US20250346389A1

US20250346389A1 - Shipping container systems

Info

Publication number: US20250346389A1
Application number: US18/660,159
Authority: US
Inventors: Brent Michael Comerford
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-05-09
Filing date: 2024-05-09
Publication date: 2025-11-13

Abstract

There is disclosed a container system comprising an outer container comprising a base and a plurality of upstanding walls, a first closure flap wherein the first closure flap overlays the base and substantially covers an opening formed by the top ends of the upstanding walls when the outer container is in a closed configuration, and wherein the first closure flap includes a retention element that extends from the closure flap downward into the cavity of the outer container when the outer container is in a closed configuration, and a suspension insert including a product retention compartment, and a plurality of suspension elements maintaining a cushion gap is on all sides of the product retention compartment when the shipping container system is in a closed configuration.

Description

BACKGROUND

Shipping products to consumers has become a vital part of our everyday lives. Shipping containers are typically designed to maximize efficiency in packing shipping vehicles. Frequently, a shipping container contains items that fill only a small portion of the volume of the container, requiring the space to be filled with other material, such as air-filled plastic pouches or shredded paper. Alternative solutions include affixing products to a piece of cardboard using plastic film of sorts and adding some pieces to cause the plastic wrapped board and product to remain positioned in the cavity of the box. Existing solutions are expensive and use excess materials, including excessive waste materials. More economical and ecologically friendly systems are needed.

SUMMARY

The present disclosure is directed to shipping container systems, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.
In some embodiments of the present disclosure, a shipping container is described. In some embodiments, the container system comprises an outer container comprising a base and a plurality of upstanding walls defining a cavity, a first closure flap extending from a top end of one of the plurality of upstanding walls opposite the base wherein the first closure flap overlays the base and substantially covers an opening formed by the top ends of the upstanding walls when the outer container is in a closed configuration, and wherein the first closure flap includes a retention element that extends from the closure flap downward into the cavity of the outer container when the outer container is in a closed configuration, and a suspension insert including a product retention compartment comprising a top section connected to a bottom section, and a suspension element extending outwardly from a first end of the product retention compartment, wherein the suspension element abuts against a first upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein a cushion gap is on all sides of the product retention compartment when the suspension insert is installed in the outer container, wherein the bottom section of the product retention compartment comprises a first bottom panel connected to a first side of the top section and folds to connect to a second side of the product retention compartment opposite the first side of the top section.
In some embodiments, the bottom section of the product retention compartment further comprises a second bottom panel connected to the second side of the top section opposite the first side of the top section, and the first bottom panel and the second bottom panel fold to connect on the bottom section of the product retention compartment.
In some embodiments, the product retention compartment has a volume when a product is inserted into the product retention compartment and the top section and the bottom section of the product retention compartment physically contact the product contained therein.
In some embodiments, the suspension insert further comprises a second suspension element extending outwardly from a second end of the product retention compartment, wherein the suspension element abuts against a second upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein the first upstanding wall and the second upstanding wall are opposite each other.
In some embodiments, the second suspension element extends from a second end of the top section of the product retention compartment, wherein the second end is opposite the first end of the top section of the product retention compartment.
In some embodiments, the first suspension element and the second suspension element exert a retention force while abutting against the first upstanding wall and the second upstanding wall of the outer container.
In some embodiments, the retention force holds the suspension insert secure in a height of the outer container and along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.
In some embodiments, the suspension element folds in at least one of an upwards direction and a downwards direction maintaining the cushion gap between the product retention compartment and the outer container.
In some embodiments, a maximum height of the suspension element when installed in the outer container is less than an interior height of the outer container.
In some embodiments, at least one of the first bottom panel and the second bottom panel further comprises a bottom suspension element abutting against at least one of the first upstanding wall and a second upstanding wall of the outer container.
In some embodiments, the suspension insert further comprises an aperture in the top section of the product retention compartment allowing visibility into the product retention compartment.
In some embodiments, the product retention compartment is substantially flat when the product retention compartment is empty.
In some embodiments, the seam on the bottom section of the product retention compartment is held together by at least one of an interlocking closure, a locking closure, a glue, a tape, a semi-permanent adhesive, a permanent adhesive, a radio-frequency (RF) welding, a heat bond, and a stitching.
The container system of claim 1, wherein the suspension element secures the suspension insert along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.
In some embodiments, the outer container and the suspension insert are formed from a single blank, wherein the suspension insert folds over a second upstanding wall of the outer container and down towards the base of the outer container maintaining the cushion gap between the suspension insert and the second upstanding wall, wherein the second upstanding wall is opposite the first upstanding wall of the outer container.
In some embodiments, the outer container is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics.
In some embodiments, the suspension insert is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics.
In some embodiments, the product retention compartment includes a selectively closeable opening.
In some embodiments, the outer container further comprises a plurality of support elements maintaining the cushion gap between the product retention compartment and the outer container.
In some embodiments, the plurality of upstanding walls comprises a third upstanding wall and a fourth upstanding wall opposite each other, wherein the third upstanding wall further comprises a first sidewall flap extending along the base of the outer container, and the fourth upstanding wall further comprises a second sidewall flap extending along the base of the outer container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a shipping container system, according to one embodiment of the present disclosure;

FIG. 2 shows another perspective view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 3 shows a cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 4 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 5 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 6 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 7 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 8 shows a bottom view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 9 shows a front view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 10 shows a rear view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 11 shows a top view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 12 shows a left-side view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 13 shows a right-side view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 14 shows an unfolded blank folded to form the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 15 shows a perspective view of a shipping container system, according to one embodiment of the present disclosure;

FIG. 16 shows a cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure;

FIG. 17 shows another cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure;

FIG. 18 shows another cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure;

FIG. 19 shows another cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure;

FIG. 20 shows a rear view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 21 shows a bottom view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 22 shows a top view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure;

FIG. 23 shows a left-side view of the shipping container system of FIG. 1 according to one embodiment of the present disclosure;

FIG. 24 shows a right-side view of the shipping container system of FIG. 1 according to one embodiment of the present disclosure;

FIG. 25 shows another front view of the shipping container system of FIG. 1 viewed from an elevated angle, according to one embodiment of the present disclosure;

FIG. 26 shows an unfolded blank folded to form the shipping container system of FIG. 1 , according to one embodiment of the present disclosure; and

FIG. 27 shows a perspective view of the unfolded blank of FIG. 12 , according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

The following description contains specific information pertaining to implementations in the present disclosure. The drawings in the present application and their accompanying detailed description are directed to merely exemplary implementations. Unless noted otherwise, like or corresponding elements among the figures may be indicated by like or corresponding reference numerals. Moreover, the drawings and illustrations in the present application are generally not to scale, and are not intended to correspond to actual relative dimensions.
FIG. 1 shows a perspective view of a shipping container system, according to one embodiment of the present disclosure. As shown in 100, the shipping container system includes outer container 110 and suspension insert 150. In a preferred embodiment, the shipping container system includes a base, a plurality of upstanding walls, and a lid. Outer container 110 may include a base, a plurality of upstanding walls, and a lid that, when in a closed configuration, define a volume. In the depicted embodiment, outer container 110 comprises a base (not visible), four upstanding walls 113, 115, 117, 119, and lid 120. As depicted, upstanding walls 113, 115, 117, 119 extend upwards from the sides of base (not visible) substantially perpendicular to base (not visible). In the depicted embodiment, upstanding walls 113, 115, 117, 119 include side wall 113 and side wall 115 on opposing sides, and front end wall 117 and back end wall 119 are on opposing ends. As depicted, base (not visible) and upstanding walls 113, 115, 117, 119 define cavity 135. In some embodiments, outer container 110 may have less than four upstanding walls. In some embodiments, outer container 110 may have more than four upstanding walls.
Outer container 110 may be arranged in an open configuration as shown in FIG. 1 . Outer container 110 may also be arranged in a closed configuration. In the depicted embodiment, a lid extends from a top end of back end wall 119. In some embodiments, the lid comprises first closure flap 120 and second closure flap 125. In a closed configuration, first closure flap 120 may be rotated about its hinged attachment to the top end of back end wall 119 so that closure flap 120 folds over towards front end wall 117 and substantially covers cavity 135 or opening defined by the top ends of upstanding walls 113, 115, 117, 119 such that outer container 110 is in a closed configuration. When in a closed configuration, outer container 110, upstanding walls 113, 115, 117, 119, and a first closure flap 120 define a volume.
In the depicted embodiment, first closure flap 120 includes retention element 121, 123 that extend from the terminal ends of a first side and a second side of first closure flap 120, wherein the first side and the second side of first closure flap 120 are opposite each other. In the depicted embodiment, when the outer container is in a closed configuration, retention elements 121, 123 may rotate about its hinged attachment to ends of the first side and the second side of first closure flap 120 so that retention elements 121, 123 fold extending downward into cavity 135 when outer container 110 is in a closed configuration. Retention elements 121, 123 may have a length less than a length of outer container 110 or substantially the same as the length of outer container 110. Retention elements 121, 123 may have a height less than a height of outer container 110 or substantially the same as the height of outer container 110.
In the depicted embodiment, the lid includes second closure flap 125 extending from a side of first closure flap 120 that is opposite the side of first closure flap 120 that is coupled to the top end of back end wall 119. In a closed configuration, second closure flap 125 substantially covers the front end wall 117 and closure tabs 127, 129 tuck into the slots formed in side walls 113, 115. Closure tabs 127, 129 may have a width less than a height of upstanding walls 113, 115, 117, 119, substantially the same as the height of upstanding walls 113, 115, 117, 119, less than a height of outer container 110, or substantially the same as the height of outer container 110.
As shown in 100, the shipping container system further includes suspension insert 150. Suspension insert 150 may be disposed within cavity 135 of outer container 110. Suspension insert 150 includes product retention compartment 160. In some embodiments, product retention compartment 160 may include a top section connected to a bottom section. In some embodiments, product retention compartment 160 may include a top, a plurality of sidewalls, and a bottom configured to contain a product for shipping. In some embodiments, product retention compartment 160 may include sidewalls between the top section and the bottom section, forming a rectangular cavity for containing a product. In some embodiments, product retention compartment 160 may include a top and a bottom connected at the sides forming a marquise shape when a product is placed into the product retention compartment 160. Product retention compartment 160 may encapsulate a product for shipping, such as a mobile phone, a tablet computer device, and the like. In the depicted embodiment, suspension insert 150 includes portal 156. In some embodiments, portal 156 may be an opening cut in the top section of product retention compartment 160. In other embodiments, portal 156 may include a translucent or transparent covering to allow visibility into product retention compartment 160 without leaving a large opening in product retention compartment 160.
In the depicted embodiment, product retention compartment 160 is empty. When product retention compartment 160 is empty, the bottom section of product retention compartment 160 may be visible through portal 156. In some embodiments, the bottom section of product retention compartment 160 may include bottom panels 167, 169, wherein a first bottom panel 167 connected to a first side of the top section, and a second bottom panel 169 connected to a second side of the top section opposite the first side of the top section, and the first bottom panel and the second bottom panel fold to connect on the bottom section of product retention compartment 160.
In the depicted embodiment, bottom panels 167, 169 connecting at seam 165 on the bottom section of product retention compartment 160 are visible through portal 156. In some embodiments, seam 165 extends along a length of the product retention compartment 160. In some embodiments, seam 165 on the bottom section of the product retention compartment 160 is held together by at least one of an interlocking closure, a locking closure, a glue, a tape, a semi-permanent adhesive, a permanent adhesive, a radio-frequency (RF) welding, a heat bond, a stitching, or any other ways to attach or lock seam 165. In some embodiments, seam 165 is an overlapping section of material from bottom panels 167, 169. In some embodiments, seam 165 is formed from bottom panels 167, 169 folding and the free edge of each of bottom panels 167, 169 joining together at seam 165.
In some embodiments, product retention compartment 160 includes a selectively closeable opening. In some embodiments, the bottom panels 167, 169 include a selectively closeable mechanism such that bottom panels 167, 169 may selectively close and open at seam 165. In some embodiments, the selectively closeable mechanism may include various types of slit closures. For example, wherein each of bottom panels 167, 169 have at least one slit perpendicular to the free edge of bottom panels 167, 169 such that bottom panels 167, 169 may interlock with each other at the corresponding slit. In another example, a first bottom panel may have a slit substantially parallel to the free edge, and a second bottom panel may have a cutout tab to insert into the slit when bottom panels 167, 169 fold to connect on the bottom section of product retention compartment 160. The selectively closeable opening allows for a product to be easily placed into and removed from product retention compartment with little to no damage to suspension insert 150.
FIG. 2 shows another perspective view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. As shown in 200, suspension insert 250 is installed in outer container 210. As depicted, suspension insert 250 includes product retention compartment 260 and suspension element 251 extending outwardly from an end of protect retention compartment 260. In the depicted embodiment, suspension element 251 extends from an end of the top section of product retention compartment 260. In some embodiments, suspension element may extend from an end of the bottom section of product retention compartment 260. In some embodiments, a plurality of suspension elements may extend from product retention compartment 260. In the depicted embodiment, when suspension insert 250 is installed in outer container 210, suspension element 251 abuts against back end wall 219 creating a cushion gap on all sides of product retention compartment 260 for maintaining the security of the product contained therein. In some embodiments, one or more suspension elements extending from one or more ends of product retention compartment 260 may abut against one or more of upstanding walls 213, 215, 217, 219 of outer container 210.
In the depicted embodiment, suspension element 251 folds in an upwards direction maintain the cushion gap between product retention compartment 260 and outer container 210. In some embodiments, suspension element 251 folds in at least one of an upwards direction and a downwards direction maintaining the cushion gap between production retention compartment 260 and outer container 210. A maximum height of suspension element 251 when installed in outer container 210 is less than a maximum interior height of outer container 210.
FIG. 3 shows a cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. As shown in 300, the shipping container system may be formed from a single blank of material. In the depicted embodiment, outer container 310 and suspension insert 350 are formed from a single blank of material. As depicted, suspension insert 350 is connected to front end wall 317 by joint element 352 and connector element 353. In the depicted embodiment, a first side of joint element 352 is connected to a top end of front end wall 317. As depicted, joint element 352 extends from a top end of front end wall 317 folding at a substantially 90-degree angle forming a flat surface at the top of front end wall 317. In the depicted embodiment, connector element 353 extends from joint element 352 folding at a substantially 90-degree angle in relation to joint element 352. In the depicted embodiment, connector element 353 extends from a second side of joint element 352 that is opposite the first side of joint element that is connected to the top end of front end wall 317. In the depicted embodiment, connector element 353 is substantially parallel to front end wall 317 when suspension insert 350 is installed in outer container 310 such that there is a cushion gap between front end wall 317 and product retention compartment 360.
In the depicted embodiment, suspension insert 350 extends along a length of an interior length of outer container 310 from front end wall 317 towards back end wall 319. A maximum length of product retention compartment 360 is less than the maximum length of the interior length of outer container 310. As depicted, product retention compartment 360 is shown in its substantially flat, unoccupied configuration. In some embodiments, a first end of product retention compartment 360 is connected to connector element 353 at a front end of outer container 310, and a second end of product retention compartment 360 is connected to suspension element 351 that abuts against back end wall 319. As depicted, connector element 353 is connected to one end of top section of product retention compartment 360, and suspension element 351 is connected to an opposite end of top section of product retention compartment 360.
Additionally, 300 shows support elements 343, 349 formed by diagonal support sections extending from the side wall 315 towards the front end wall 317 and back end wall 319, respectively. Support elements 343, 349 maintain the cushion gap between product retention compartment 360 and outer container 310. In some embodiments support elements 343, 349 may represent internal sidewall tabs. Product retention compartment 360 is shown in its flat, unoccupied configuration. When a product is installed in product retention compartment 360, the space between the top section and the bottom section of product retention compartment expands to accommodate the product.
FIG. 4 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 400 depicts cushion gap 352 a between front end wall 417 and connector element 453 that is connected to the first end of product retention compartment 460. In the depicted embodiment, the suspension element 451 extends from the second end of product retention compartment 460. As depicted, suspension element 451 abuts against back end wall 419 creating a cushion gap on all sides of product retention compartment 460. As depicted a maximum length of product retention compartment 460 is less than the maximum interior length of outer container 410 further ensuring a cushion gap on all sides (front, back, left, right, above, and below) of product retention compartment 460. In the depicted embodiment, at least a portion the side walls 413, 415 are double layered providing reinforcement to outer container 510 and protection of a product when suspension insert 450 is installed in outer container 410. In some embodiments, one or more of the plurality of upstanding walls 413, 415, 417, 419 may be one or more layers.
In the depicted embodiment, the juncture at which suspension element 451 meets the end of top section of product retention compartment 460 shows inward notches such that suspension element 451 is a trapezoid shape and the width of top section of product retention compartment 460 at the juncture is less than the width of the remainder of top section of product retention compartment 460. In some embodiments, the entire top section product retention compartment 460 is substantially the same width from the first end to the second end of product retention compartment 460. In some embodiments, suspension element 451 is a rectangular shape. In some embodiments, suspension element 451 has a maximum width that is less than or substantially equal to a maximum interior width of outer container 410.
FIG. 5 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 500 shows the structure of the outer container 510 underneath suspension insert (not pictured), including the support and cushion system of shipping container system. The depicted embodiment shows base 511, side walls 513, 515, front end wall 517, and back end wall 519 of outer container 510. Additionally, 500 shows support elements 541, 543, 547, 549 formed by diagonal support sections extending from side walls 513, 515 towards the front end wall 517 and back end wall 519. In some embodiments support elements 541, 543, 547, 549 may represent internal sidewall tabs. As depicted, support element 541 extends from an inner layer of side wall 513 in a diagonal direction to abut against front end wall 517, and support element 543 extends from an inner layer of side wall 515 in a diagonal direction to abut against front end wall 517. Similarly, support element 547 extends from an inner layer of side wall 513 in a diagonal direction to abut against back end wall 519, and support element 549 extends from an inner layer of side wall 515 in a diagonal direction to abut against back end wall 519. Support elements 541, 543, 547, 549 maintain the cushion gap between product retention compartment (not pictured) and outer container 510, particularly beneath product retention compartment (not pictured) as well as in front, back, and to the sides of product retention compartment (not pictured).
In the depicted embodiment, side wall 513 further includes sidewall flap 514 extending from an end of an inner layer of side wall 513. Similarly, side wall 515 further includes sidewall flap 516 extending from an end of an inner layer of side wall 515. Sidewall flaps 514, 516 extending along base 511 of outer container 510 are visible in this view. Sidewall flaps 514, 516 are properly depicted inside cavity 535 of outer container 510. In some embodiments, sidewall flaps 513, 515 provide structural reinforcement to outer container 510. Sidewall flaps 514, 516 have a maximum length less than the maximum interior length of outer container 510. The depicted embodiment shows an interior edge of sidewall flaps 514, 416 each have a semi-circle cutout. In some embodiments, the interior edge of sidewall flaps 514, 416 have a substantially flat edge.
In the depicted embodiment, sidewall flaps 513, 515 each have a width that is less than half the width of outer container, such that the portion of base 511 that a full interior length of base 511 is visible between sidewall flaps 514, 516 as it is not covered by sidewall flaps 514, 516. In some embodiments, sidewall flaps 513, 515 may each have a width that is substantially equal to half the width of interior width of outer container 510 such that the full interior length of base 511 is not visible between sidewall flaps 514, 516. In some embodiments, sidewall flaps 513, 515 may each have a width that is greater than half the width of interior width of outer container 510 such that sidewall flaps 513 overlap over base 511. In the depicted embodiment, there are two sidewall flaps 513, 515. In some embodiments, there are less than two sidewall flaps. In some embodiments, there are more than two sidewall flaps. In some embodiments, there are no sidewall flaps.
FIG. 6 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. As shown in 600, bottom section 611 of outer container 610 of product retention compartment 660 is separately visible through portal 656 in top section 655 of product retention compartment 660. At a first end of product retention compartment 660, cushion gap 652 a between front end wall 617 and product retention compartment 660 is visible. Cushion gap 652 a is formed by connector element 653 extending from the end of product retention compartment 660 folding upwards to joint element 652 that folds and connects with front end wall 617. In some embodiments, product retention compartment connector element 653 end flap extends past an end of bottom section 657 of product retention compartment 660 and top section 655 of product retention compartment 660 and folds upwards or downwards to create cushion gap 652 a. In some embodiments, at least one of a first end and a second end of product retention compartment 660 includes an aperture through which a product may be inserted into or removed from product retention compartment 660.
At a second end of product retention compartment 660, cushion gap 652 b is formed between a second end of product retention compartment 660 and back end wall 619. In the depicted embodiment, a first end of suspension element 651 is connected to an end of top section 655 of product retention compartment 660, and a second end of suspension element 651 opposite the first end of suspension element 651 abuts against back end wall 619. A maximum length of product retention compartment 660 is less than the maximum interior length of outer container 610, such that cushion gaps are maintained between all sides of product retention compartment 660 and outer container 610. In the depicted embodiment, suspension element 651 secures suspension insert 650 along a length of outer container 610 while maintaining cushion gaps between product retention compartment 660 and outer container 610.
FIG. 7 shows another cross-section of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 700 shows product retention compartment 760 maintains a floating configuration with an air gap between the edges of product retention compartment 760 and sidewalls 713, 715 of outer container 710. In the depicted embodiment, top section 755 of product retention compartment 760 and bottom section 757 of product retention compartment 760 do not contact outer container 710. In some embodiments, the sides of the product retention compartment 760 do not contact sidewalls 713, 715 of outer container 710. The contact between suspension element 751 and back end wall 719 of outer container 710, and the contact between connector element with joint element and front end wall of outer container 710 maintain air gaps or cushion gaps around product retention compartment 760, thereby maintaining the security of a product in product retention compartment 760.
In the depicted embodiment, product retention compartment 760 is substantially flat as it is empty without any product inside. In some embodiments, product retention compartment 760 has a volume when a product is inserted in between top section 755 and bottom section 757 of product retention compartment 760, and top section 755 and bottom section 757 of product retention compartment 760 physically contact the product contained therein. In some embodiments, product retention compartment further includes sidewalls connecting top section 755 with bottom section 757, such that product retention compartment 760 is a rectangular shape with a volume even empty. In some embodiments, product retention compartment 760 may be a marquise shape formed by tension resulting from a seam that overlaps on the bottom section of the product retention compartment pulling tension across the top section of the product retention compartment causing the top section to bow upwards and the bottom section to bow downwards.
FIG. 8 shows a bottom view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 800 shows a bottom view of base 811 of outer container 810 in an open configuration as first closure flap 820, closure tabs 827, 829, and second closure flap 825 are visible.
FIG. 9 shows a front view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 900 shows the front view of front end wall 917 of outer container 910 in an open configuration as first closure flap 920, closure tabs 927, 929, and second closure flap 925 are visible.
FIG. 10 shows a rear view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 1000 shows the rear view of back end wall 1019 of outer container 1010 in an open configuration as first closure flap 1020, closure tabs 1027, 1029, and second closure flap 1025 are visible.
FIG. 11 shows a top view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. The cushion gaps 1152 a, 1152 b, 1152 c, 1152 d between product retention compartment 1160 and outer container 1110 are visible from this vantage point.
FIG. 12 shows a left-side view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 1200 shows outer container 1210 in an open configuration with side wall 1213, retention element 1221, and closure tab 1227.
FIG. 13 shows a right-side view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. 1300 shows outer container 1310 in an open configuration with side all 1315, retention element 1323, and closure tab 1329.
FIG. 14 shows an unfolded blank folded to form the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. A person of ordinary skill in the art will recognize how to fold the blank to form the shipping container system including outer container 1410 and suspension insert 1450. In some embodiments, outer container 1410 is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics. In some embodiments, suspension insert 1450 is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics. In the depicted embodiment, sidewalls 1413, 1415 have two layers, an inner layer and an outer layer, that are folded over to form double-layered sidewalls thereby maintaining a cushion gaps between product retention compartment of suspension insert 1450 and sidewalls 1413, 1415 once shipping container system is in a folded configuration.
In the depicted embodiment, suspension insert is conned to front end wall 1417 via joint element 1452 and connector element 1453. A person of ordinary skill in the art would recognize that joint element and connector element fold over and down towards base 1411 of outer container 1410, wherein connector element 1453 may be substantially parallel to front end wall 1417 of outer container 1410 maintaining a cushion gap between suspension insert 1450 and front end wall 1417 wall, wherein front end wall 1417 is opposite back end wall 1419 of outer container 1410 when shipping container system is in a folded configuration.
In the depicted embodiment, bottom panels 1467, 1469 each include bottom suspension elements 1466, 1468, such that when in a folded configuration, bottom suspension elements 1466, 1468 abut against back end wall 1419 maintaining a cushion gap between product retention compartment and outer container 1410. Bottom suspension elements 1466, 1468 may fold in at least one of an upwards direction and a downward direction maintaining the cushion gap between product retention compartment and outer container 1410. In some embodiments, at least one of bottom panels 1467, 1469 further comprise at least one bottom suspension element 1466, 1468 abutting against at least one of front end wall 1417 and back end wall 1419 of outer container 1410. A person of ordinary skill in the art will recognize that in practice, portions of the shipping container system may be trimmed to accommodate construction of the Outer Container and the Inner Container without interference of other components.
In some embodiments, outer container 1410 and suspension insert 1450 are formed from separate blanks. In some embodiments, suspension insert 1450 may include a first suspension element and a second suspension element extending outwardly from opposite ends of the product retention compartment, wherein the first suspension element abuts against a first upstanding wall of the outer container, and the second suspension element abuts against a second upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein the first upstanding wall and the second upstanding wall are opposite each other. In some embodiments, the first suspension element extends from a first end of the top section of the product retention compartment, and the second suspension element extends form a second end of the top section of the product retention compartment, wherein the first end and the second end of the top section of the product retention compartment are opposite each other. In some embodiments, the first suspension element and the second suspension element each exert a retention force while abutting against the first upstanding wall and the second upstanding wall of the outer container. In some embodiments, the retention force holds the suspension insert secure in a height of the outer container and along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.
FIG. 15 shows a perspective view of a shipping container system, according to one embodiment of the present disclosure. The shipping container may be a box for securing and shipping devices such as tablet computers, laptop computers, mobile phones, and other electronic devices. As shown in FIG. 15 , the shipping container includes an outer container including a base, upstanding sidewalls, and a lid with securing panels and flaps. The shipping container includes an inner compartment for securing and retaining a device shipped therein. The inner compartment includes a presentation tray that is attached to the lid of the outer container such that, when the lid of the outer container is opened, the presentation tray of the inner container lifts and pivots the device into a convenient and aesthetically pleasing presentation configuration.
FIG. 16 shows a cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure. As shown in FIG. 2 , the shipping container system may be formed from a single-piece blank, such that the outer container and the inner container are constructed from a single-piece blank folded into the shipping container system. The shipping container system includes the outer container having a front closure flap connected to the lid, connected to the rear wall, connected to the bottom, which is connected to the end walls and the front wall, wherein the front wall folds into the internal cavity of the outer container and forms the inner container. The shipping container system includes a front wall air cushion gap formed between the outer container and the inner container by the folding of the front wall, the cushion gap, and the front wall of the inner container.
FIG. 17 shows another cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure. As shown in FIG. 17 , the inner container includes cushion elements below the inner container, formed by folded flaps extending from the ends of the inner container into the outer container cavity and between the bottom of the outer container and the bottom of the inner container. The cushion elements may provide a support force maintaining a cushion gap between the outer container and the inner container.
As shown in FIG. 17 , the inner container includes side cushion elements extending from the ends of the inner container wherein the side cushion elements form and maintain a cushion gap at the ends of the inner container. The side cushion elements further includes a securing element selectively connected to the lid of the outer container. When the lid of the outer container is opened, the lid of the outer container applies a presentation force to the securing elements, lifting the lid of the inner container and positioning the bottom of the inner container to present the device stored in the shipping container system in an aesthetically pleasing manner. When the lid of the outer container is in a closed configuration, the bottom of the inner container is positioned in a substantially flat orientation relative to the top and bottom of the outer container, and the lid of the inner container applies a retention force to the device in the inner compartment.
FIG. 18 shows another cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure. As shown in FIG. 18 , the folding of the shipping container system included outer container end walls formed by an up-and-over construction, and the front wall of the outer container includes an air gap between the outer container and the inner container. The front of the bottom of the inner container includes a front gap retention element to maintain the cushion gap between the inner and outer containers. FIG. 19 shows another cross-section of the shipping container system of FIG. 1 according to one embodiment of the present disclosure. As shown in FIG. 19 , the front gap retention element extends from the inner container bottom to the inside of the front wall of the outer container. A rear gap is formed and maintained between a rear of the inner container and the rear wall of the outer container by the depth of the inner container bottom as it extends through the depth of the outer container cavity.
FIG. 20 shows a rear view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. FIG. 21 shows a bottom view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. FIG. 22 shows a top view of the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. As shown in FIG. 22 , the cushion elements extending form the ends of the inner container have a fold such that the element forms a v-shaped cushion element between the inner container and the outer container. In some embodiments, flaps extending from the outer container lid apply a retention force towards the bottom of the outer container on the vertex of the v-shaped flap holding the inner container lid securely in place and applying a retention force on the device stored therein when the shipping container system is in a closed configuration.
FIG. 23 shows a left-side view of the shipping container system of FIG. 1 according to one embodiment of the present disclosure. FIG. 24 shows a right-side view of the shipping container system of FIG. 1 according to one embodiment of the present disclosure. FIG. 25 shows another front view of the shipping container system of FIG. 1 viewed from an elevated angle, according to one embodiment of the present disclosure. FIG. 26 shows an unfolded blank folded to form the shipping container system of FIG. 1 , according to one embodiment of the present disclosure. FIG. 27 shows a perspective view of the unfolded blank of FIG. 12 , according to one embodiment of the present disclosure.
From the above description, it is manifest that various techniques can be used for implementing the concepts described in the present application without departing from the scope of those concepts. Moreover, while the concepts have been described with specific reference to certain implementations, a person having ordinary skill in the art would recognize that changes can be made in form and detail without departing from the scope of those concepts. As such, the described implementations are to be considered in all respects as illustrative and not restrictive. It should also be understood that the present application is not limited to the particular implementations described above, but many rearrangements, modifications, and substitutions are possible without departing from the scope of the present disclosure.

Claims

What is claimed is:

1. A container system comprising:

an outer container comprising a base and a plurality of upstanding walls defining a cavity, a first closure flap extending from a top end of one of the plurality of upstanding walls opposite the base wherein the first closure flap overlays the base and substantially covers an opening formed by the top ends of the upstanding walls when the outer container is in a closed configuration, and wherein the first closure flap includes a retention element that extends from the closure flap downward into the cavity of the outer container when the outer container is in a closed configuration; and

a suspension insert including a product retention compartment comprising a top section connected to a bottom section, and a suspension element extending outwardly from a first end of the product retention compartment, wherein the suspension element abuts against a first upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein a cushion gap is on all sides of the product retention compartment when the suspension insert is installed in the outer container, wherein the bottom section of the product retention compartment comprises a first bottom panel connected to a first side of the top section and folds to connect to a second side of the product retention compartment opposite the first side of the top section.

2. The container system of claim 1, wherein the bottom section of the product retention compartment further comprises a second bottom panel connected to the second side of the top section opposite the first side of the top section, and the first bottom panel and the second bottom panel fold to connect on the bottom section of the product retention compartment.

3. The container system of claim 1, wherein the product retention compartment has a volume when a product is inserted into the product retention compartment and the top section and the bottom section of the product retention compartment physically contact the product contained therein.

4. The container system of claim 1, wherein the suspension insert further comprises a second suspension element extending outwardly from a second end of the product retention compartment, wherein the suspension element abuts against a second upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein the first upstanding wall and the second upstanding wall are opposite each other.

5. The container system of claim 4, wherein the second suspension element extends from a second end of the top section of the product retention compartment, wherein the second end is opposite the first end of the top section of the product retention compartment.

6. The container system of claim 4, wherein the first suspension element and the second suspension element exert a retention force while abutting against the first upstanding wall and the second upstanding wall of the outer container.

7. The container system of claim 6, wherein the retention force holds the suspension insert secure in a height of the outer container and along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.

8. The container system of claim 1, wherein the suspension element folds in at least one of an upwards direction and a downwards direction maintaining the cushion gap between the product retention compartment and the outer container.

9. The container system of claim 1, wherein a maximum height of the suspension element when installed in the outer container is less than an interior height of the outer container.

10. The container system of claim 1, wherein at least one of the first bottom panel and the second bottom panel further comprises a bottom suspension element abutting against at least one of the first upstanding wall and a second upstanding wall of the outer container.

11. The container system of claim 1, wherein the suspension insert further comprises an aperture in the top section of the product retention compartment allowing visibility into the product retention compartment.

12. The container system of claim 1, wherein the product retention compartment is substantially flat when the product retention compartment is empty.

13. The container system of claim 1, wherein the seam on the bottom section of the product retention compartment is held together by at least one of an interlocking closure, a locking closure, a glue, a tape, a semi-permanent adhesive, a permanent adhesive, a radio-frequency (RF) welding, a heat bond, and a stitching.

14. The container system of claim 1, wherein the suspension element secures the suspension insert along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.

15. The container system of claim 1, wherein the outer container and the suspension insert are formed from a single blank, wherein the suspension insert folds over a second upstanding wall of the outer container and down towards the base of the outer container maintaining the cushion gap between the suspension insert and the second upstanding wall, wherein the second upstanding wall is opposite the first upstanding wall of the outer container.

16. The container system of claim 1, wherein the outer container is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics.

17. The container system of claim 1, wherein the suspension insert is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics.

18. The container system of claim 1, wherein the product retention compartment includes a selectively closeable opening.

19. The container system of claim 1, wherein the outer container further comprises a plurality of support elements maintaining the cushion gap between the product retention compartment and the outer container.

20. The container system of claim 1, wherein the plurality of upstanding walls comprises a third upstanding wall and a fourth upstanding wall opposite each other, wherein the third upstanding wall further comprises a first sidewall flap extending along the base of the outer container, and the fourth upstanding wall further comprises a second sidewall flap extending along the base of the outer container.