PACKAGING ITEMS WITH TENSIONABLE RETENTION ELEMENTS
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S.
Provisional Patent Application No. 60/199,419, filed on April 24, 2000.
BACKGROUND OF THE INVENTION The invention relates to packaging in general, and, more particularly, to packaging boxes and/or inserts for accommodating an item or items in a secure manner.
One example of a prior art insert is shown in Figure 1. The insert includes a panel (such as corrugated cardboard) with a center base section 10 and two side sections 20 and 22. A plastic film 30 extends across the center base section 10 and is adhered to side section 20 and 22 at the glue strips 40. To operate this design, side sections 20 and 22 are folded upwardly about fold lines 50 and 52, lifting the film 30 to accommodate one or more product (s) between the center base section 10 and the film 30. Then, side sections 20 and 22 are folded downwardly about fold lines 50 and 52 until they are underneath and substantially flat against center base section 10. The downward folding of side sections 20 and 22 stretches and tensions the film 30 about the product (s) . The tensioning of the film 30 securely holds the product (s) between the center base section 10 and the film 30.
In this example, the insert has a series of fold lines 60, 62, 64 and 66 which allow the insert to be folded around the product (s) . A tab 70 is provided for insertion into a slot 72 to secure the insert in the folded position. As can be seen in Figure 1 , the arrangement of the glue strips 40 forms two pockets 80 and 82 for accommodating the product (s) . When the insert is folded around the product (s) , the two pockets 80 and 82 face each other.
Alternative prior art arrangements of glue strips 42, 44, 46 and 48 are illustrated in Figures 2 through 5. These provide different formations of the pockets.
In addition to the above-referenced prior art, the following representative patents in this area are incorporated by reference herein: U.S. Patent Nos . 3,905,474 to Haibara; 5,259,507 to Smith; 5,323,896 to Jones; 5,676,245 to Jones;
5,678,695 to Ridgeway et al . ; 5,694,744 to Jones; 6,010,006 to Ridgeway et al . ,- 6,148,590 to Ridgeway et al . ,- and 6,148,591 to Ridgeway et al .
OBJECT AND SUMMARY OF THE INVENTION
An object of the invention is to provide alternative arrangements for securing items being shipped in packaging boxes .
In accordance with an embodiment of the invention, a packaging box or insert is provided with a tensionable retention or resilient element. The tensionable retention or resilient element is capable of holding down, supporting and/or suspending an item or items being shipped.
The tensional retention or resilient element may take many forms. For example, it may be in the form of a plastic film. Other suitable materials include fabrics, cellulose, rubbers, polymers, and any other material providing the desired pliability, elasticity, and/or flexibility. The shape of the tensionable retention or resilient element may be in the form of a sheet, tube, pocket or any other suitable configuration. It may also have additional features, such as slits, holes, or punctures to allow the desired result with respect to the item or items to be secured.
As an example, the invention may be in the form of a packaging insert having a panel (such as corrugated cardboard, or other suitable material) with a base section, one or more foldable side sections, and one or more foldable spacer flaps. One or more tabs may project from one or more side sections. A plastic film extends across the base section and is adhered on one side to a side section and on the other side to one or more tabs .
To operate such a design, one or more of the side sections is folded upwardly about suitable fold lines, lifting the film to accommodate one or more product (s) between the base section and the film. Then, the side sections are folded downwardly about suitable fold lines until they are underneath and substantially flat against the base section. The downward folding causes one or more tabs to swing approximately 180 degrees, stretching and tensioning the film. On the other side, the downward folding of the side section also tensions the film. Once the side sections are underneath and
substantially flat against base section, the spacer flaps are folded upwardly to provide spacing and/or support above the base section. The spacer flaps may be provided with notches which accommodate extensions on the base section, thereby locking the spacer flaps in the upright position.
As another example, the invention may be in the form of a packaging insert having a panel with a base section, two side sections, and two spacer flaps, with each spacer flap having two cinching flaps. A plastic film extends across the base section and is adhered to the side sections.
To operate such a design, the side sections are folded upwardly, lifting the film to accommodate one or more product (s) between the base section and the film. Then, the cinching flaps are folded upwardly, and the spacer flaps are folded upwardly, with the cinching flaps positioned on the inside of the side sections. This causes the cinching flaps to press against and cinch the film.
As another example, the invention may be in the form of a packaging insert having a panel with a base section, a single side section, and one to four spacer flaps. A plastic film extends across the base section and is adhered to the base section and to the side section.
To operate such a design, the side section is folded upwardly, lifting the film to accommodate one or more product (s) between the base section and the film. Then, the side section is folded downwardly until it is underneath and substantially flat against the base section, thereby stretching and tensioning the film. The spacer flaps are then
folded upwardly to provide spacing and/or support above the base section. As alternatives, the extent of the spacer flaps may extend beyond the width of the base section, or the extent of the spacer flaps may be coextensive with the width of the base section. The spacer flaps may be separated from the base section or respective side section by cuts, with the fold lines suitably arranged to give the desired result.
Various other examples are described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
Figures 1 through 5 show prior art configurations, as discussed above ;
Figure 6 shows a packaging insert in accordance with a first example embodiment of the present invention,-
Figure 6A shows a variation of a feature of the packaging insert shown in Figure 6 ;
Figure 7 shows a packaging insert in accordance with a second example embodiment of the present invention; Figure 8 shows a packaging insert in accordance with a third example embodiment of the present invention;
Figure 9 shows a packaging insert in accordance with a fourth example embodiment of the present invention;
Figure 10 shows a packaging insert in accordance with a fifth example embodiment of the present invention;
Figures 11 to 14 show a packaging insert in accordance with a sixth example embodiment according to the present invention;
Figures 15 to 19 show a packaging insert in accordance with a seventh example embodiment according to the present invention;
Figures 20 to 25 show a packaging insert in accordance with an eighth example embodiment according to the present invention;
Figures 26 to 29 show a packaging insert in accordance with a ninth example embodiment according to the present invention; and Figures 30 to 34 show a packaging insert in accordance with a tenth example embodiment according to the present invention.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS Figure 6 shows a design comprising a panel (such as corrugated cardboard) with a center base section A, two side sections Bl and B2 , and one to four spacer flaps CI to C4. Two tabs Dl and D2 project from side section Bl, and two tabs D3 and D4 project from side section B2. A plastic film E extends across the center base section A and is adhered to side section Bl and to the tabs D3 and D4 at the glue strips G.
To operate this design, side section Bl is folded upwardly about fold lines F5, F6 and F7, lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, side section B2 is folded downwardly about fold lines F8 , F9 and F10 until it is underneath and substantially flat against center base section
A, and side section Bl is folded downwardly about fold lines F5, F6 and F7 until it is also underneath and substantially flat against center base section A. The downward folding of side section B2 causes the tabs D3 and D4 to swing approximately 180 degrees, stretching and tensioning the film. On the other side, the downward folding of side section Bl also tensions the film, along with the action of the tabs Dl and D2 on the film. The tensioning of the film securely holds the product (s) between the center base section A and the film. Once the side sections Bl and B2 are underneath and substantially flat against center base section A, the spacer flaps CI to C4 are folded upwardly to provide spacing and/or support above the center base section A.
As an additional or alternative method of operation, one or more product (s) may be accommodated in the space between the film E and the side section Bl . In addition, the insert may be placed in a packaging box upside down, i.e., with the film side of center base section A facing down. In such an arrangement, the spacer flaps CI to C4 may be folded upwardly, i.e., away from the film side of center base section A, in order to provide spacing and/or support above the side section Bl, which accommodates the product (s) .
Figure 6A shows a variation of a feature of the packaging insert shown in Figure 6. Here, the design comprises one or more lifting tabs J cut in the side sections Bl and B2 and foldable with the spacer flaps CI to C4. It will be appreciated that when the spacer flaps are folded in one direction about the fold lines FI to F4, the lifting tabs
J move in the other direction. Thus, the lifting tabs J provide spacing and/or support on the opposite side from the spacer flaps CI to C4. It will be appreciated that the lifting tabs J may be used with any of the other embodiments with spacer flaps, as described below, and that the lifting tabs J need not be cut out of the side sections, but may be cut out of whichever panel is suitable with respect to the particular design, such as base section A.
Figure 7 shows a design substantially similar to that shown in Figure 6. This design comprises a panel with a center base section A, two side sections Bl and B2 , and one to four spacer flaps CI to C4. Two tabs D3 and D4 project from side section B2. A plastic film E extends across the center base section A and is adhered to side section Bl and to the tabs D3 and D4 at the glue strips G. The glue strip G on the tabs D3 and D4 may extend across the center base section A, as shown.
This design operates similarly to the design of Figure 6. First, side section Bl is folded upwardly about fold line F5, lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, side section B2 is folded downwardly about fold lines F8, F9 and F10 until it is underneath and substantially flat against center base section A, and side section Bl is folded downwardly about fold line F5 until it is also underneath and substantially flat against center base section A. As in the design of Figure 6, the downward folding of side section B2 causes the tabs D3 and D4 to swing approximately 180 degrees,
stretching and tensioning the film. On the other side, the downward folding of side section Bl also tensions the film. Once the side sections Bl and B2 are underneath and substantially flat against center base section A, the spacer flaps CI to C4 are folded upwardly to provide spacing and/or support above the center base section A. In this embodiment, the spacer flaps CI to C4 have notches H which accommodate extensions I on the center base section A, thereby locking the spacer flaps CI to C4 in the upright position. Figure 8 shows a drawing of an alternative design, comprising a panel with a center base section A, two side sections Bl and B2 , and two spacer flaps CI and C2. Spacer flap CI has two cinching flaps Dl and D2, and spacer flap C2 has two cinching flaps D3 and D4. A plastic film E extends across the center base section A and is adhered to side sections Bl and B2 at the glue strips G.
To operate this design, side sections Bl and B2 are folded upwardly about fold lines FI and F2, lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, cinching flaps Dl to D4 are folded upwardly about the respective fold lines F5, and spacer flaps CI and C2 are folded upwardly about fold lines F3 and F4, with the cinching flaps Dl to D4 positioned on the inside of the side sections Bl and B2. This causes the cinching flaps Dl to D4 to press against and cinch the film E, thereby tensioning the film E to secure the product (s) .
The design in Figure 9 comprises a panel with a base section A, a single side section Bl, and one to four spacer
flaps CI to C4. A plastic film E extends across the base section A and is adhered to the base section A and to the side section Bl at the glue strips G.
To operate this design, side section Bl is folded upwardly about fold line F5, lifting the film E to accommodate one or more product (s) between the base section A and the film E (or, as mentioned above, between the side section Bl and the film E) . Then, side section Bl is folded downwardly about fold line F5 until it is underneath and substantially flat against base section A, thereby stretching and tensioning the film. The spacer flaps CI to C4 are then folded upwardly to provide spacing and/or support above the base section A (or in the opposite direction, if the product is placed between the side section Bl and the film E) . The design in Figure 10 is substantially similar to that in Figure 9. The differences are that the width of the base section A is coextensive with the extent of the spacer flaps CI to C4 , the spacer flaps CI and C2 extend from the base section A and are foldable with respect to the base section A about fold lines FI and F2, and the spacer flaps C3 and C4 are separated from the side section Bl by cuts and are foldable with respect to the base section A about fold lines F3 and F4. The operation is similar to that of the design in Figure 9. The design illustrated in Figures 11 to 14 includes a panel with a center base section A, two side sections Bl and
B2 , two bottom panel sections Dl and D2 , and two spacer flaps
CI and C2. Each bottom panel section Dl and D2 extends from a
respective one of the two side sections Bl and B2 , and each bottom panel section Dl and D2 include a respective locking tab Tl and T2 having a respective slit Gl and G2. A plastic film E extends across the center base section A and is adhered to side sections Bl and B2 or bottom panel section Dl and D2 at glue strips G.
To operate this design, side sections Bl and B2 are folded upwardly about fold lines FI and F2 and/or bottom panel sections Dl and D2 are folded upwardly about fold lines F3 and F4, lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, side sections Bl and B2 are folded downwardly approximately 90 degrees about fold lines FI and F2 and bottom panel sections Dl and D2 are folded downwardly approximately 90 degrees about fold lines F3 and F4 so that the bottom panel sections Dl and D2 are approximately parallel to the center base section A, stretching and tensioning the film E. The locking tabs Tl and T2 are interlocked via the respective slits Gl and G2 as illustrated in Figure 13. Thus a space S is formed between the center base section A and the interlocked bottom panel sections Dl and D2. Then, the spacer flaps CI and C2 are folded upwardly approximately 45 degrees about fold lines F5 and F6 to provide positive closure at the unglued sides of the film E as well as to provide shock absorption and desired spacing when the packaging insert is inserted into an appropriately sized container.
The design illustrated in Figures 15 to 19 includes a panel with a center base section A, two side sections Bl and
B2, six spacer flaps CI, C2 , C3 , C4 , C5 and C6 and two spacer tabs Tl and T2 extending from a spacer tab carrier T3. A plastic film E extends across the center base section A and is adhered to side sections Bl and B2 at glue strips G. A slit H is formed in the center base section A and arranged and configured to receive the spacer tabs Tl and T2, as described below.
To operate this design, as shown in Figure 16, tab carrier T3 is folded downwardly about fold line F9, and spacer tabs Tl and T2 are folded about fold lines F10 and Fll.
Spacer tabs Tl and T2 are inserted into slit H. Side sections Bl and B2 are folded upwardly about fold lines FI and F2 , lifting film E to accommodate one or more product (s) between the center base section A and the film E. The spacer tabs Tl and T2 may be used to secure and locate the product (s) relative to the center base section A, and the opening J formed by the folding of the tab carrier T3 and the spacer tabs Tl and T2 may also be used to secure and locate the product (s) relative to the center base section A. Then, as shown in Figure 17, the side sections Bl and B2 are folded downwardly approximately 180 degrees about the fold lines FI and F2 , stretching and tensioning the film E. Then, as shown in Figures 18 and 19, each of the six spacer flaps CI, C2 , C3 , C4, C5 and C6 is folded upwardly approximately 90 degrees about a respective fold line F3 , F , F5, F6, F7 and F8. The packaging insert may then be inserted into an appropriately sized container. The several layers of the center base section A and the two side sections Bl and B2 provides shock
absorption for the product (s) accommodated by this design. The thickness of these materials as well as the arrangement of the several fold lines may provide spacing between the center base section A and the two side sections Bl and B2 , thereby providing increased shock absorption.
The design illustrated in Figures 20 to 25 includes a panel with a center base section A, two first side sections Bl and B2 , two second side sections B3 and B4, two first spacer sections CI and C2 and two second spacer sections C3 and C4. Two spacer tabs Tl and T2 extend from the center base section A, and a plastic film E extends across the center base section A andv is adhered to first side sections Bl and B2 at glue strips G.
To operate this design, as shown in Figure 21, first side sections Bl and B2 are folded upwardly about fold lines FI and F2 , lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, side sections Bl and B2 are folded downwardly approximately 180 degrees about fold lines FI and F2 , stretching and tensioning the film E. Side sections B2 and B3 are folded in an opposite direction approximately 180 degrees about fold lines F3 and F4, to form a Z-shape configuration underneath center base section A, as shown in Figure 22. Then, as shown in Figure 23, spacer sections C3 and C4 are folded about fold lines F7 and F8. Then, as shown in Figure
24, spacer sections CI and C2 are folded upwardly approximately 90 degrees about fold lines F5 and F6. As shown in Figure 25, the spacer tabs Tl and T2 extend from the center
base section A unfolded to provide positive stops for the folded spacer sections C3 and C4. Slots HI, H2, H3 and H4 may be provided in the panel for strain relief purposes. The packaging insert may then be inserted into an appropriately sized container.
The design illustrated in Figures 26 to 29 includes a panel with a center base section A, two first side sections Bl and B2 , two second side sections B3 and B4 and two spacer sections CI and C2. A plastic film E extends across the center base section A and is adhered to first side sections Bl and B2 at glue strips G. Four slots HI, H2 , H3 and H4 are formed in the panel, and eight locking tabs Tl, T2 , T3, T4 , T5, T6, T7 and T8 are formed in the panel. The arrangement of the four slots HI, H2 , H3 and H4 and the eight locking tabs Tl, T2, T3, T4, T5 , T6 , T7 and T8 permits the panel to be folded into two configurations, as described below.
To operate this design, first side sections Bl and B2 are folded upwardly about fold lines FI and F2, lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, first side sections Bl and B2 are folded downwardly approximately 180 degrees about fold lines FI and F2 , stretching and tensioning the film E. Then, to achieve the first folded configuration, which may be, for example, a configuration for use in transporting the product (s), the second side sections B3 and B4 are folded in an opposite direction approximately 180 degrees about fold lines F3 and F4. In this position, the locking tab Tl is in alignment with slot HI, locking tab T4 is
in alignment with slot H2 , locking tab T5 is in alignment with slot H3 , and locking tab T8 is- in alignment with slot H4. Then, spacer sections CI and C2 are folded upwardly approximately 90 degrees about fold lines F5 and F6, engaging each locking tab Tl, T4, T5 and T8 with the respective aligned slot HI, H2, H3, H4.
To achieve the second folded configuration, which may be, for example, a configuration for use in displaying the product (s) , neither the second side sections B3 and B4 nor the spacer sections CI and C2 are folded. Rather, when only the first side sections Bl and B2 are folded, locking tab Tl is in alignment with locking tab T2 , locking tab T4 is in alignment with locking tab T3 , locking tab T5 is in alignment with locking tab T6, and locking tab T8 is in alignment with locking tab T7. Folding the several pairs of aligned tabs, either inwardly or outwardly, maintains the panel in the second folded configuration.
The design shown in Figures 26 to 29 is particularly useful for packaging items, such as picture frames, that benefit from extra cushioning when shipped, but may be usefully displayed in their packaging without requiring much additional space.
The design illustrated in Figures 30 to 34 includes a panel with a center base section A, two first side sections Bl and B2, two second side sections B3 and B4 and one spacer sections CI . A plastic film extends across the center base section A and is adhered to side sections Bl and B2 at glue strips G. -,--
To operate this design, as shown in Figure 31, first side sections Bl and B2 are folded upwardly about fold lines FI and F2, lifting the film E to accommodate one or more product (s) between the center base section A and the film E. Then, as shown in Figure 32, first side sections Bl and B2 are folded downwardly approximately 180 degrees about fold lines FI and F2 , stretching and tensioning the film E, and second side sections B3 and B4 are folded in an opposite direction approximately 180 degrees about fold lines B3 and B4. Then, as shown in Figure 33, spacer section CI is folded upwardly approximately 90 degrees about fold line F5. It should be appreciated that a pair of panels may be used, each of the pair of panels being used to secure one of two opposite ends of the product (s), as illustrated in Figure 34. Another variation, not illustrated, is the use of more than one sheet of film. For example, two or more sheets of film could be used on the same side of the sheet, or on opposite sides of the sheet. It will be appreciated that this provides a plurality of compartments for products, such as between adjacent films, or on opposite sides of the sheet. Additionally, the film may be adhered anywhere on the sheet, e.g., on the spacer flaps CI to C4 , to create different and/or additional tensioning. Adherence to various combinations of the various panels is possible without departing from the scope of the invention.
It will be appreciated by persons of ordinary skill in the art that various other modifications may be made without departing from the scope of the invention.