US20230356909A1

US20230356909A1 - Retention packaging system

Info

Publication number: US20230356909A1
Application number: US18/142,517
Authority: US
Inventors: John McDonald
Original assignee: Pac360 Design Inc
Current assignee: Pac360 Design Inc
Priority date: 2022-05-03
Filing date: 2023-05-02
Publication date: 2023-11-09

Abstract

A packaging system for packaging an article and maintaining the article therein can comprise a container, an article positioned in the container, a first anchor member positioned between the article and the container, a second anchor member positioned between the article and the container, and a resilient sheet member comprising a first portion fixed to the first anchor member and a second portion fixed to the second anchor member so as to connect the first anchor member to the second anchor member. The first and second anchor members can be captured between the article and the container so as to maintain tension in the resilient sheet member against the article.

Description

BACKGROUND OF THE INVENTIONS

Field of the Inventions

The present inventions relate to packaging systems, for example, including retention packaging systems incorporating a resilient sheet member retaining an article to be packaged or shipped against another surface within a container.

Description of the Related Art

Protective packaging devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact against the inner walls of the box which could be caused by shocks imparted to the box during loading, transit, and unloading.
In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is suspended or retained within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.
U.S. Pat. No. 11,124,348 discloses a number of inventions related to retention and suspension structures which incorporate a sheet of resilient material heat sealed to corrugated cardboard. In the designs disclosed in the U.S. Pat. No. 11,124,348 patent, the resilient sheet is attached to a piece of foldable cardboard so that the resilient material is tensioned by folding the cardboard, and for example, the resilient sheet material is stretched around the article. SUMMARY OF THE INVENTIONS
At least one of the inventions disclosed herein includes the realization that retention and suspension type packaging systems can be improved, in terms of reduced cost, by incorporating a design in which the ends of resilient sheet members are anchored within a container by relatively stiffer members that are captured within the container, due to their size and configuration, without the need of otherwise being directly attached to each other. For example, a packaging system can include a resilient sheet member attached to first and second anchor members that are made from a material that is stiffer than the resilient sheet material. In use, the anchor members can be entirely independent of one another, except for being connected by way of the resilient sheet member. With an appropriate configuration, the anchor members can be inserted into a container in such a way that they are captured in a position in which the resilient sheet member is stretched over the article in a way that maintains the article in a desired orientation within the container.
An aspect of at least one of the inventions disclosed herein includes the realization that sizing of the anchor members relative to the container and the article to be packaged can result in sufficient capturing or constraint of the movement of the anchor members in use, without the need for additional rigid members or corrugated cardboard within the container. For example, aspect of at least one of the inventions disclosed herein includes the realization that sizing an anchor member to have overall effective dimensions, for example, a height that is less than the height of a sidewall of a container and a width that is less than a width of the sidewall of the container, the anchor member can be received within a space between a portion of the article and the sidewall of the container with the top of the container pressing the anchor member into the space so as to maintain tension in the resilient sheet member.
Another aspect of at least one of the inventions disclosed herein includes a realization that a retention assembly, which might form part of a packaging system, such as the first and second anchor members and the resilient sheet member described above, can be conveniently manufactured and stored in an efficient manner where first and second anchor members are separably attached to one another. For example, the first and second anchor members can be attached to each other along a predetermined separation location, which can optionally be in the form of a “snap tear line” or using other techniques or devices that allow the first and second anchor members to be detached from one another in a predetermined location.
In the connected state, the first and second anchor members, as well as the resilient sheet member, can be more easily stacked, packaged, shipped, counted, etc. up until the time of use. At the time of use, user can detach the first anchor member from the second anchor member, then deploy the retention assembly for use.
Thus, in some embodiments, a retention assembly, which can optionally be used as part of a packaging system, comprises a resilient sheet member, a first anchor member attached to a first end of the resilient sheet member, and a second anchor member attached to a second end of the resilient sheet member. The first and second anchor members can be separate from one another or can be connected in a detachable manner for separation at a predetermined location.
Another aspect of at least one of the inventions disclosed herein includes the realization that for some packaging solutions, based on the size of the container and the size of the article used, the desired length of the resilient sheet member is longer than the sum of certain dimensions of the first and second anchor members. Thus, in some embodiments, a retention assembly can include first and second anchor members attached to each other with a third member positioned between the first and second anchor members, optionally in a co-planar orientation. The resilient sheet member is attached to the first and second anchor members. As such, the resilient sheet member can be more easily attached to the first and second anchor members, which is more easily performed with the anchor members maintained in a predetermined spaced apart and optionally coplanar, orientation.
Additionally, the first and second anchor members optionally can be attached to the third member in a detachable manner, such as with a snap tear line, or using other techniques or components. As such, the assembly, including the first and second anchor members can be more easily maintained in predetermined relative orientation and optionally, generally coplanar orientation, with the resilient sheet member attached to the first and second anchor members and lying flat against the first and second anchor members and the third member. Such a configuration can be more efficiently stored, stacked, packaged, counted, etc., until use. At the time of use, a user can detach the first and second anchor members from the third member, for packaging of an article.
Another aspect of at least one of the inventions disclosed herein includes the realization that where an additional member is connected between the first and second anchor members, such an additional member can also be used as part of a packaging solution. For example, the additional member can be sized to fit within the container into which the first and second anchor members are to be inserted. For example, the additional member can be placed against or juxtaposed to a top, bottom or sidewall of the container so as to provide extra protection for the article to be packaged.
Further, the additional member can be provided with fold lines to facilitate folding into a configuration providing an air gap, such as a raised platform. In such a configuration, the additional member can be used to maintain the article in a position spaced apart from a surface of the container to provide additional protection.
Another aspect of at least one of the inventions disclosed herein includes the realization that when first and second anchor members are used along with an additional member within a container, surfaces of the additional member can be used to provide a further anchoring or capturing effect for the first and second anchor members. For example, where an additional member is placed adjacent or juxtaposed to a first sidewall of the container, a portion of the first anchor member can be inserted into a space between the additional member and the first sidewall of the container, thereby providing an additional constraint on the movement of the first anchor member.
Thus, in some embodiments, a packaging system includes first and second anchor members attached to each other with a first resilient sheet member and a third member connecting the first and second frame members, wherein the third frame member includes fold lines configured for folding the third member into a raised platform configuration.
Another aspect of at least one of the inventions disclosed herein includes the realization that where a length of the resilient sheet member is greater than certain dimensions of the first and second anchor members, the resilient sheet member can be attached to the first and second anchor members, which are attached with a frangible connection portion, within the resilient sheet member folded onto itself so as to accommodate a slacked portion created due to the length of the resilient sheet member being greater than dimensions of the first and second anchor members. As such, the first and second anchor members can be moved through a heat sealing machine in the attached state and the folded portion of the resilient member can be maintained in a position spaced away from the attachment locations and thereby preventing interference with the attachment process, which can include heat sealing or other attachment techniques.
In some embodiments, a packaging assembly for packaging an article and maintain the article therein can comprise a container, an article positioned in the container, a first anchor member positioned between the article and the container, a second anchor member positioned between the article and the container, and a resilient sheet member comprising a first portion fixed to the first anchor member and a second portion fixed to the second anchor member so as to connect the first anchor member to the second anchor member. The first and second anchor members can be captured between the article and the container so as to maintain tension in the resilient sheet member against the article.
In some embodiments, a retention assembly can comprise a first anchor member comprising a first top edge and a first bottom edge, a second anchor member comprising a second top edge and a second bottom edge, a resilient sheet member comprising a first end portion fixed to the first anchor member at a first position spaced away from the first top edge and a second end portion fixed to the second anchor member at a second position spaced away from the second top edge portion, wherein the first and second anchor members are either separate from each other or are connected to each other with a first frangible snap tear line.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the inventions disclosed herein are described below with reference to the drawings of several embodiments of the present packaging assembly kits which are intended to illustrate, but not to limit, the inventions. The drawings contain the following figures:

FIG. 1 is an exploded, perspective view of a packaging assembly in accordance with an embodiment, including container, a retention assembly including first and second anchor members connected to each other with a resilient sheet member, and an article to be packaged;

FIG. 2 is a perspective view of the packaging assembly illustrated in FIG. 1 , in an assembled state;

FIG. 3 is a schematic top plan view of the assembly of FIG. 2 , with the top removed;

FIG. 4 is a sectional view of the assembly of FIG. 3 , taken along line 4.-4.;

FIG. 5 is a sectional view of the assembly of FIG. 2 , with the lid in the closed position, and taken along line 5.-5. of FIG. 3 ;

FIG. 6 is a top plan view of an optional embodiment of the anchor member and resilient sheet of FIG. 1 in which the first and second anchor members are attached with a detachable portion;

FIG. 7 is another embodiment of the assembly of FIG. 6 , in which the anchor members include additional fold lines for changing effective dimensions of the first and second anchor members;

FIG. 8 is another alternative embodiment of the embodiment of FIG. 7 , in which the resilient sheet member has a longer size and includes a portion folded onto itself for accommodating the extra length of the resilient sheet member;

FIG. 9 is a perspective view of the embodiment of FIG. 8 ;

FIG. 10 is a perspective of the embodiment of FIGS. 8 and 9 with the anchor members separated from each other and folded along the optional fold lines;

FIG. 11 is a perspective view of the embodiment of FIG. 10 inserted into the container and with the resilient sheet stretched over the article in the container;

FIG. 12 is a top plan view of a further embodiment of the assembly of FIG. 1 , including first and second anchor members attached with a third member and with a resilient sheet member attached across the first and second anchor members and the third member;

FIG. 13 is a perspective view of the embodiment of FIG. 12 ;

FIG. 14 is a perspective exploded view of the embodiment of FIG. 13 , with the first and second anchor members and the third member separated from one another and with the third member folded into a raised platform configuration;

FIG. 15 is a perspective view of the embodiment of FIG. 14 inserted into a container;

FIG. 16 is a top plan view of the embodiment illustrated in FIG. 15 ;

FIG. 17 is a sectional view of the embodiment of FIG. 15 taken along line 17.-17. of FIG. 16 , and with the lid in the closed position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An improved packaging system is disclosed herein. The packaging system includes an improved structure which provides new alternatives to known suspension packaging systems.
In the following detailed description, terms of orientation such as “top,” “bottom,” “front,” “upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,” “midpoint,” and “end” may be used here to simplify the description in the context of the illustrated embodiments. Because other orientations are possible, however, the present inventions should not be limited to the illustrated orientations. Additionally, the term “suspension” is not intended to require that anything, such as an article to be packaged, is suspended above anything. Rather, the terms “suspended” as used herein, is only intended to reflect that such an article is held in a position spaced from another member, such as at least some of the walls of a container or box. Those skilled in the art will appreciate that other orientations of various components described herein are possible.
With reference to FIG. 1 , a packaging assembly 100 includes a container 102, an article 104, and a retention assembly 106. The article 104 can be any type of body or product that is intended to be stored or shipped in a protected manner. For example, the article 104 can be in the form of a handheld communication device, modem, a hard drive, laptop computer, or other products with less rectangular shapes, including cylindrical, spherical, or other sculptural shapes. Thus, although the article 104 illustrated herein has the appearance of a generally rectangular box, the embodiments disclosed herein can be used with an article 104 of any shape or size.
The container 102 can have any type of configuration including those of boxes designed as display boxes, shipping boxes, or boxes for temporary storage. The illustrated container 102 includes a bottom 110, a first sidewall 112, a second sidewall 114, a third sidewall 116, a fourth sidewall 118, and a top 120. The top 120, which can be considered as a lid, is attached to the first sidewall 112 and so as to be foldable between opened and closed positions. However, the top 120 can be attached or detached in any known fashion. Additionally, the container 102 can be made from a single or multiple pieces of material. In some embodiments, the container 102 is made from corrugated cardboard. However, but without limitation, the container 102 can be made from any of various materials, including but without limitation, paper, cardboard, corrugated cardboard, plastic, and other appropriate materials. The chosen material for constructing the container 102 can be any material appropriate for serving as the structural components of a storage or shipping container, and thus is stiffer than the resilient sheet member of the retention assembly 106 (described below).
Further, the container 102 and various parts thereof can have any dimensions, as desired. For example, the dimensions of the container 102 can be chosen based on the corresponding dimensions of the article 104 to be contained within the container 102. In the illustrated embodiment, the first and second sidewalls 112, 114 have approximately the same dimensions, including a width 122 and a height 124. Similarly, the third and fourth sidewalls 116, 118 have a width 126 and the height 124. As such, the bottom 110 has a length 126 and a width 122. The top 120 can have approximately the same dimensions as the bottom 110.
As illustrated herein, the container 102, including the component sidewalls 112, 114, 116, 118, the bottom 110, and the top 120 are illustrated in a single wall thickness. However, the container 102 or any component thereof can be formed from double or more layers of the material. A description of the interactions between the retention assembly 106, the container 102, and the article 104 below are described herein are described in terms of relative sizes and interactions with the inner surfaces of the container 102. Thus, all of the dimensions of the container 102, including the dimensions 122, 124, and 126 can be considered as internal dimensions of the container 102.
The bottom 110 and sidewalls 112, 114, 116, 118 of the container 102 form an internal cavity 130, which can also be considered as an enclosed interior space. As noted above, the top 120 can be moved between the illustrated open position, and a closed position in which the top 120 is disposed over the bottom 130 spaced apart by approximately the height 124 with portions of the top 120 either spaced adjacent to or covering the top edges of the sidewalls 112, 114, 116, 118.
With reference to FIGS. 2, 3, and 4 , the article 104 to be contained within the container 102, as noted above, can have any shape. Regardless of the shape of the article 104, for purposes of the following description, the article 104 can have a first side portion 140, second side portion 142, a third side portion 144, a fourth side portion 146, a top portion 148, and a bottom portion 150. As illustrated in FIG. 2 , when the article 104 is placed within the cavity 130, the first side portion 140 is juxtaposed to the first sidewall 112 of the container 102, a second side portion 142 is juxtaposed to the second sidewall 114, the third side portion 144 is juxtaposed to the third sidewall 116 and the fourth side portion 146 is juxtaposed to the fourth sidewall 118. Similarly, the bottom portion 150 (not illustrated in FIG. 2 ) is placed on or juxtaposed to the bottom 110 of the container and finally when the lid 120 is moved to the closed position (FIG. 4 ), the top 120 is juxtaposed to the top portion 148 of the article 104.
With continued reference to FIG. 1 , the retention assembly 106 can include a first anchor member 160, a second anchor member 162 and a resilient sheet member 164. Similarly to the container 102, the anchor members 160, 162 can be made from any material. In some embodiments, the anchor members 160, 162 are made from a paper or cardboard material which can include, but without limitation, paper, cardboard, corrugated cardboard, plastic, or other appropriate materials. The chosen material for constructing the anchor members 160, 162 and other embodiments of those described herein, can be any substantially rigid material common, and in some embodiments, a foldable material. In embodiments using layered cardboard products, the material forming the anchors 160, 162 can have outer layers formed from plastics or paper based or wood based materials. Such materials can include, for example, pulp, cardboard, cartonboard, paperboard, paper, chipboard, and other such paper based and wood based materials known to those in the art. The outer layers can be formed from other materials such as plastics including high density polyethylene (HDPE), low density polyethylene (LDPE), polyvinyl chloride (PVC), nylon, composites such as fiberglass, metals and any other such material as used by those in the art. The outer layers can be porous, including the fibrous materials and plastic materials described above, with the porosity chosen to enhance sealing between the frame member and between the anchor members 160, 162 and the resilient sheet member 164.
The inner layers of the material used for forming embodiments of the anchor members 160, 162 with corrugated carboard can have a corrugated structure. For example, such a corrugated structure of the inner layer can include those used for producing fluted cardboard such as, but not limited to, “A-flute,” “B-flute,” “C-flute,” “D-flute,” and “E-flute” cardboard. Other types of corrugated structures using cardboard packaging similar devices can also be used.
The anchor member 160 can include a top edge 170, a bottom edge 172, a first lateral edge 174, and a second lateral edge 176. As such, the first anchor member 160 includes an overall effective width 177 and an overall or effective height 175.
In the illustrated embodiment, the anchor member 160 is attached to the resilient sheet member 164 at an attachment portion 178 (illustrated in cross-hatching). The connection portion 178 is spaced from the top edge 170 by a spacing 179. The attachment portion 178 is generally closer to the bottom edge 172 than the top edge 170.
Similarly, the anchor member 162 includes a top edge 180, a bottom edge 182, a first lateral edge 184, and a second lateral edge 186. The anchor member 162 can have approximately the same end width as the height 175 and width 177 of the first anchor member 160. Additionally, the anchor member 162 can include an attachment portion 188 at which the retention sheet member 164 is attached to the anchor member 162.
The resilient sheet member 164 can be made from any type of resilient material. In some embodiments, the resilient sheet member 164 can be formed of one or more layers of polyethylene films, low density polyethylene (LDPE), polyurethane, TPU, or virtually any polymer, or plastic film. Density of the layers used for the resilient sheet member 164 can be varied to provide the desired retention characteristics such as overall strength, resiliency, and vibrational response. Preferably, the density of the material used to form the resilient sheet member 164 is chosen such that the resilient sheet member 164 is substantially resilient when used to package a desired article 104.
In the illustrated embodiment, the resilient sheet member 164 includes a first end portion 190 attached or fixed to the first anchor member 160 and a second end portion 192 attached or fixed to the second anchor member 162. The portion of the resilient sheet member 164 between first and second end portions 190, 192 has a length 194. Portions 190, 192 can be attached to the anchor members 160, 162 using any known technique, including that disclosed in U.S. Pat. No. 11,124,348 with reference to the drawings of FIGS. 5-14B including the description of the system 400 described the specification of U.S. Pat. No. 11,124,348 at column 10, line 59—column 23, line 34, the entire contents of which is hereby expressly incorporated by reference. With regard to embodiments where the anchor members 160, 162 are made from fibrous material, such as but not limited to, corrugated cardboard, and where the resilient sheet member 164 is made from polyurethane, polyethylene, polypropylene, or polystyrene, the temperatures, times and pressures that can be used for heat sealing the resilient sheet member 164 to the anchor members 160, 162 is disclosed at column 22, line 34—column 23, line 30 of the U.S. Pat. No. 11,124,348, which is hereby incorporated by reference.
In some embodiments, the anchor members 160, 162 can have shapes that are about the same as or smaller than sidewalls of the container 102 to which they would be juxtaposed in use. For example, but without limitation, the anchor members 160, 162 can be configured to be juxtaposed to sidewalls 112, 114, respectively, in use. As such, the width 177 of the anchor members 160, 162 can be approximately equal to or less than the width 122 of the sidewalls 112, 114. Similarly, the height or effective height 175 of the anchor members 160, 162 can be approximately the same as or less than the height 124 of the sidewalls 112, 114. As such, the anchor members 160, 162 can be considered as being configured to be received within the cavity 130 juxtaposed to the sidewalls 112, 114 respectively.
For example, with reference to FIG. 2 , the article 104 has been placed in the cavity 130 with the bottom portion 150 of the article 104 resting on the bottom 110 of the container 102. In this orientation, the first side portion 140 of the article 104 is juxtaposed to and spaced from the sidewall 112, the second portion 142 is juxtaposed to the sidewall 114, the third side portion 144 is juxtaposed to the sidewall 116, and the fourth side portion 146 is juxtaposed to the sidewall 118. Additionally, the top portion 148 is juxtaposed to the top 120 when the top 120 is in the closed position (FIGS. 4 and 5 ).
With continued reference to FIG. 2 , the retention assembly 106 has been inserted into the cavity 130 and the first anchor member 160 is positioned between the sidewall 112 and the first side portion 140. Similarly, the second anchor member 162 is positioned between the sidewall 114 and the second side portion 142. Additionally, the top edge 170 of the first anchor member 160 and the top edge 180 of the second anchor member 162 are disposed adjacent the top 120 (when the top 120 is in the closed position, FIGS. 4 and 5 ). Thus, attachment portions 178 and 188 of the first and second anchor members 160, 162 are spaced away (downwardly) from the top 120. As such, with the anchor members 160, 162 in the illustrated position, the resilient sheet member 164 is stretched across the top portion 148 of the article 104 with the ends 190, 192 of the resilient sheet member 164 secured at a position in the cavity 130, lower than the upper portion 148 of the article 104.
As shown in FIG. 5 , with the anchor members 160, 162 having an effective height 175 and width 177 (FIG. 1 ) that are approximately equal to or smaller than the height 124 and width 122, respectively, the anchor members 160, 162 can be captured in the space between the sidewall 112 and the first side portion 140 and between the sidewall 114 and the second side portion 142 even though the anchor members 160, 162 may have some degree of movement. For example, as illustrated in phantom line in FIG. 5 , because the effective thickness of the anchor members 160, 162 may be smaller than the larger spacing between the article 104 and the sidewalls 112, 114, the anchor members 160, 162 can still be effectively captured in those spaces.
For example, as shown in FIG. 5 , the top edges 170, 180 of the anchor members 160, 162 are pressed downwardly in the direction of arrow D, by contact with the top 120, against the tension generated in the resilient sheet member 164. As such, the top 120 presents a restraint on the available range of movement of the anchor members 160, 162. In use, tension is created in the resilient sheet member 164, for example, generating a pulling force in the direction of arrows T. As such, if the tension (in the tension direction T) illustrated in FIG. 5 , were to dislodge the anchor members 160, 162 from the positions illustrated in solid line, such tension might cause the anchor member 160 to pivot counterclockwise illustrated phantom line, around the top edge 170, until making contact with the article 104. Similarly, the tension T might cause the anchor member 162 to pivot clockwise (as viewed in FIG. 5 ) about the top edge 180 to the position illustrated in phantom line in FIG. 5 , making contact with the article 104.
In this scenario, the article 104 itself presents a constraint on the available range of movement of the anchor members 160, 162. As such, the anchor members 160, 162 remain in the spaces between the article 104 and the sidewalls 112, 114, with the ends 190, 192 of the resilient sheet member 164 maintained at a position lower than the upper portion 148 of the article 104. As such, the top 120 and the article 104 provide constraints on the movement of the anchors 160, 162 that are sufficient to maintain tension in the resilient sheet member 164. Those that are skilled in the art can choose a material for the resilient sheet member 164 and relative dimensions of the container 102, the resilient sheet member 164 and the anchor members 160, 162 to result in the desired retaining force of the article 104 desired position within the container 102.
The embodiment of the retention assembly 106 illustrated in FIG. 1 includes two anchor members 160, 162 which are separate and independent from one another, except for being connected together by the resilient sheet member 164. In other words, the anchor members 160, 162 are only connected together by the resilient sheet member 164.
FIG. 6 illustrates a modification of the retention assembly 106, identified generally by the reference numeral 206. Parts, features, components of the retention assembly 206 can be the same or similar to the retention assembly 106 are identified with the same reference numeral, except that “100” has been added thereto.
As illustrated in FIG. 6 , the retention assembly 206 includes a first anchor member 260 and a second anchor member 262 attached to one another with a detachable portion 261. The detachable portion 261 can be formed with any type of technique or device for allowing the anchor members 260, 262 to be attached to each as a result of manufacturing and for storage, stacking, or packaging purposes, and then detached for use. For example, the detachment portion 261 can be configured to maintain the anchor members 260, 262 in a predetermined orientation, including but not limited to the aligned relative orientation illustrated in FIG. 6 . Optionally, the predetermined relative orientation be include the outer surfaces of the anchor members 260, 262 being in a generally flat and coplanar arrangement. Additionally, the detachable portion 261 can be configured to allow the anchor member 260 to be detached from the anchor member 262 in a reasonably reproduceable manner resulting in the predetermined desired sizing of the anchor members 260, 262.
For example, the anchor members 260, 262 can be formed from a single piece of cardboard, including but without limitation a corrugated cardboard, with the detachable portion 261 in the form of a score line, which can be considered as forming a frangible portion. In some embodiments, the score line could include sufficient cutting of the material so as to form what is referred in the industry as a “snap tear” line. A snap tear line or frangible snap tear line, is known by those of ordinary skill in the art as a type of scoring for materials such as corrugated cardboard, in which the user can snap such material on a predetermined line by bending, and oftentimes by bending in a first direction by about 45 degrees or more and subsequent bending in the opposite direction by about 45 degrees or more, resulting in a rupture of the material and typically accompanied by a “snapping” sound.
As such, use of a snap tear line for the detachment portion 261 can provide the optional additional benefits of efficient construction in that no additional material is required to be added to the anchor members 260, 262 and the benefit of a toolless procedure for detaching the anchor members 260, 262. However, other techniques can also be used for forming the detachment portion 261, for example but without limitation, a line drawn with ink as an indication for a location for a user to cut the material forming the anchor members 260, 262, a crush or fold line for creating a physical and/or visual indicator for where a user should cut material to separate the anchor members 260, 262 or other devices and techniques.
In the optional embodiment of FIG. 6 , with the anchor members 260, 262 attached to one another in a generally coplanar state, the embodiment of FIG. 6 provides the optional additional advantage of simplified illustration of the anchor members 260, 262 in a manufacturing device for heat sealing the resilient sheet member 164 to the connection portions 278 and 288.
FIG. 7 illustrates yet another embodiment of the retention assembly 106, identified generally by the reference numeral 306. Parts, components, and features of the retention assembly 306 are identified with the same reference numerals as the retention assemblies 106, 206, except that an additional “100” has been added thereto.
The retention assembly 306 can provide the optional benefits of additional anchoring characteristics and/or convenient adjustability of certain dimensions of the anchor members.
For example, as shown in FIG. 7 , the anchor members 360, 362 are attached to each other along the detachable portion 361. Additionally, the anchor members 360, 362 include optional lateral fold lines 363 and 365, respectively. The fold lines 363, 365, or any fold lines described herein can be formed in any known manner. In the context of packaging, many different techniques exist for forming predetermined fold lines in materials used for packaging, including but not limited the materials listed above for forming the container 102 or anchors 160, 162. In the context of cardboard packaging materials, fold lines can be in the form of visual indicators intended for providing an indication to a user as to where a predetermined intended fold might be located. Additionally, fold lines can be in the form of physical alterations of the material itself. For example, but without limitation, the fold lines 363, 365 can be formed as perforations in the anchor members 360, 362, i.e., broken cut lines passing partially or completely through the material. As such, the broken cut lines are in the form of a localized weakening of the material. For example, the material does not provide the same resistance against bending in the area of the broken cut lines and thus can be more easily bent or folded along the broken cut lines, but without rupturing completely apart and thus retaining a substantial portion of its structural integrity. In other embodiments, or in addition to partial cuts, fold lines can be formed by crushing the material along the fold lines, which is also another way of compromising the physical integrity of the material in such a way as to facilitate easy bending or folding along a line without completely rupturing the material, and preserving a substantial portion of the physical integrity of the material such that it can still be used for packaging and remain as an integrated or attached piece of material.
In the context of the embodiments of FIG. 7 , the lateral fold lines 363, 365 can provide for a way to adjust the effective height of the anchor members 360, 362, in use. For example, if the anchor members 360, 362 were separated at the detachable portion 361, each would have an overall height of 375 from the top edge 370 to the bottom edge 372. As such, the spacing from the top edge 370 to the attachment portion 378 would be 379. Thus, in use, with the top edge 370 touching a top of a container (top 120 of container 102) one end of the resilient sheet member 164 would be secured of the dimension 379 within the container 102.
However, if the anchor member 360 were folded along the fold line 363, for example, forming approximately 90 degree bend, the effective height of the anchor member 360 would be reduced to the dimension 375A and thus the spacing 379 would be reduced to the effective spacing 379A. Folding the anchor member 362 along the fold line 365 would have the same or a similar effect.
As such, the fold lines 363, 365 provide a way for an optional reduction of the effective height of the anchor members 360, 362, the user can choose to utilize at the time of use. Leaving the fold lines 363, 365 unfolded results in a taller effective height of the anchor members 360, 362, thereby pushing the ends of the retention sheet 164 deeper into the cavity 130 of the container 102, which can be desirable for generating more tension over an article 104 to be packaged for accommodating a smaller article 104. On the other hand, folding one or both of the anchor members 360, 362 along the fold lines 363, 365 provides a shorter effective height anchor members 360, 362, which can be desirable for accommodating a larger article 104 or generating less tension in the retention sheet member 164.
Use of the lateral fold lines 363, 365 can also provide another optional advantage. For example, when the anchor members are folded along the lateral fold lines 363, 365, the contact between the top of the anchor member, which is then formed by the folded portion of the anchor members 360, 362, is larger and can provide an additional stabilizing effect of the orientation of the anchor members 360, 362 within the cavity 130, described in greater detail below with reference to FIGS. 10 and 11 .
With continued reference to FIG. 7 , the anchor members can optionally include longitudinal fold lines 367A, 367B, 369A, 369B. The longitudinal fold lines can be used for adjusting an effective width of the anchor members 360, 362. For example, in the state illustrated in FIG. 7 , the overall width of the anchor members 360, 362 is dimension 377. However, were it desired to alter the effective width of the anchor members 360, 362, the anchor members can be folded along the fold lines 367A, 367B, 369A, 369B which would thereby reduce the effective overall width of the anchor members 360, 362 to dimension 377A. Optionally, an anchor member 360 or 362 could be folded along only one of its fold lines, for example, only 369A or 369B which would result in an effective overall width being a value between dimension 377 and 377A.
Similarly, as described above with reference to the fold lines 363, 365, folding the anchor members 360, 362 along one or both of the fold lines 367A, 367B, 369A, 369B can provide additional stabilizing effect by altering a characteristic of the contact between the anchor members 360, 362 and the container 102, described in greater detail below with reference to FIGS. 10 and 11 .
FIGS. 8 and 9 illustrate yet another modification of the retention assemblies 106, 206, 306, identified generally by the reference numeral 406. Parts, components, and features of the retention assembly 406 that are similar or the same as those of the retention assemblies 106, 206, or 306, are identified with the same reference numeral, except that an additional “100” has been added thereto.
With continued reference to FIGS. 8 and 9 , the retention assembly 406 includes anchor members 460, 462 as described above with reference to the embodiment of FIG. 7 , in combination with a modified resilient sheet member 464 which is longer than the sum of the heights of the anchor members 460, 462.
As noted above with reference to FIG. 6 , the length 194 of the resilient sheet member 164 between the attachment portions 278, 288 (i.e., the free or detached portion of the resilient sheet member 164) is about equal to the spacing 279 of both of the anchor members 260, 262. In the modification of FIG. 8 , the resilient sheet member 464 is substantially longer in the sum of the spacings 479. As such, in the illustrated embodiment of FIGS. 8 and 9 , the resilient sheet member 464 includes a folded portion 491 in which the resilient sheet member 464 is folded onto itself. This can provide optional benefits in the manufacturing process as well as for purposes of storage or stacking, shipping, and/or handling of the retention assembly 406.
With regard to manufacturing, the anchor members 460, 462, remaining attached to one another along the detachable portion 461, can be fed through a manufacturing machine such as that disclosed in U.S. Pat. No. 11,194,348 which is expressly incorporated herein by reference. The resilient sheet material forming the resilient sheet member 464 can be placed on top of the connected anchor members 460, 462, folded to form the folded portion 491, then heat sealed the attachment portions 478 and 482. As such, the 494 of the resilient sheet member 464 can be different than the sum of the spacings 479 of the anchor members 460, 462. As such, the length 494 of the resilient sheet member 464 can be chosen to provide the desired retention characteristics based on the size of the article 104 and the container 102. Additionally, the folded portion 491 of the resilient sheet member 464 helps provide benefits and the ease of manufacturing, storing, stacking, and handling of the retention assembly 406.
FIGS. 10 and 11 illustrate use of the retention assemblies 306, 406. As shown in FIG. 10 , the anchor members of either the retention assembly 306 or 406 can be folded along certain fold lines to change the effective height or width thereof. Although portions of the following description is directed only to the retention assembly 306, the same descriptions also apply to the retention assembly 406.
As shown in FIG. 10 , when the anchor member 360 is folded along both the fold lines 367A and 367 (FIG. 7 ), the effective height of the anchor member 360 becomes the height dimension 375A. Similarly, the effective width of the anchor member 360 becomes the width dimension 377A. The same applies to the anchor member 362. As reflected in FIG. 10 , either of the resilient sheet members 164, 464 can be used in the embodiments of FIGS. 10 and 11 .
As shown in FIG. 11 , the first anchor members 360 and the second anchor member 362 can be inserted into the cavity 130 of the container 102. The effective height 375A can be approximately the same as or smaller than the height 124 of the cavity 130. Additionally, the effective width 377A of the anchor members 360, 362 can be approximately equal to or smaller than the width 122 of the cavity 130.
Inserted into the positions illustrated in FIG. 11 , the folded portions of the anchor members 360, 362 can provide additional contact with internal portions of the container 102 and thus can provide additional stability for the anchor members 360, 362. For example, as illustrated in FIG. 11 , with the anchor member 360 folded along the fold line 363, an enlarged top wall portion 363A is formed, which has an upper surface facing upwardly and thus oriented to be juxtaposed to and make contact with the top 120 (when in the closed position). Additionally, with the anchor member 360 folded along fold lines 367A and 367B, additional sidewall portions 367A(1), 367B(1) are formed on lateral sides of the anchor member 360. These additional wall portions 367A(1) and 367B(1) can provide additional contact with sidewalls 118 and 116, respectively, of the container 102 and thus provide additional stability. The same applies to any folded portions of the anchor member 362, although not illustrated in FIG. 11 .
FIGS. 12-17 illustrate yet another modification of the retention assemblies 106, 206, 306, and 406 identified generally by the reference numeral 506. Parts, components, and features of the retention assembly 506 that are the same as or similar to those of the retention assemblies 106, 206, 306, or 406, are identified with the same reference numeral, except that an additional “100” has been added thereto.
The retention assembly 506 can provide an optional dual benefit of spacing apart the anchors 560, 562 in a predetermined orientation and also connecting them together. For example, with reference to FIG. 12 , the retention assembly 560 includes an intermediate portion 559 connecting the anchor member 560 to the anchor member 562. In the illustrated embodiment, the intermediate portion 559 can be the same material is that used to form the anchor members 560, 562. The intermediate portion 559 is attached to the anchor member 560 with a detachable portion 561A and is attached to the anchor member 562 with a detachable portion 561B. The detachable portions 561A, 561B can be formed in any of the above-described techniques, and in some embodiments, is a snap tear line formed in corrugated cardboard.
The length 557 of the intermediate portion 559 can be chosen to provide the desired result. For example, in some embodiments, the length 557 of the intermediate portion 559 is chosen such that the resilient sheet member 164 lies flat against the anchor members 560, 562 when the intermediate portion 559 is connected as illustrated in FIG. 12 . However, optionally, a longer resilient sheet member with a folded portion, such as the resilient sheet member 464 can also be used with the embodiment of FIG. 12 .
Similarly, the width 596 of the intermediate portion 559 can also be chosen to provide other functions or uses. For example, the width 596 can be chosen to be the same as the width of the anchor members 560, 562 at the connections along the detachable portions 561A, 561B, which is illustrated in the embodiment of FIG. 12 . Additionally, the width 596 of the intermediate portion 559 can be chosen to conform to the container 102 for additional protection for the article 104, or for other uses. For example, the width 596 and length 557 of the intermediate portion 559 can be chosen to be smaller than corresponding dimensions of the bottom 130, or the top 120 (FIG. 1 ) such that the intermediate portion 559 can be used to provide an effective double wall configuration in use for packaging the article 104.
Optional additional benefits can also be provided where the intermediate portion 559 is configured to be shaped into a raised platform. For example, the intermediate portion 559 can include optional lateral fold lines 597A, 597B such that longitudinal edge portions of the intermediate member 559 can be folded, for example, to a 90 degree angle, described in greater detail below with reference to FIG. 14 . Additionally, the intermediate portion can include longitudinal fold lines 598A, 598B, configured to allow lateral edge portions, the intermediate portion 559 to be folded to approximately a 90 degree angle, described in greater detail below with reference to FIG. 14 .
When folded as described above, the effective length of the intermediate portion 559 is reduced to the length 557A and the width of the intermediate portion 559 is reduced to width dimension 596A.
With reference to FIG. 14 , the intermediate portion 559 is illustrated in the folded configuration in which edge portions are folded about the lateral fold lines 597A, 597B and edge portions are folded about the longitudinal fold lines 597A, 597B such that the intermediate portion 549 is transformed into a raised platform configuration. For example, the height 1000 of the raised platform formed by the intermediate portion 559 is defined by the spacing between the fold lines and the extreme edges of the material forming the intermediate portion 559. Optionally, the intermediate portion 559 can include additional cut lines or snap tear lines for convenient removal of the four (4) corners of the intermediate portion 559, on the outer sides of the four (4) intersections of the fold lines 1) 597A, 598B, 2) 597A, 598A, 3) 597B, 598A, and 4) 597B, 598B. Such removal, although not required, can facilitate easier folding of the intermediate portion 559 into the raised platform configuration. Additionally, in some embodiments, the intermediate portion 559 can include additional score lines (not illustrated) to provide additional flexation in use.
In use, the intermediate portion 559 can be placed into the internal cavity 130 so as to provide a raised platform or a raised support platform therein having an upper surface 1002 that is spaced above the bottom 110 of the container 102. The article 104 can be placed on top of the surface 1002 and thus be spaced above a bottom 110 by the height 1000, with an air gap. The anchor members 560, 562 and the resilient sheet member 164 can then be placed over the article 104.
In some embodiments, the effective width 596A of the intermediate portion 559 can be less than the effective width 577A of the anchor members 560, 562. For example, in some embodiments, the effective width 596A of the folded intermediate portion 559 can be sufficiently smaller than the effective width 577A of the anchor members 560, 562 that the intermediate portion 559 can be nested within anchor members 560, 562. Similarly, the dimensions of the intermediate portion 559, and optionally the locations of the lines 597A, 597B can be chosen such that the effective length 557A of the intermediate portion 559, when folded, is less than the length 126 of the cavity 130. Additionally, the dimensions of the intermediate portion 559 can be chosen such that the effect of length of line 557A is sufficiently smaller than the length 126 such that the anchor members 560, 562 can fit in spaces between the ends of the intermediate portion 559 and the walls 112, 114 of the container 102.
For example, as shown in FIG. 16 , the effective width 596A (FIG. 14 ) of the intermediate portion 559 is sufficiently small so as to fit between the anchor members 560, 562 folded about the longitudinal fold lines 567A, 567B, 569A, 569B (FIG. 12 ).
Additionally, with reference to FIG. 17 , the effective length 557A of the intermediate portion 559 is sufficiently less than the length 126 of the cavity 130 that spaces 1004, 1006 are formed between the intermediate portion 559 and the sidewalls 112, 114 of the container 102. The dimensions of the intermediate portion 559 can be chosen such that the spaces 1004, 1006 are sufficiently large that a portion of the anchor members 560, 562 can fit into the spaces 1004, 1006 respectively.
As such, the anchor members 560, 562 can be inserted into the cavity 130 and optionally, into spaces between the outer surfaces of the intermediate member portion 559 and the inner surfaces of the walls 112, 114, 116, 118 into the orientation illustrated in FIG. 17 . With the top 120 in place, upper edges of the anchor members 560, 562 are pressed downwardly into the cavity 130 so as to generate tension in the resilient sheet member 164. Additionally, portions of the anchor members 560, 562 extending into the spaces 1004, 1006, can provide additional restraints on the movements of the anchor members 560, 562, thereby providing optional additional stability to the retention of the article 104 against the intermediate portion 559.
While several embodiments are presented in the foregoing detailed description, a vast number of variations exist. The embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description provides those skilled in the art with a convenient road map for implementing the described embodiments. Various changes can be made in the function and arrangement of elements without departing from the scope defined by the claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.

Claims

What is claimed is:

1. A packaging assembly for packaging an article and maintaining the article therein, the packaging assembly comprising:

a container comprising a top, a bottom, and first, second, third and fourth sidewalls, wherein the top is configured to be moved between opened and closed positions, wherein in the closed position, the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall form an enclosed interior space;

an article comprising a first side portion, a second side portion, a top portion and a bottom portion, wherein the article is positioned in the enclosed interior space, between the top, bottom, first sidewall, second sidewall, third sidewall, and fourth sidewall, with the first side portion juxtaposed to the first sidewall, the second side portion juxtaposed to the second sidewall, the top portion juxtaposed to the top, and the bottom portion juxtaposed to the bottom;

a first anchor member positioned between the article and the first sidewall, the first anchor member having a first shape with a first height and a first width smaller than those of the first sidewall;

a second anchor member separate from the first anchor member positioned between the article and the second sidewall, the second anchor member having a second shape with a second height and a second width smaller than those of the second sidewall; and

a resilient sheet member comprising a first portion fixed to the first anchor member and a second portion fixed to the second anchor member so as to connect the first anchor member to the second anchor member;

wherein the first anchor member is captured between first side portion of the article, the top, the bottom, the first sidewall, the third sidewall and the fourth sidewall and the second anchor member is captured between the second side portion of the article, the top, the bottom, the second sidewall, the third sidewall and the fourth sidewall such that the resilient sheet member is stretched over the top portion of the article with the top pushing the first and second anchor members downwardly so as to maintain tension in the resilient sheet member.

2. The packaging assembly of claim 1 additionally comprising a platform member between the bottom portion of the article and the bottom of the container, the platform member maintaining a spacing between the bottom portion of the article and the bottom of the container.

3. The packaging assembly of claim 2, wherein the platform member comprises a first side surface juxtaposed to the first sidewall and a second side surface juxtaposed to the second sidewall, a lower portion of the first anchor member being positioned between the first side surface and the first sidewall and a lower portion of the second anchor member being positioned between the second side surface and the second sidewall.

4. A packaging assembly for packaging an article and maintaining the article therein, the packaging assembly comprising:

a container;

an article positioned in the container;

a first anchor member positioned between the article and the container;

a second anchor member positioned between the article and the container; and

wherein the first and second anchor members are captured between the article and the container so as to maintain tension in the resilient sheet member against the article.

5. The packaging assembly of claim 4, wherein the container comprises atop, a bottom, and first, second, third and fourth sidewalls, and an enclosed interior space.

6. The packaging assembly of claim 5 additionally comprising a platform member between a bottom portion of the article and the bottom of the container, the platform member maintaining a spacing between the bottom portion of the article and the bottom of the container.

7. The packaging assembly of claim 6, wherein the platform member comprises a first side surface juxtaposed to the first sidewall and a second side surface juxtaposed to the second sidewall, a lower portion of the first anchor member being positioned between the first side surface and the first sidewall and a lower portion of the second anchor member being positioned between the second side surface and the second sidewall.

8. The packaging assembly of claim 5, wherein the first anchor member comprises a first shape with a first height and a first width smaller than those of the first sidewall, wherein the second anchor member is separate from the first anchor member and comprises a second shape with a second height and a second width smaller than those of the second sidewall.

9. The packaging assembly of claim 5, wherein the first anchor member is captured between a first side portion of the article, the top, the bottom, the first sidewall, the third sidewall and the fourth sidewall and the second anchor member is captured between a second side portion of the article, the top, the bottom, the second sidewall, the third sidewall and the fourth sidewall such that the resilient sheet member is stretched over a top portion of the article with the top pushing the first and second anchor members downwardly so as to maintain tension in the resilient sheet member.

10. The packaging assembly of claim 4, wherein the first and second anchor members are made from corrugated cardboard.

11. A retention assembly, comprising:

a first anchor member comprising a first top edge and a first bottom edge;

a second anchor member comprising a second top edge and a second bottom edge; and

a resilient sheet member comprising a first end portion fixed to the first anchor member at a first position spaced away from the first top edge and a second end portion fixed to the second anchor member at a second position spaced away from the second top edge portion;

wherein the first and second anchor members are either separate from each other or are connected to each other with a detachable portion.

12. The retention assembly of claim 11, wherein the first anchor member comprises a first length between the first position and the first top edge, the second anchor member comprising a second length between the second position and the second top edge, and the resilient member comprising a third length between the first and second positions that is greater than a sum of the first and second lengths.

13. The retention assembly of claim 12, wherein the first top edge and second top edge are connected to each other with a first frangible snap tear line and the resilient sheet member is folded onto itself to accommodate the third length being greater than the sum of the first and second lengths.

14. The retention assembly of claim 11 wherein the first and second anchor members are made from corrugated cardboard, the retention assembly further comprising a third member made of corrugated cardboard and comprising a first edge connected to the first top edge along the detachable portion and a second side edge connected to the second top edge along a second detachable portion, so as to connect the first and second anchor members together.

15. The retention assembly of claim 14, wherein the third member comprises a plurality of fold lines arranged such that the third member can be folded into a raised support platform.

16. The retention assembly of claim 11, wherein the first anchor member comprises a first fold line spaced from the first top edge such that an effective height of the first anchor member can be shortened by folding the first anchor member at the first fold line.

17. The retention assembly of claim 11, wherein the first anchor member, the second anchor member and the resilient member are configured to retain a position of an article within a container with the first anchor member captured between a first side portion of the article, a top, a bottom, a first sidewall, a third sidewall and a fourth sidewall of a container, and with the second anchor member captured between a second side portion of the article, the top, the bottom, the third sidewall, the fourth sidewall, and a second sidewall of the container, such that the resilient sheet member is stretched over a top portion of the article with the top of the container pushing the first and second anchor members downwardly into the container so as to maintain tension in the resilient sheet member.

18. The retention assembly of claim 11, wherein the detachable portion comprises a first frangible snap tear line.