Retaining box template and methods of use

Foldable templates include sheet material with a front surface and a retaining element connected to the sheet material extending over at least a portion of the front surface. In box insert configurations, the sheet material has transverse and longitudinal creases, the retaining element extending across the creases. In retaining box configurations, the sheet material includes a base panel and opposing longitudinal side walls, with transverse creases extending across the base panel and side walls. In each template, folding the sheet material upward along transverse creases opens a receiving area between the front surface and retaining element to receive a product. In the box insert configuration, folding the sheet material downward underneath the front surface along transverse creases pulls the retaining element tight over the product. In the retaining box configuration, folding the side walls upward flattens the transverse creases and pulls the retaining element tight over the product.

BACKGROUND

1. Technical Field

Exemplary embodiments of the present disclosure relate to packaging. More specifically, embodiments of the present disclosure relate to packaging templates that may be assembled, incorporated, and/or inserted into a box, and to methods of performing the same.

2. The Relevant Technology

In many industries, packaging materials are used to deliver products to clients. Often such packaging materials take the form of boxes in which the item(s) are placed for delivery. Such boxes may, of course, be of virtually any size and configuration. It may be that the product is placed directly inside the box without any additional material. In such cases, an item may move around within the box or contact another item and become damaged or destroyed thereby. Accordingly, steps are often taken to protect the product against excessive movement within the box.

For instance, when a product is placed directly inside of a box, care is often taken to select a box that has dimensions that generally correspond to the dimensions of the product being boxed so that the product fits snugly within the box. Such may be desirable to prevent excess movement of the product and, consequently, reduce the shaking or movement of the product therein. The dimensions of standard sized boxes, however, often do not correspond to the size of the products being packaged therein. As a result, the products being packaged routinely do not fit snugly into standard-sized boxes.

To avoid excessive movement of the packaged product in such cases, some additional material may be provided around the product to reduce movement of the product within the box. For instance, foam peanuts, bags of air, bubble-wrap, and the like may be used to protect a fragile or other product. Thus, the product may be cushioned or otherwise protected from being damaged or destroyed.

Packaging items in boxes that are too large or that require additional cushioning may be costly and inefficient. For instance, the additional material used in creating the larger packages and in cushioning items packaged therein increases the cost of packaging the product. Furthermore, storing a large assortment of premade boxes of various sizes can require significant amounts of storage space that could otherwise be eliminated or more efficiently used. Moreover, packages that are too large for a particular item are more expensive to ship. Shipping prices are often affected by the size of the shipped package, and not just the weight of the package. Thus, reducing the size of an item's package may reduce the price of shipping the item in certain situations.

On the other hand, buying boxes and other shipping materials in bulk may save on costs and labor. For instance, buying a large assortment of box sizes in order to accommodate a variety of product sizes may be more expensive in the long run than simply buying a bulk lot of a single size of box large enough to ship any size of product to be shipped.

One attempt to avoid such costs and inefficiencies has been to develop systems for creating custom sized boxes on-demand. Such systems create templates out of a planar material which may be folded to form boxes. The template includes sections (or panels) that fold along creases to form the top, bottom, and sidewalls of the box. Importantly, the planar material may be stored as a fan-fold bale, which reduces space required to store packaging materials. However, such custom box templates require additional time and resources to design and create a new box template for each item to be shipped.

In addition, while customized boxes and additional packaging materials may be effective in protecting a product enclosed in the box, they often fail to retain the product in an optimal position once the box is opened. For instance, inserted packaging materials may conceal the product from view when the box is opened upon arrival—detracting from the initial presentation of the product. Inserted packaging materials may also fall out the opened box, allowing the product to shift or even drop out of the box. In some cases a deliberate distance between the product and the surrounding transport packaging is needed in a few or all directions to ensure the product is not damaged due to vibrations, g-forces and/or deformations/dents to the transport packaging.

Presentation inserts and box elements designed to overcome these additional problems often resurrect one or more of the aforementioned problems. For instance, the presentation inserts and box elements may be designed for a single or small window of size applications as opposed to being customizable. In addition, it can be cumbersome to insert or otherwise arrange the product into such presentation inserts and box elements. Furthermore, retaining the presentation material in a secured configuration often requires complex procedures that can be time-consuming to learn and execute. In view of the foregoing, one may be left to choose between suboptimal solutions to a complex problem.

Although the above-described solutions may reduce some of the costs and inefficiencies associated with packaging and shipping with boxes, there are still some inefficiencies that may be addressed.

BRIEF SUMMARY OF THE INVENTION

This disclosure relates to packaging templates that may be assembled, incorporated, and/or inserted into a box and to methods of performing the same. In particular, embodiments described herein include a foldable template that includes a sheet material and a product retaining element connected thereto. The sheet material can have a plurality of creases with the retaining element disposed atop (or over) a surface of the sheet material and spanning and/or extending across (or over) at least a portion of the plurality of creases. The template or sheet material thereof can be foldable into a box or foldable into a box insert. Accordingly, the template can retain and/or display the product within the box when the box is opened.

In a box insert configurations, for example, the sheet material can have a plurality of transverse creases and a plurality of longitudinal creases. In a retaining box configuration, for example, the sheet material can include a base panel and one or more longitudinal side wall panels, with one or more transverse creases extending across the base panel and side wall panel(s). In each template, folding the sheet material upward along one or more transverse creases can open a receiving area between a portion of the front surface of the sheet material (or base panel) and a portion of the retaining element in order to receive a product therebetween. In the box insert configuration, folding the sheet material downward underneath the front surface along at least one transverse crease can pull the retaining element tight over the product. In the retaining box configuration, folding the side wall(s) upward can flatten the one or more transverse creases and can pull the retaining element tight over the product.

In one embodiment, a foldable template for forming a product retaining box can include a sheet material having a front surface, and comprising a base panel, at least a first side wall panel, at least a first longitudinal crease, a first transverse crease, and/or an optional second transverse crease. The base panel can have a perimeter comprising a first transverse edge, a second transverse edge (opposite the first transverse edge), an upper longitudinal edge (extending between the first and second transverse edges), and/or a lower longitudinal edge (extending between the first and second transverse edges opposite the upper longitudinal edge). The first side wall panel can be connected to the base panel and/or can extend from the upper longitudinal edge. The first longitudinal crease can be disposed between the base panel and the first side wall panel.

The first transverse crease can be disposed on the base panel and/or side wall panel(s). For instance, the first transverse crease can be disposed between the first and second transverse edges of the base panel and can extend from the lower longitudinal edge across the first longitudinal crease and into the first side wall panel. Some embodiments can include first and second transverse creases separated by a first longitudinal length, with the first and second transverse creases being disposed between the first and second transverse edges of the base panel and extending from the lower longitudinal edge across the first longitudinal crease and into the first side wall panel. An area on the front surface (e.g., between the first and second transverse creases and/or between the upper and lower longitudinal edges can comprise a product receiving area.

The foldable template also includes a retaining element connected to the sheet material. The retaining element can be disposed over at least a portion of the front surface and/or can extend across the first (and optional second) transverse crease. In such a configuration, folding the sheet material along the first (and optional second) transverse crease can increase the distance between the retaining element and the receiving area. In addition, unfolding the sheet material along the first (and optional second) transverse crease such that the base panel is in a planar configuration can decrease the distance between the retaining element and the receiving area. Moreover, folding the sheet material along the first longitudinal crease such that the first side wall panel is oriented perpendicular to the base panel can retain the base panel in the planar configuration.

Another embodiment includes a method of retaining a product in a box. The method can include providing a foldable template (e.g., one of the foldable templates described herein), folding the sheet material along at least a first transverse crease thereby increasing the distance between a portion of the retaining element and the front surface of the sheet material, placing a product in the receiving area between the portion of the retaining element and the front surface of the sheet material, flattening the sheet material along the first transverse crease such that the base panel is in a substantially planar configuration thereby decreasing the distance between the portion of the retaining element and the front surface of the sheet material such that the retaining element is stretched over the product as the base panel and/or sheet material is flattened, and/or folding the sheet material at the first longitudinal crease such that the first side wall panel is folded upward towards the front surface into an erected configuration thereby retaining the base panel in the substantially planar configuration.

In another embodiment, the sheet material can include the base panel, a lid panel connected to the base panel and extending from the first transverse edge, an end wall panel disposed between the base panel and the lid panel, a front wall panel connected to the base panel and extending from the second transverse edge opposite the end wall panel, a securing flap connected to the front wall panel opposite the base panel, a third transverse crease disposed between the base panel and the front wall panel, a fourth transverse crease disposed between the front wall panel and the securing flap, a fifth transverse crease disposed between the base panel and the end wall panel, and/or a sixth transverse crease disposed between the end wall panel and the lid panel. The retaining element can also extend across the first and second and third and fifth transverse creases.

A further embodiment includes another method of retaining a product in a box. The method can include providing a foldable template (e.g., one of the foldable templates described herein), bending the sheet material at one or more of the first and second transverse creases thereby increasing the distance between a portion of the retaining element and the front surface of the sheet material, placing a product in the receiving area between a portion of the retaining element and the front surface of the sheet material, manipulating the sheet material such that the retaining element secures the product against the front surface, wherein manipulating the sheet material can comprise flattening the base panel at the first and second transverse creases such that the base panel is substantially planar thereby decreasing the distance between the portion of the retaining element and the front surface of the sheet material such that the retaining element is stretched over the product as the base panel is flattened, folding the sheet material at the first and second longitudinal creases such that the first and second side wall panels are folded upward towards the front surface into an erected configuration thereby retaining the base panel in a flattened configuration, folding the sheet material at the third transverse crease such that the front wall panel is folded upward towards the front surface into an erected configuration, and/or folding the securing flap downward towards the front surface substantially against the front wall panel thereby securing the first and second side wall panels and the front wall panel in the respective erected configurations.

In yet another embodiment, a foldable template for forming a customized product retainer box insert configured to retain products of various sizes can include a sheet material having a base format with a substantially rectangular shape, opposing front and back surfaces, and/or a plurality of longitudinal creases extending between opposing first and second sides of the sheet material. The plurality of longitudinal creases can include a pair of outer longitudinal creases and at least one inner longitudinal crease disposed between the opposing outer longitudinal creases. The sheet material can also include a plurality of transverse creases extending between opposing upper and lower sides of the sheet material. The plurality of transverse creases can include a pair of outer transverse creases and at least one inner transverse crease disposed between the opposing outer transverse creases. The foldable template can also include a retaining element connected to the sheet material. The retaining element can be disposed over at least a portion of the front surface and/or can extend across the plurality of longitudinal creases and/or the plurality of transverse creases. In some embodiments, folding the sheet material along one or more of the creases in a first direction can increase the distance between the retaining element and the front surface of the sheet material. Similarly, folding the sheet material along one or more of the creases in a first direction can decrease the distance between the retaining element and the front surface of the sheet material

Yet a further embodiment includes a method of retaining a product in a customized product retainer box insert configured to retain products of various sizes. The method can include providing a foldable template (e.g., as described herein), placing a product between a portion of the retaining element and the front surface of the sheet material, selecting from among the plurality of transverse creases a first selected transverse crease disposed peripheral to a first side of the product and a second selected transverse crease disposed peripheral to a second side of the product opposite the first side of the product, and/or manipulating the sheet material such that the retaining element secures the product against the front surface, wherein manipulating the sheet material comprises folding the sheet material at the first selected transverse crease and the second selected transverse crease such that a first portion of the sheet material peripheral to the first selected transverse crease and a second portion of the sheet material peripheral to the second selected transverse crease are folded substantially against the back surface. In at least some embodiments, manipulating the sheet material can stretch the retaining element over the product as the sheet material is folded at the first selected transverse crease and the second selected transverse crease.

These and other objects and features of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosure as set forth hereinafter.

DETAILED DESCRIPTION

Before describing the present disclosure in detail, it is to be understood that this disclosure is not limited to the specific parameters or configurations of the particularly exemplified systems, apparatus, assemblies, products, devices, kits, methods, and/or processes, which may, of course, vary. It is also to be understood that much, if not all of the terminology used herein is only for the purpose of describing particular embodiments of the present disclosure, and is not necessarily intended to limit the scope of the disclosure in any particular manner. Thus, while the present disclosure will be described in detail with reference to specific configurations, embodiments, and/or implementations thereof, the descriptions are illustrative only and are not to be construed as limiting the scope of the claimed invention. Accordingly, various modifications can be made to the present disclosure without departing from the spirit and scope of the invention as defined by the claims.

Various aspects of the present disclosure, including devices, systems, methods, etc., may be illustrated with reference to one or more exemplary embodiments or implementations. As used herein, the terms “exemplary embodiment” and/or “exemplary implementation” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments or implementations disclosed herein. In addition, reference to an “implementation” of the present disclosure or invention includes a specific reference to one or more embodiments thereof, and vice versa, and is intended to provide illustrative examples without limiting the scope of the invention, which is indicated by the appended claims rather than by the following description.

Furthermore, unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. While a number of methods, materials, components, etc. similar or equivalent to those described herein can be used in the practice of the present disclosure, only certain exemplary methods, materials, components, etc. are described herein.

It will be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “crease” includes one, two, or more creases. Similarly, reference to a plurality of referents should be interpreted as comprising a single referent and/or a plurality of referents unless the content and/or context clearly dictate otherwise. Thus, reference to “creases” does not necessarily require a plurality of such creases. Instead, it will be appreciated that independent of conjugation; one or more creases are contemplated herein.

As used throughout this application the words “can” and “may” are used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Additionally, the terms “including,” “having,” “involving,” “containing,” “characterized by,” as well as variants thereof (e.g., “includes,” “has,” and “involves,” “contains,” etc.), and similar terms as used herein, including the claims, shall be inclusive and/or open-ended, shall have the same meaning as the word “comprising” and variants thereof (e.g., “comprise” and “comprises”), and do not exclude additional, un-recited elements or method steps, illustratively.

Various aspects of the present disclosure can be illustrated by describing components that are coupled, attached, connected, and/or joined together. As used herein, the terms “coupled”, “attached”, “connected,” and/or “joined” are used to indicate either a direct association between two components or, where appropriate, an indirect association with one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly attached”, “directly connected,” and/or “directly joined” to another component, no intervening elements are present or contemplated. Thus, as used herein, the terms “connection,” “connected,” and the like do not necessarily imply direct contact between the two or more elements. In addition, components that are coupled, attached, connected, and/or joined together are not necessarily (reversibly or permanently) secured to one another. For instance, coupling, attaching, connecting, and/or joining can comprise placing, positioning, and/or disposing the components together or otherwise adjacent in some implementations.

As used herein, directional and/or arbitrary terms, such as “top,” “bottom,” “front,” “back,” “forward,” “rear,” “left,” “right,” “up,” “down,” “upper,” “lower,” “inner,” “outer,” “internal,” “external,” “interior,” “exterior,” “anterior,” “posterior,” “proximal,” “distal,” and the like can be used only for convenience and/or solely to indicate relative directions and/or orientations and may not otherwise be intended to limit the scope of the disclosure, including the specification, invention, and/or claims. According, such directional and/or arbitrary terms are not to be construed as necessarily requiring a specific order or position.

To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Furthermore, alternative configurations of a particular element may each include separate letters appended to the element number. Accordingly, an appended letter can be used to designate an alternative design, structure, function, implementation, and/or embodiment of an element or feature without an appended letter. Similarly, multiple instances of an element and or sub-elements of a parent element may each include separate letters appended to the element number. In each case, the element label may be used without an appended letter to generally refer to instances of the element or any one of the alternative elements. Element labels including an appended letter can be used to refer to a specific instance of the element or to distinguish or draw attention to multiple uses of the element. However, element labels including an appended letter are not meant to be limited to the specific and/or particular embodiment(s) in which they are illustrated. In other words, reference to a specific feature in relation to one embodiment should not be construed as being limited to applications only within said embodiment.

Various modifications can be made to the illustrated embodiments without departing from the spirit and scope of the invention as defined by the claims. Thus, while various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. It is also noted that systems, apparatus, assemblies, products, devices, kits, methods, and/or processes, according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties, features, components, members, and/or elements described in other embodiments disclosed and/or described herein. Thus, reference to a specific feature in relation to one embodiment should not be construed as being limited to applications only within said embodiment.

The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims

Exemplary embodiments of the present disclosure generally relate to packaging templates that may be assembled, incorporated, and/or inserted into a box, and to methods of performing the same. In particular, embodiments described herein include a foldable template that includes a sheet material and a product retaining element connected thereto. The sheet material can have a plurality of creases with the retaining element disposed atop (or over) a surface of the sheet material and spanning and/or extending across (or over) at least a portion of the plurality of creases. The template or sheet material thereof can be foldable into a box or foldable into a box insert. Accordingly, the template can retain and/or display the product within the box when the box is opened.

In a box insert configurations, for example, the sheet material can have a plurality of transverse creases and a plurality of longitudinal creases. In a retaining box configuration, for example, the sheet material can include a base panel and one or more longitudinal side wall panels, with one or more transverse creases extending across the base panel and side wall panel(s). In each template, folding the sheet material upward along one or more transverse creases can open a receiving area between a portion of the front surface of the sheet material (or base panel) and a portion of the retaining element in order to receive a product therebetween. In the box insert configuration, folding the sheet material downward underneath the front surface along at least one transverse crease can pull the retaining element tight over the product. In the retaining box configuration, folding the side wall(s) upward can flatten the one or more transverse creases and can pull the retaining element tight over the product.

As used herein, the term “template” refers to a flat stock of material that can be folded into a box or box insert. A template may have cuts, notches, cutouts, divides, and/or creases that allow the template to be bent and/or folded into a box or box insert. Additionally, a template may be made from any suitable material, generally known to those skilled in the art. For example, cardboard or corrugated paperboard may be used as the template material. Such template materials may have any suitable dimensions (i.e., length, width, thickness, etc.), weight, and/or rigidity/strength to permit the template to be bent and/or folded into a box or box insert.

As used herein, the term “crease” shall refer to a line along which any portion of the template may be folded. For example, a crease may be an indentation in the template material, which may facilitate the folding of a portion of the template that is adjacent to the crease. A suitable indentation may be created by applying sufficient pressure to reduce the thickness of the material in the desired location and/or by removing some of the material along the desired location, such as by scoring.

The terms “notch,” “cutout,” and “cut” are used interchangeably herein and shall refer to a shape made by removing material from the template or by separating one portion of the template material from another portion, such that an incision is made through the template.

Reference will also be made herein to two or more aligned creases. As used herein, “aligned” and similar terms do not necessarily imply exact planar, linear, and/or axial alignment and does not necessarily require the same or identical plane, line, and/or axis. Accordingly, creases may deviate from exact planar, linear, and/or axial alignment without necessarily becoming misaligned. Rather, substantially aligned creases can still be aligned in at least some embodiments described herein.

Reference will also be made herein to one or more products. As used herein, a product includes one or more items, goods, or other objects. Reference to a “product” should be interpreted as comprising a single object and/or a plurality of objects. Similarly, reference to “products” does not necessarily require a plurality of such objects. Instead, it will be appreciated that independent of conjugation; one or more objects are contemplated herein.

Accordingly, the packaging templates described herein can be folded at the positions of the creases to produce structural components or aspects of a (custom) box or box insert that retains a product. For instance, the folded panels, flaps, and/or tabs described herein can produce one or more of the side walls, top, bottom, etc. of the box, or can comprise reinforcing, securing, or locking features thereof.

Those skilled in the art will appreciate that the packaging templates can be assembled into a box in a variety of ways, methods, and/or mechanisms. For instance, the creased and/or cut flaps and/or tabs can be folded to produce the side walls of a box having a hingedly-opening and/or flap-tucking upper top and/or lid. Furthermore, flaps and/or tabs extending (seamlessly) outward from one or more panels can be folded inward (e.g., to a 90 degree angle relative to the wall from which it extends).

Reference will now be made to the figures to describe various aspects of example embodiments of the disclosure. It is to be understood that some of the drawings included herewith, and which are referenced herein, are diagrammatic, schematic, and other representations of example embodiments, and are not limiting on the present disclosure. Moreover, while various drawings are provided at a scale that is considered functional for some embodiments, the drawings are not necessarily drawn to scale for all contemplated embodiments. No inference should therefore be drawn from the drawings as to the necessity of any scale. Rather, the proportionality, scale, size, shape, form, function, and/or other feature of the disclosed embodiments can be altered without necessarily departing from the scope of this disclosure (unless such feature is expressly described herein as essential).

Furthermore, as indicated above, in the exemplary embodiments illustrated in the figures, like structures will be provided with similar reference designations, where possible. Specific language will be used herein to describe the exemplary embodiments. Nevertheless it will be understood that no limitation of the scope of the disclosure is thereby intended. Rather, it is to be understood that the language used to describe the exemplary embodiments is illustrative only and is not to be construed as limiting the scope of the disclosure (unless such language is expressly described herein as essential).

Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of this disclosure. Unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with another feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments.

It is noted that between each adjacent element of the packaging templates disclosed herein, where one element is designed to be folded relative to the other, such as between adjacent panels or between a panel and an adjacent tab or flap, a crease or cut may be formed in the sheet material so as to enable smooth and straight folding between the elements. Creases are identified in the figures with broken/dashed lines, and cuts are identified with bold/solid lines. However, it will be appreciated that in certain alternative embodiments, one or more creases can be replaced by a notch and/or one or more notches can be replaced by a crease.

FIG. 1illustrates an exemplary embodiment of a foldable template10having a longitudinal length L100(extending between a first transverse or side edge102aand an opposing second transverse or side edge102b) and a transverse width W100(extending between an upper longitudinal edge102cand an opposing lower longitudinal side edge102d). Foldable template10can be useful for forming a product retaining box (see e.g.,FIGS. 3C and 3D) and can include a sheet material100having a front surface101. Template10can comprise a base panel104, a first side wall panel104aconnected to base panel104, a first longitudinal crease105adisposed between base panel104and first side wall panel104a, a first transverse crease150, and/or an optionally second transverse crease152. Base panel104can have a perimeter comprising a first transverse edge120, a second transverse edge126(opposite first transverse edge120), an upper longitudinal edge130(extending between first transverse edge120and second transverse edge126), and/or a lower longitudinal edge132(extending between first transverse edge120and second transverse edge126opposite upper longitudinal edge130). First side wall panel104acan extend from upper longitudinal edge130.

In some embodiments, first transverse crease150and/or second transverse crease152can extend from lower longitudinal edge132, across first longitudinal crease105a, and (entirely or partially) through first side wall panel104a. Sheet material100can also include a second side wall panel104bconnected to base panel104and extending from lower longitudinal edge132. A second longitudinal crease105bcan be disposed between base panel104and second side wall panel104b. In some embodiments, first transverse crease150and/or second transverse crease152can extend from first side wall panel104a, across first longitudinal crease105a, across lower longitudinal edge132, and (entirely or partially) through second side wall panel104b. In addition, in some embodiments, a product receiving area105of template10can be defined and/or be at least partially bound by first transverse crease150, second transverse crease152, first longitudinal crease105a, and/or second longitudinal crease105b.

Sheet material100can also include a front wall panel110connected to base panel104and extending from second transverse edge126, a securing flap112connected to front wall panel110and extending from side edge128thereof (opposite base panel104), a third transverse crease154disposed between base panel104and front wall panel110, and/or a fourth transverse crease156disposed between front wall panel110and securing flap112.

Sheet material100can also include a first side wall tab111aextending from first side wall panel104a(adjacent front wall panel110) and/or a first tab crease113adisposed between first side wall tab111aand first side wall panel104a. In at least one embodiment, first tab crease113acan be substantially aligned with third transverse crease154. In other embodiments, third transverse crease154can extend across the interface between first side wall tab111aand first side wall panel104a(such that no additional first tab crease113amay be required). A cut142can substantially separate and/or disconnect first side wall tab111aand front wall panel110. Sheet material100can also include a second side wall tab111bextending from second side wall panel104band/or a second tab crease113bdisposed between second side wall tab111band second side wall panel104b. In at least one embodiment, second tab crease113bcan be substantially aligned with third transverse crease154. In other embodiments, third transverse crease154can extend across the interface between second side wall tab111band second side wall panel104b(such that no additional first tab crease113bmay be required). A cut144can substantially separate and/or disconnect second side wall tab111band front wall panel110.

Sheet material100can also include an end wall panel108connected to base panel104and extending from first transverse edge120, a lid panel106connect to end wall panel108and extending opposite base panel104(such that end wall panel108is disposed between base panel104and lid panel106), a fifth transverse crease158disposed between base panel104and end wall panel108, and/or a sixth transverse crease160disposed between end wall panel108and lid panel106. Lid panel106can have a perimeter comprising a first transverse edge122, a second transverse edge124(opposite first transverse edge122), an upper longitudinal edge134(extending between first transverse edge122and second transverse edge124), and/or a lower longitudinal edge136(extending between first transverse edge122and second transverse edge124, and opposite upper longitudinal edge134).

Sheet material100can also include one or more lid flaps connected to and/or extending from lid panel106. For instance, a first longitudinal lid flap106acan extend from first longitudinal edge134, a second longitudinal lid flap106bcan extend from second longitudinal edge136, and/or a transverse lid flap114can extend from second transverse edge124. In at least one embodiment, a seventh transverse crease162can be disposed between lid panel106and transverse lid flap114(e.g., extending from first longitudinal lid flap106ato second longitudinal lid flap106b). A first lid flap tab114acan extend from an upper edge146of transverse lid flap114. A cut115acan substantially separate and/or disconnect first lid flap tab114aand first longitudinal lid flap106a. A second lid flap tab114bcan extend from a lower edge148of transverse lid flap114. A cut115bcan substantially separate and/or disconnect second lid flap tab114band second longitudinal lid flap106b.

Sheet material100can also include a first end wall tab108aextending from an upper end138of end wall panel108. A cut109acan substantially separate and/or disconnect first end wall tab108aand first side wall panel104a. A cut109bcan substantially separate and/or disconnect first end wall tab108aand longitudinal lid flaps106a. Sheet material100can also include a second end wall tab108bextending from a lower end140of end wall panel108opposite first end wall tab108a. A cut109ccan substantially separate and/or disconnect second end wall tab108band second side wall panel104b. A cut109dcan substantially separate and/or disconnect second end wall tab108band longitudinal lid flaps106b.

First longitudinal crease105acan extend longitudinally across the first side of sheet material100(e.g., between base panel104and first side wall panel104a, between end wall panel108and first end wall tab108a, between lid panel106and first longitudinal lid flap106a, and/or between transverse lid flap114and first lid flap tab114a. Second longitudinal crease105bcan extend longitudinally across the second side of sheet material100(e.g., between base panel104and second side wall panel104b, between end wall panel108and second end wall tab108b, between lid panel106and second longitudinal lid flap106b, and/or between transverse lid flap114and second lid flap tab114b.

In at least one embodiment, securing flap112, front wall panel110, base panel104, end wall panel108, lid panel106, and/or transverse lid flap114can all have the same width Wb. Base panel104can have a length L104, which can be substantially the same or similar to a length L106of lid panel106. Similarly, a length L112of securing flap112, a length L110of front wall panel110, a length L150between crease150and crease154, a length L152between crease152and crease158, a length L108of end wall panel108, and/or a length L114of lid flap114can be substantially the same or similar.

Template10can also include a retaining element200connected to sheet material100. In at least some embodiments, retaining element200can comprise a non-opaque material, such as a clear, polymeric stretch film. It will be appreciate, however, that translucent materials and/or polymeric sheets are also contemplated herein. In some embodiments, retaining element200can have elastomeric properties suitable for being stretched in at least one (longitudinal) direction.

Retaining element200can be attached to any suitable portion of sheet material100, can be disposed over at least a portion of front surface101(e.g., receiving area105), and/or can extend across first transverse crease150(and optional second transverse crease152). For instance, as depicted inFIG. 1, a first portion202of retaining element200can be attached to front wall panel110on front surface101of sheet material100. A second portion204of retaining element200can be attached to end wall panel108on front surface101of sheet material100. It will be appreciated, however, that first portion202of retaining element200can alternatively be attached to base panel104(e.g., between first transverse crease150and first transverse edge126) or securing flap112(e.g., on front surface101). It will also be appreciated that first portion202of retaining element200can alternatively be attached to an opposing rear surface of sheet material100. Similarly, second portion204of retaining element200can alternatively be attached to base panel104(e.g., between second transverse crease152and first transverse edge120) or lid panel106or lid flap114extending therefrom.

In addition, in at least one embodiment, at least one longitudinal side edge206,208of retaining element200can be substantially unattached to sheet material100(e.g., between first transverse crease150and second transverse crease152and/or between first and second portions202,204). Retaining element200can be attached to sheet material100by means of at least one fastener300. As depicted inFIG. 1, fastener300can comprise an adhesive (e.g., such as a glue or adhesive tape). Fastener300can alternatively comprise a clamp, rivet, staple, or any other suitable fastener as known to those skilled in the art.

In certain embodiments, retaining element200and/or longitudinal side edges206,208thereof, does not extend beyond one or more of upper longitudinal edge130and lower longitudinal edge132. However, retaining element200and/or longitudinal side edges206,208thereof, may extend beyond one or more of upper longitudinal edge130and lower longitudinal edge132in other embodiments.

Another embodiment includes a method of retaining a product in a box, illustratively depicted inFIGS. 2 through 3Dand with continued reference toFIG. 1. The method can include providing template10, folding sheet material100along at least first transverse crease150, thereby increasing the distance between a portion of retaining element200and receiving area105, base panel104, and/or front surface101of the sheet material100. For instance, as illustrated inFIG. 2, sheet material100can be folded at first transverse crease150and second transverse crease152to effectively loosen and/or create slack in retaining element200such that retaining element200moves away from a portion of sheet material100. First transverse crease150and second transverse crease152can be folded to right angles, as depicted, or to any suitable obtuse angle or acute angle. Additional creases (e.g.,156;113a,113b, and/or154;158;160;162,105a, and/or105b) can be maintained in an unfolded configuration such that other panels (e.g.,112,110,111a,111b,108,108a,108b,106,106a,106b,114,114a, and/or114b) or portions of sheet material100are maintained in a planar configuration. It will be appreciate, however, that the one or more additional creases may be folded as desired.

A product800can be placed (e.g., inserted) in receiving area105, against front surface101and/or between the portion of retaining element200and the portion of front surface101. It will be appreciated that whileFIG. 2illustrates a side elevation view of template10, with base panel104and side wall panels104a,104bin a vertical orientation such that retaining element200loops outward, to the side, template10can be oriented in any suitable manner. For instance, base panel104may be place on top such that retaining element200loops downward or on the bottom such that retaining element200loops upward without necessarily departing from the scope of this disclosure.

As illustrated inFIGS. 3A-3D, the method can also include manipulating sheet material100such that retaining element200secures product800against front surface101and/or within retaining area105. In at least one embodiment, for example, manipulating sheet material100can include flattening sheet material100along first transverse crease150and second transverse crease152such that base panel104and side wall panels104a,104bare in a substantially planar configuration. Straightening sheet material100along first transverse crease150and second transverse crease152can decrease the distance between the portion of retaining element200and front surface101of sheet material100such that retaining element200is tightened and/or stretched over product800as sheet material100is flattened.

Sheet material100can also be folded at first longitudinal crease105aas illustrated inFIG. 3Asuch that first side wall panel104ais folded upward (towards product800and/or front surface101) into an erected configuration (e.g., perpendicular to base panel104). Folding first side wall panel104acan straighten first transverse crease150and second transverse crease152and/or retain base panel104in the substantially planar configuration (with first transverse crease150and second transverse crease152in a straightened configuration). Accordingly, retaining element200can be drawn substantially tight over the top of product800and maintained in the tightened and/or stretched configuration by folding at least first side wall panel104a.

As illustrated inFIG. 3B, second side wall panel104bcan also be folded upward along crease105binto an erected configuration. Side wall tabs111aand111bcan also be folded (inward) along respective creases113aand113b(over the top of retaining element200).FIG. 3Cfurther illustrates that side wall panels104aand104band side wall tabs111aand111bcan be secured in their folded configurations by folding front wall panel110upward along crease154into an erected configuration and folding securing flap112downward along crease156substantially against side wall tabs111aand111band/or substantially parallel to front wall panel110. This folding can also further tighten and/or stretch retaining element200in certain embodiments as retaining element200is pulled toward the distal edge of securing flap112into the interface between securing flap112and front wall panel110.

It is noted that in such a configuration, template10and/or sheet material100thereof can be configured into a box with an open lid. Accordingly, product800can be retained and/or displayed in receiving area105by retaining element200while the box (i.e., folded template10and/or sheet material100thereof) is in the open configuration. In some embodiments, therefore, product800can be displayed when the box is opened by a receiving individual. Furthermore, product800may not fall out of the box if it is accidentally opened up-side-down or in another orientation.

As illustrated inFIG. 3D, lid panel106can be closed over the top of product800. For instance, end wall108can be folded upward (toward front surface101) at crease158into an erected configuration. End wall tabs108aand108bcan be folded inward at longitudinal creases105aand105b, respectively, and disposed inside or outside erected side walls104aand104b, respectively. Longitudinal lid flaps106aand106bcan also be folded (inward, toward front surface101) at longitudinal creases105aand105b, respectively, and disposed inside or outside erected side walls104aand104b, respectively. Transverse lid flap114can also be folded (inward, toward front surface101) at transverse crease162and disposed inside folded securing flap112or outside erected front wall110. Lid flap tabs114aand114bcan also be folded (inward, toward front surface101) at longitudinal creases105aand105b, respectively, and disposed inside folded securing flap112or outside erected front wall110.

Template10and/or sheet material100thereof can, thus, be folded into a box, whereby product800can be retained therein by retaining element800.

In yet another embodiment, a foldable template for forming a customized product retainer box insert configured to retain products of various sizes is provided. As illustrated inFIGS. 4A and 4B, for instance, a foldable template20can include a (substantially rectangular shaped) sheet material400having a longitudinal length L400, a transverse width W400, a front surface432, an opposing back surface436, a plurality of longitudinal creases410extending between a first side402and an opposing second side404of sheet material400, and/or a plurality of transverse creases420extending between an upper side406and an opposing lower side408of sheet material400. In one or more embodiments, the plurality of longitudinal creases410can be disposed substantially parallel one to another at substantially and/or at substantially right-angles (i.e., 90 degrees) relative to the plurality of transverse creases420.

It will be appreciated that foldable template20and/or sheet material400thereof need not have a (completely or perfectly) rectangular perimeter or outer shape. For instance, foldable template20and/or sheet material400thereof can have one or more rounded, curved, angles, notched, protruding, or altered edges, corners, or configurations (thereof). In some embodiments, foldable template20and/or sheet material400thereof can comprise a base portion or base format (e.g., disposed within the perimeter (or interior to the outer edges) of the foldable template20and/or sheet material400thereof). In at least one embodiment, the (inner) base portion or base format can have a substantially rectangular shape or configuration. It will also be appreciated that the plurality of longitudinal creases410and/or the plurality of transverse creases420can extend (entirely or at least partially) across the base portion or base format in one or more embodiments.

The plurality of longitudinal creases410can include a pair of outer longitudinal creases and at least one inner longitudinal crease disposed between the opposing outer longitudinal creases. For instance, crease420acan comprise a first outer crease, crease420jcan comprise a second outer crease, and any of creases420bthrough420ican comprise an inner crease. Alternatively, any of creases420can comprise a first outer crease because selection of a second outer crease can determine the number of inner creases. The plurality of transverse creases420can also include a pair of outer transverse creases and at least one inner transverse crease disposed between the opposing outer transverse creases, similar to the longitudinal creases.

In some embodiments, the plurality of longitudinal creases410and/or plurality of transverse creases420can be spaced evenly apart between the opposing first and second sides402,404and the opposing upper and lower sides406,408of sheet material400. It will be appreciated, however, that uneven spacing of creases410,420is also contemplate herein. In certain embodiments, the plurality of longitudinal creases410can include at least three, four, five, six, seven, eight, nine, ten, twenty, or more longitudinal creases410. Similarly, the plurality of transverse creases420can include at least three, four, five, six, seven, eight, nine, ten, twenty, or more transverse creases420, in some embodiments. Between any of creases410and420can be a product receiving area430. In some embodiments, receiving area430can be adjustable (larger or smaller) depending upon the size of a product to be placed therein and/or the selected creases410and/or420.

Template20can also include a retaining element500connected to sheet material400. It will be appreciated that retaining element500can have features similar to retaining element200. Accordingly, the description of retaining element200can also apply to retaining element500. For instance, retaining element500can also comprise a non-opaque material, such as a clear, polymeric stretch film, a translucent material, and/or other polymeric sheets. In some embodiments, retaining element500can have elastomeric properties suitable for being stretched in at least one (longitudinal) direction. Furthermore, retaining element500can be disposed over at least a portion of front surface432and/or can extend across the plurality of longitudinal creases410and/or the plurality of transverse creases420.

Retaining element500can have a first longitudinal edge502and an opposing second longitudinal edge504. As depicted inFIG. 4A, longitudinal edges502and504can be disposed, respectively, adjacent to upper side406and an opposing lower side408of sheet material400. In an alternative embodiment, however, longitudinal edge502and/or504may be disposed inward of upper side406and opposing lower side408of sheet material400, respectively. Thus, longitudinal edges502and504may not extend beyond (or past) upper side406and opposing lower side408, respectively. In an alternative embodiment, however, longitudinal edges502and504may extend beyond (or past) upper side406and opposing lower side408, respectively. In addition, in at least one embodiment, at least one longitudinal side edge502,504of retaining element500can be substantially unattached to sheet material500(e.g., between any first transverse crease420and any second transverse crease420).

Retaining element500can be attached to any suitable portion of sheet material400. For instance, as depicted inFIG. 4B, a first portion506of retaining element500can be wrapped around side edge404and/or attached to rear surface436of sheet material400(e.g., between side edge404and any crease420). However, first portion506of retaining element500can alternatively be attached to front surface432in other embodiments. A second portion508of retaining element500can also be wrapped around side edge402and/or attached to rear surface436of sheet material500(e.g., between side edge402and any crease420). However, second portion508of retaining element500can alternatively be attached to front surface432in other embodiments. Retaining element500can be attached to sheet material400by means of at least one fastener300, as described above.

First portion506and second portion508need not be attached to the same surface and/or at the same relative position relative to side edges404,402, respectively. Thus, first portion506(and/or second portion508) can be attached between edge404(and/or402) and any selected and/or suitable crease420.

Yet another embodiment includes a method of retaining a product in a box, illustratively depicted inFIGS. 5 through 10and with continued reference toFIGS. 4A and 4B. The method can include providing template20and placing a product800abetween a portion of retaining element500and a portion of front surface432of sheet material400(e.g., between two longitudinal creases410and/or between two transverse creases420). For instance, product800acan be inserted between retaining element500and front surface432and/or placed in receiving area430.

Certain embodiments can also include folding sheet material400along at least one transverse crease420(at any suitable angle), in a first direction, thereby increasing the distance between a portion of retaining element500and receiving area430and/or front surface432of the sheet material400. For instance, as illustrated inFIG. 5, sheet material400can be folded at a first selected transverse crease420cand a second selected transverse crease420h(to effectively loosen and/or create slack in retaining element500such that retaining element500moves away from a portion of sheet material400, making additional room or space for the placement of product800a). It will be appreciated, however, that sheet material400can be folded along any suitable number of creases. Accordingly, one or more additional creases420may be folded as desired.

As depicted inFIG. 6, the folded crease or creases (e.g., creases420cand420h) can be straightened or unfolded (in a second direction opposite the first direction). In certain embodiments, retaining element500can be at least partially tightened and/or pulled over product800aas sheet material400is straightened (at the one or more creases).

As illustrated inFIG. 7, the method can also include selecting from among the plurality of transverse creases420a first selected transverse crease420bdisposed peripheral to a first side of product800aand/or a second selected transverse crease420idisposed peripheral to a second side of product800aopposite the first side of product800a. The selected transverse creases can be the same or different creases discussed in connection withFIGS. 5 and 6above. Furthermore, the method can include manipulating sheet material400such that retaining element500secures product800awithin receiving area430and/or against front surface432. In certain embodiments, manipulating sheet material432can include folding sheet material400at the first selected transverse crease420band/or the second selected transverse crease420i(in the second direction) such that a first portion401aof sheet material400peripheral to first selected transverse crease420band/or a second portion401bof sheet material400peripheral to second selected transverse crease420iare folded substantially against back surface436. It will be appreciated, however, that any suitable crease420or combination of creases420can be selected and/or folded as part of manipulating sheet material400. Accordingly, one or more additional creases420may be folded as desired.

In at least one embodiment, manipulating sheet material400(further) tightens and/or stretches retaining element500over product800aas sheet material400is folded at first selected transverse crease420band/or second selected transverse crease420i(in the second direction). Thus, retaining element500can retain and/or maintain product800awithin receiving area430and/or against front surface432.

As depicted inFIG. 8, illustrating the manipulated and/or folded template20and/or sheet material400turned 90 degrees, the method can also include selecting from among the plurality of longitudinal creases410a first selected longitudinal crease410b(disposed peripheral to a first, upper side of product800a) and/or a second selected longitudinal crease410e(disposed peripheral to a second, lower side of product800aopposite the upper side of the product). In addition, manipulating sheet material400, as described above, can further comprise folding sheet material400at first selected longitudinal crease410band/or second selected longitudinal crease410e(in the first direction). Accordingly, a third portion401cof sheet material400peripheral to first selected longitudinal crease410band/or a fourth portion410dof sheet material400peripheral to second selected longitudinal crease410ecan be folded upward (e.g., towards front surface432and/or in the first direction) thereby securing first portion401aand/or second portion401bof sheet material400substantially against back surface436such that retaining element500remains stretched over product800a. In other embodiments, the third and/or fourth portions401c,401dcan be folded in a second direction (e.g., downward, toward back surface436).

In one or more embodiments, and as illustrated inFIG. 9, the method can also include selecting from among the plurality of longitudinal creases410a third selected longitudinal crease410a(e.g., disposed in third portion401cof sheet material400) and/or selecting from among the plurality of longitudinal creases410a fourth selected longitudinal crease410f(e.g., disposed in fourth portion401dof sheet material400). In addition, manipulating sheet material400can further include folding sheet material400at third selected longitudinal crease410a(in the second direction) such that a part401eof third portion401cis folded (downward) towards front surface432and/or folding sheet material400at fourth selected longitudinal crease410f(in the second direction) such that a part401fof fourth portion401dis folded (downward) towards front surface432.

As illustrated inFIG. 10, the method can also include placing the manipulated and/or folded template20into a box600. Box600can be sized to fit manipulated and/or folded template20. Alternatively, template20can be manipulated and/or folded to fit within box600. Those skilled in the art will appreciate in light of the disclosure provided herein, that folding creases410and/or420adjacent to product800amay be desirable in certain embodiments in order to reduce the size of manipulated and/or folded template20, thereby reducing the required size of box600. Thus, template20can comprise a customizable, foldable box insert template. In addition, as noted above, retaining element500can secure and/or display product800awithin box600.

FIGS. 11-13further illustrate that template20can accommodate various sizes of products. For instance, as depicted inFIG. 11, a product800b(smaller than product800ain at least one direction) can be positioned in receiving area430. Product800bcan then be secured and/or displayed in receiving area430by retaining element500by folding sheet material400at creases420dand420hsuch that portions401gand401hoverlap under sheet material400, at least one of portion401gand401hbeing folded against rear surface436, as illustrated inFIG. 12. Template20can then be further manipulated by folding along one or more longitudinal creases410as illustrated inFIG. 13and described previously to reduce the size of folded template20and make folded template20suitable for insertion into box600.

The foregoing detailed description makes reference to specific exemplary embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope contemplated herein and as set forth in the appended claims. In particular, while illustrative exemplary embodiments in this disclosure have been more particularly described, the present disclosure is not limited to these embodiments, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the foregoing detailed description, which examples are to be construed as non-exclusive.

Moreover, any steps recited in any method or process described herein and/or recited in the claims may be executed in any order and are not necessarily limited to the order presented in the claims, unless otherwise stated (explicitly or implicitly) in the claims. Accordingly, the scope of the invention should be determined solely by the appended claims and their legal equivalents, rather than by the descriptions and examples given above.

It will also be appreciated that various features, members, elements, parts, and/or portions of certain embodiments of the present invention are compatible with and/or can be combined with, included in, and/or incorporated into other embodiments of the present invention. Thus, disclosure a certain features, members, elements, parts, and/or portions relative to a specific embodiment of the present invention should not be construed as limiting application or inclusion of said features, members, elements, parts, and/or portions to the specific embodiment. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present invention. Likewise, certain embodiments can include fewer features than those disclosed in specific examples without necessarily departing from the scope of this disclosure.