fold line of the first blank when the first and second blanks are in their assembled configuration with the second blank overlying the first blank. The second central fold line extends from one edge of the center panel to an outer edge of at least one of its contiguous opposing flap panel. Each contiguous end flap and flap panel is separated by a fold line, and each flap panel is separated from said second center panel by a fold line.
The second blank flap panels have a peripheral edge that is longer than half the distance between the central fold line and a parallel fold line, with the peripheral edge being an edge not parallel with the central fold line.
In accordance with an embodiment of the invention, a box is formed and filled using the above blanks. The first blank first and second flap panels are rotated about their fold lines, from the plane of the first blank toward a position in which the first flap panel's peripheral edge and the second flap panel's peripheral edge are separated by a distance equal to or less that the distance between the first flap panel fold line and the second flap fold line. A support film member is secured to the first and second flap panels in a position and dimensioning to be taut when the container is in a rectangular or square cross-sectional configuration and flaccid when said container is in a hexagonal configuration. The second blank's first flap panel is then fixed to the first blank's first flap panel and the second blank's second flap panel to the first blank's second flap panel. The second blank's second flap panel having its fold line parallel to the first blank's central fold line. This places the central fold line of the second blank parallel to the central fold line of the first blank when in the assembled configuration. The container is then folded to a substantially flat configuration for transportation to a user.
In accordance with an embodiment of the invention, to use the box, the formed box is unfolded to a substantially rectangular or square configuration by folding at least one flap panel about its fold line to a position superadjacent a central panel and conforming the container to a hexagonal cross-section.
In accordance with an embodiment of the invention, the support film member is secured to the first blank's first and second flap panels by passing each of two ends of the support film member through one of the elongated slots and fixing the two ends of the support film to its respective flap panel.
In accordance with an embodiment of the invention, the support film member can be a pouch, and an article can be inserted into the pouch while the box is in a hexagonal cross-sectional configuration. The box can be supported in its hexagonal cross-sectional configuration on a substantially horizontal planar surface and positioned with its first blank center panel central fold line substantially vertical relative to horizontal planar surface. An article can then be inserted into the pouch while the support film of the pouch is flaccid. The pouch can also have a flap member and an adhesive containing region, with the flap member folding onto the adhesive containing region to secure the article product within the pouch.
In accordance with another embodiment of the invention, the support film can be secured to the first blank's first and second flap panels by wrapping a first end of a first support film around a peripheral edge of the first blank's first flap panel and a second end of the support film around a peripheral edge of the first blank's second flap panel. A second support film can then be secured to the first blank's first and second flap panels by passing each of two ends of said support film through one of the elongated slots and fixing each of the two ends of to its respective flap panel. The second support film can be in the form of a pouch and the product inserted into the pouch while the box is in a form having a hexagonal cross-section. The pouch can have a flap member and an adhesive containing region with the flap member being folded onto the adhesive containing region to secure the product within the pouch.
In accordance with a further embodiment of the invention, a box for retaining products, especially fragile products, for shipping comprises a first center panel with four flap panels contiguous with the edges of the first center panel. The four flap panels are separated from the center panel by a flap panel fold line. The first center panel has a central fold line extending parallel to two of the flap panel fold lines that extends from the edge of the center panel to an outer edge of at least one of its contiguous flap panels. The opposing first and a second flap panels have an elongated slot that are parallel to the other elongated slot and to the first center panel and second central fold lines.
A second blank has a second center panel is contiguous with, and separated by a fold line, four flap panels, with a second central fold line extending parallel to the first central fold line. The second central fold line extends from an edge of the second center panel to an outer edge of at least one of its contiguous flap panels. At least one contiguous flap panel has one of the first or the second central fold line extending from its contiguous edge with the center panel to its outer edge. The flap panel is folded about its fold line to a position superadjacent to its contiguous central panel, and the box is conformed to a hexagonal cross-section. The box includes a support film having two ends is secured at each end to a panel contiguous with a center panel, along a line that is parallel to the central fold line. The support film is positioned and dimensioned to be taut when the box is in a rectangular or square cross-sectional configuration and flaccid when the box is in a hexagonal configuration.
At least one end of said support film can pass through the elongated slot from the interior side of the elongated slot containing panel to the exterior side of the elongated slot containing panel, and then secured to the exterior side of the elongated slot containing panel. The support film can be a pouch with the elongated slots being substantially midway between the edges of the panel to which it is attached. The support film can also be secured to the panels at a position proximate one of the center panels for supporting an article between the support film and the center panel.
In accordance with a further embodiment of the invention, a package is formed and filled by using at least one blank having a first blank center panel and four flap panels and a first central fold line extending parallel to two flap panel fold lines. The central fold line extends from an edge of the center panel to an outer edge of at least one of its contiguous flap panels. The first and a second of the four flap panels being on opposing sides of said first center panel.
A second center panel is contiguous with a flap panel at each of its four edges, and separated therefrom by an edge fold line. At least one of the flap panels has a pair of opposing end flaps contiguous therewith and separated therefrom by a fold line. A second central fold line is parallel to the first central fold line and extends from an edge of the center panel to an outer edge of at least one of its contiguous flap panels. The pair of opposing end flaps are each separated from a neighboring flap panel by a slot, and each contiguous end flap and flap panel is separated by a fold line.
In accordance with a still further embodiment of the invention the box is assembled by rotating the two flap panels contiguous with the first central panel about their fold lines, from the plane of the first central panel toward a position in which the two flap panels are separated by a distance equal to or less that the distance between the two flap panel fold lines with said first central panel. A support film is secured to the first two flap panels. A second center flap panel is fixed to a first center panel flap panel that has the support film secured thereto, forming a box. The box is folded to a substantially flat configuration, for transportation to a user.
In accordance with a further embodiment of the invention a flattened box is unfolded to a substantially rectangular or square configuration, and at least one flap panel is folded about its fold line with a center panel to a position superadjacent to the center panel. The box is then conformed to a hexagonal cross-section and supported in its hexagonal cross-sectional configuration on a substantially horizontal planar surface. The box is positioned with its first blank center panel central fold line substantially vertical relative to said substantially horizontal planar surface. An article is then insert into the box for support by the support film member while said support film member is flaccid. The support film can be a pouch, and inserting an article into the box for support by the support film while it is flaccid comprising inserting an article into the pouch. The at least one flap panel is folded about its fold line with a center panel from the position superadjacent to the center panel, to an end closure position and the box is restored to its square or rectangular cross-sectional configuration. The box is then sealed as for example, by applying an adhesive tape to the ends of the box.
The invention will be described with the accompanying drawings, in which:
It is advantageous to define several terms before describing the invention. It should be appreciated that the following definitions are used throughout this application. Where the definition of terms departs from the commonly used meaning of the term, applicant intends to utilize the definitions provided below, unless specifically indicated.
For the purposes of the present invention, the term “box” refers to an enclosure of any size and shape formed from a single or multiple bonded corrugated sheet that has the appropriate score lines, as well known in the art. The terms package and container are used herein interchangeable with the term “box”.
For the purposes of the present invention, the term “clearance space” as used herein, refers to the space between flap side edges and an adjacent side wall, when the box is in its erected configuration.
For the purposes of the present invention, the term “slot” refers to the manufacturing method that makes a cut that can be approximately, 3/16 of an inch wide between adjacent bottom flaps, or wider. For example, 114, 180, 186, 184, 181, and 182 represent slots as illustrated in
For the purposes of the present invention, the terms “corrugated paper”, corrugated plastic, and the term “corrugated board” are used interchangeably, and are inclusive of single, double and triple wall corrugated materials for shipping boxes, as well known in the art.
For the purposes of the present invention, the term “double wall” refers to corrugated material that has two corrugated layers separated by a flat sheet and two outer flat sheets.
For the purposes of the present invention, the term “knock down” refers to the box when it is flattened as illustrated, for example, in
For the purposes of the present invention, the terms “opened”, “assembled”, and “erected” refers to the configuration of the box as illustrated for example, in
For the purposes of the present invention, the term “score lines” may also be referred to as “fold lines” or “crush lines”. Forming fold lines in blanks from which boxes are made is well known in the art, and any desired one of the well known techniques can be used. As seen in
For the purposes of the present invention, the term “score” refers to the manufacturing method that linearly crushes the corrugated sheet to enable a fold line to be formed, as well known in the art.
For the purposes of the present invention, the terms “side panels” the side wall panels of a rectangular box, as for example, panels 101, 102, 103, 152, 153, and, 155 of
The terms end panels and side panels are terms of convenience and are used to identify a first pair of opposing side walls and a second pair of opposing side walls. While generally, end panels, such as 104, 105, 105A, 160, 161, 190, 192, 194, and 196 of
For the purposes of the present invention, the term “flap” and/or “flaps” may be used when referring to end panels.
For the purposes of the present invention, the term “substantially”, as used herein means tolerance ranges normal used in the paper box industry.
For the purpose of the present invention, the term “suspension layer” refers to the film structure that attaches to box panels for securing objects during shipping. Multiple suspension layers can be used and suspension layer can be used in combination with retention layer(s).
For the purpose of the present invention, the term “pouch” refers to a film structure that encloses and forms a suspension layer.
For the purpose of the present invention, the terms “pouch”, “film”, and “suspension layer” refers to structure that can be an anti-static/static dissipating material, and is preferably a material that will hold a product under tension when stretched. The material tends to return to its un-stretched form rather than to deform or elongated to a longer dimension, and thus, will hold a product firmly, and under tension. The product is accordingly not free to move, or rattle around in the box. The film is resilient and returns to its original shape when after being subjected to a vibration or jarring action. The film thus cushions and cradles the object being transported. The method in which films are joined to the walls of the box can include, by way of example, welding, heat activated adhesives, co-adhesives, pressure sensitive tapes, and hot melt glues. Epoxies and silicone adhesive can be used. Pressure sensitive tapes for the pouch structure are provided with a release film which is removed when the pouch is to be sealed closed.
For the purpose of the present invention, the terms “fixing” and “securing”, when referring to the attaching of a panel of one blank to a panel of another blank, or the attaching of a retaining member such as 1164 of
For the purpose of the present invention, the term “void fill” refers to any material used to fill the empty space around an object being shipped inside a box. More commonly known to those skilled in the art it refers to stuffing popcorn/peanuts, Bubble Wrap, airbags, paper product, foam and Styrofoam. Void fill can be used in conjunction with suspension and retention packages, but preferable, the suspension and retention packages of the present invention negate the need for void fill.
For the purpose of the present invention, the term “erected” refers to the box being unfolded as to have square corners and a closed bottom, as well known in the art.
For the purpose of the present invention, the term “RSC” means regularly slotted cardboard, as well known in the industry.
For the purpose of the present invention, the term “die cut panels” refers to the industry standard method of forming blanks such as illustrated in
The term “substantially” as referred to herein indicates a near, close to relationship, not significantly departing from a particular quality. For example, while 50% would not be substantially 100%, but a value that provides the desired result though not exactly equal to the ideal or optimum value, would be considered to be substantially the exact, ideal, or optimum value. A substantially vertical article could depart from the perpendicular relationship with a horizontal plane, but would not depart to the extent that it begins to lose its stability or requires an external support to be self supporting.
There are four simple advantages to the suspension packaging system of the present invention. The product provides exceptional cushioning and vibration protection while greatly reducing warehouse space, eliminating inner cushioning materials, saving labor, and reducing material costs.
In a preferred embodiment, the system uses a film pouch centered within a box that is secured in place by trapping the ends of the film between two layers of corrugated for exceptional strength. The film passes through the first corrugated layer utilizing a 3/6″ tall slit and is then turned 90 degrees to be glued between the corrugated panels. The corrugated layers are completely glued as well to create an exceptionally strong box in its own right.
The firmly attached stretchable film can now be used for two purposes. First, as a pre-made pouch for loading items to be shipped in that is virtually indestructible. It requires the packer to keep both ends of the box open so that loading can be easily facilitated. Once the box is folded the film-pouch becomes taut and is ready for shipping. The design orients the box to be opened from the side so that the opening of the pouch is exposed to the user, thereby facilitating the insertion of an article or articles into the pouch.
In another embodiment, the film cooperates with a side wall of the box to form the equivalent of a pouch. In this embodiment, the article is retained between the taut film and the box, and this style of a box is referred to as a retention pack.
The box can be stood on end, that is, on its end flaps, to expose the pouch for easy insertion of an article into the pouch. The box is placed on a horizontal surface, as for example, a packing table, with the open end of the pouch.
Additionally, the film can be used as a platform for a separate pouch to be attached with a pressure sensitive adhesive, either residing on the pouch or on the film. This design orients the box to be opened from the top so that the film's full length and width are exposed.
A further aspect of the invention is that the film is trapped between two layers of corrugated that runs along the bottom of the box. The film starts from the left by having 1″ of material trapped between the layers of corrugated material, and then passes underneath the inner corrugated layer leading to the opposing corrugated layer and passing underneath to be trapped between those layers. Typically this box would be shallower or less tall than prior art boxes and to the other embodiments of the invention.
The support film of the present invention is preferably a plastic which stretches up to about 40% with high load retention, that is, without distorting or deforming, or exceeding its yield point. In one embodiment anti-static/static dissipative films can be used.
The pouch can be a folded sheet or two sheets can be heat welded to form a pouch. Additionally, multiple pouches can be provided, advantageously, in spaced, parallel rows.
The panels 102 and 103 can be provided with elongated slots 112 and 113 respectively, for use in securing the support film to the panels 102 and 103. The film 200 is centered within the box by passing it through the first corrugated layer utilizing a 3/6″ tall slit and is then turned 90 degrees to be glued between the corrugated panels 102 and 152, and 103 and 153. The corrugated layers are completely glued as well to create an exceptionally strong box in its own right.
The film used is advantageously a transparent urethane 3 mils thick. The urethane film's unique properties of stretch ability and memory make film always return to original shape. These properties enable the film to absorb repeated shock and vibration.
The center panel 101 is provided with a central fold line 106 which extends across the center panel 101 and the flap panel 104. In the embodiment of
With respect to
The center panel 155 is noted to be bounded by fold lines 158, 159, 170, and 171, and is provided with a central fold line 156. The central fold line is employed during the steps of folding the box flat, as illustrated in
The attachment of a stretchable support film 200 to the blank 100 is most readily achieved by folding the flap panels 103 and 102 toward each other thereby bringing the elongated slots 112, and 113 sufficiently close together to facilitate the insertion of one end of the support film 200 into the elongated slot 113 and the other end into the elongated slot 112. The ends of the support film are folded against their respective flaps panels. The film is preferably formed of a plastic that is stretchable up to 20% and more preferably, up to 40% without exceeding its yield point. The film can be used as a platform for a separate pouch that is attached with a pressure sensitive adhesive, either residing on the pouch or the film. This design orients the box to be opened from the top so that the film's full length and width are exposed.
In the embodiment of
Alternatively, the elongated slot 1680 and 1682 can be positioned adjacent fold lines 1630 and 1631 respectively. In this later configuration, the support film can be used to retain an article between the film and the central panel 1604. It should be understood that multiple layers of film can be used, and can be all pouch configurations, or combinations of pouches and single sheet of film.
Center panels 1608 and central fold line 1622 of blank 1600 correspond to center panel 955 and central fold line 956 of the blank of
It can be seen that panel 952 of
It is noted that
Alternatively, the elongated slot 1680 and 1682 can be positioned adjacent fold lines 1630 and 1631 respectively. In this later configuration, the support film can be used to retain an article between the film and the central panel 1604. It should be understood that multiple layers of film can be used, and can be all pouch configurations, or combinations of pouches and single sheet of film.
In the pouch design, where a pair of flaps extends through each of the elongated slots, one flap can be folded upward from the suspension layer against the wall and the other folded downward going against the wall. These flaps are extensions of the suspension layer and are what secures it to the corrugated box. It should be noted that the middle section of the film, that is, the region between the points at which the film is secured to the walls of the box, is the same dimension as the interior box footprint, in order to provide a taut film configuration.
Once the pouch(s) are filled the box can then be closed by bending in the top four box flaps over the scored fold lines and taping them down. The last step is to tape close the box flaps. With the box flaps closed and taped, the box is ready for shipment via any common carrier.
Rather than using mechanical means such as staples or the like, sealing of the two sheets of film 1802 and 1804 that form the pouch 1800 is preferably by means of a sealing technique such as disclosed in the following patents, the disclosures of which are incorporated herein by reference, as though recited in full:
The bonding type of sealing serves to seal the first leg of the “U” of film 1802 to slotted member 1850 and to the retainer member 1862, and the second leg of the “U” of film 1802 to the retainer member 1862 and outer panel 1810. The sealing procedure is applied to both ends of the film 1804 and the film 1802. The sealing procedure is essentially the same for the one piece package of
Although the present invention has been fully described in conjunction with several embodiments thereof with reference to the accompanying drawings, it is to be understood that various changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as described by the appended claims, unless they depart there from.
While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” In this disclosure and during the prosecution of this application, means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects and embodiments), and should not be improperly interpreted as limiting the scope of the application or claims. In this disclosure and during the prosecution of this application, the terminology “embodiment” can be used to describe any aspect, feature, process or step, any combination thereof, and/or any portion thereof, etc. In some examples, various embodiments may include overlapping features. In this disclosure, the following abbreviated terminology may be employed: “e.g.” which means “for example.”
This patent application is a continuation-in-part of copending patent application Ser. No. 12/570,755, filed Sep. 30, 2009, which application claims the benefit of provisional patent application 61/194,663, filed Sep. 30, 2008, and having the title “Suspension Packaging”, the disclosures of which are incorporated by reference, as though recited in full.
| Number | Date | Country | |
|---|---|---|---|
| 61194663 | Sep 2008 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12570755 | Sep 2009 | US |
| Child | 12898840 | US |
