Material storage and transport system

A material storage and transport system is disclosed. The material storage and transport system can include a material storage tray forming a storage volume defined by a bottom and walls extending up from the bottom along a perimeter of the bottom. The material storage and transport system can also include a releasable strap adapted to extend across the bottom when in a securing configuration and a sample carrier, including at least one sample secured to a sample support substrate by a molded sheet. The material storage and transport system can include a hinged lid that is integrally connected to a wall of the material storage tray, and configured to convert between a folded-in position, an opened position, and a closed position.

FIELD OF THE INVENTION

The present invention relates to systems for the storage and transport of delicate, three-dimensional materials and objects.

BACKGROUND

A variety of packaging technologies exist for storage and transport of products. These technologies, as well as, the products they package have evolved over time.

SUMMARY

In various embodiments, a material storage and transport system is disclosed. The material storage and transport system can include a material storage tray forming an open-top storage volume defined by a bottom and walls extending up from the bottom along a perimeter of the bottom. The material storage and transport system can also include a releasable strap adapted to extend across the storage volume when in a securing configuration, and a hinged lid that is integrally connected to one of the walls and/or a lid element adapted (i) to fit within the storage volume when arranged parallel to the bottom, and (ii) to be secured to the material storage tray by the releasable strap.

DETAILED DESCRIPTION OF THE INVENTION

In various embodiments, as shown inFIGS. 1-14, a material storage and transport system10is disclosed. The material storage and transport system10can include a material storage tray100forming an open-top storage volume102defined by a bottom104and walls106extending up from the bottom104along a perimeter108of the bottom104. The material storage and transport system10can include a releasable strap200adapted to extend across the bottom104when in a securing configuration. In some embodiments, as shown inFIGS. 3 and 9, the material storage and transport system10can include a lid element300adapted (i) to fit within the storage volume102when arranged parallel to the bottom104, and (ii) to be secured to the material storage tray100by the releasable strap200. In some embodiments, as shown inFIGS. 11-14, the material storage and transport system10can include a hinged lid178that is integrally connected to a wall of tray100.

The material storage and transport system10can also include a sample carrier400that includes at least one sample500secured to a sample support substrate402by a molded sheet404. The at least one sample can be a three-dimensional sample, e.g., one that is at least 0.125″ in each dimension, or at least 0.25″ in each dimension, or at least 0.375″ in each dimension, or at least 0.5″ in each dimension.

In some embodiments, the molded sheet404can include plastic. In some embodiments, the molded sheet404can be plastic. In some embodiments, the molded sheet404is secured to the sample support402substrate by adhesive. In some embodiments, in a securing configuration the sample carrier400is adapted (i) to fit within the storage volume102when arranged parallel to the bottom104, and (ii) to be secured to the material storage tray100by the releasable strap200.FIGS. 9 and 10show examples of a material storage and transport system10both in a secured configuration with the lid element (FIG. 9) and in an unsecured configuration with the lid element removed (FIG. 10).

In some embodiments, the samples500can be placed on the sample support substrate402, and the molded sheet404can be formed by heating a sheet of thermoplastic material405then vacuum sealing it to the sample support substrate402. In some embodiments, as shown inFIGS. 1-3, the samples500a-500ecan be spaced apart. In some embodiments, the samples500are at least 1″ from any edges of the sample support substrate402, or at least 0.75″ from any edges of the sample support substrate402, or at least 0.5″ from any edges of the sample support substrate402. In some embodiments, each sample is at least 0.125″ from any adjacent samples, or at least 0.5″ from any adjacent samples, or at least 0.75″ from any adjacent sample, or at least 1″ from any adjacent sample. This allows the molded sheet404to form sample storage bubbles406that fixedly attaches the samples500to the sample support substrate402and isolated the samples500from one another to minimize damage to the samples500.

In such embodiments, the sample support substrate402can include pores that allow a vacuum to be pulled through the sample support substrate402when the heated thermoplastic sheet is brought into contact with the sample support substrate402. In some embodiments, the thermoplastic sheet405is at least 100° F. when it contacts the sample support substrate402, or at least 150° F. when it contacts the sample support substrate402, or at least 175° F. when it contacts the sample support substrate402, or at least 200° F. when it contacts the sample support substrate402. In some embodiments, the thermoplastic sheet405is from 0.25 mm and 10 mm prior to bonding to the sample support substrate402, in some embodiments, the thermoplastic sheet405is from 2 mm to 9 mm, or from 3 mm to 9 mm, or from 4 mm to 8 mm, or any combination thereof (e.g., from 0.25 mm to 10 mm).

In some embodiments, the pores are present in order to allow sufficient vacuum to be pulled to form the sample storage bubbles406and secure the molded sheet404to the sample support substrate402. In some embodiments, the sample support substrate402can be continuously or intermittently coated with a heat activated adhesive to facilitate bonding between the sample support substrate402and the molded sheet404. In some embodiments, the heat activated adhesive is not tacky at room temperature (e.g., <100° F.). In some embodiments, the adhesive can be a thermoplastic resin. In some embodiments, the adhesive can be an ionically cross-linked thermoplastic based upon ethylene copolymerized with carboxyl groups and a metal ion, such as those sold by DUPONT® under the name SURLYN®.

In some embodiments, the sample support substrate402is formed of corrugated cardboard or corrugated plastic. In some embodiments, as shown inFIG. 4, the sample support substrate402can include a cut-out403so the recipient of the shipment can more easily pull the molded sheet404away from the sample support substrate402and access the samples. In some embodiments, the cut-out403can have a maximum dimension of 1.5″ or less (compared to a symmetrical sample support substrate without the cut-out), or 1.25″ or less, or 1″ or less. In some embodiments, the cut-out403can have a maximum dimension of at least 0.5″, or at least 0.75″, or at least 1″.FIG. 4shows the thermoplastic sheet405prior to vacuum and heat treatment to produce the sample storage bubbles406, which are evident inFIG. 1.

Using this approach it is possible to produce a sample carrier400that is customized for the specific samples500placed on the sample support substrate402. In particular, each of the samples500a-500ecan be isolated in a discrete sample storage bubble406. This prevents each sample500from moving parallel to the plane of the sample support substrate502. In some embodiments, the molded sheet404can be transparent or translucent so that the samples500can be viewed even when they are sealed in the sample carrier400.

In some embodiments, as shown inFIG. 3, the lid element300includes a first lid edge302comprising a first strap notch304and a second lid edge306, opposite the first lid edge302, wherein said second lid edge306comprises a second strap notch308. In some such embodiments, the first strap notch304and the second strap notch308are adapted for receiving the releasable strap200when the lid element300is secured to the material storage tray100by the releasable strap200. In some embodiments, the first strap notch304can extend over the mid-point of the first lid edge302, the second strap notch308can extend over the mid-point of the second lid edge306, or both.

In some embodiments, the lid element300is formed of a stiff material. In some embodiments, the lid element300is formed of corrugated cardboard, corrugated plastic, or wood. In some embodiments, the lid element300can be formed of two layers of B-flute cardboard adhered or laminated together.

In some embodiments, as shown inFIG. 3, the material storage and transport system10is designed so the sample carrier400fits between the bottom104and the lid element300when the lid element300is secured to the material storage tray100by the releasable strap200. In some embodiments, as shown inFIG. 3, the material storage and transport system10is designed so the sample carrier400and low-profile materials600fit between the bottom104and the lid element300when the lid element300is secured to the material storage tray100by the releasable strap200. In some embodiments, the low-profile materials600can be one or more envelopes, folders, or other organizers with material samples (e.g., textiles, wall coverings, etc.) stored therein.

The releasable strap200can be formed of a fabric, which can be stretchable or non-stretchable. The releasable strap200can be adapted to hold the stored elements (e.g., the sample carrier400and low-profile materials600) securely in the material storage and transport system. In particular, the strap prevents the sample carrier400from bouncing vertically if the material storage and transport system10is dropped or jostled. In combination with the sample storage bubbles406and the sample support substrate402fitting precisely within the material storage tray100(i.e., having the same or nearly the same length and width dimensions as the perimeter108), this limits movement of the samples500within the material storage and transport system10in all three orthogonal directions and protects the samples500from being damaged during transport. In some embodiments, the lid element300and the releasable strap200provide a compressive force that, in addition to the other components and configuration of the system, secure the material samples and other content during transport.

In some embodiments, as shown inFIGS. 3, 5A, 5B, and 8-10, the walls106comprise a first end wall110and a second end wall112opposite the first end wall110. The releasable strap200can include a first strap element202and a second strap element204. In some embodiments, as shown inFIG. 3, a proximal portion of the first strap element202is attached to the first end wall110and a proximal portion of the second strap element204is attached to the second end wall112. In some embodiments, as shown inFIG. 6A, adhesive164can be used to securely attach the straps202,204to the first and second end walls110,112. As shown inFIG. 5A, in some embodiments, the first and second end walls110,112can each include an adhesive165for securing the first and second straps202,204to the end walls, respectively. Accordingly, the adhesive164can be applied to the straps202,204in order to secure the straps to the end walls, the adhesive165can be applied to the first and second end walls110,112in order to secure the straps to the end walls, or both the adhesive164and adhesive165can be applied in order to secure the straps to the end walls. In other embodiments, as shown inFIG. 6B, the ends of each strap202,204can be connected in a manner such that they cannot be easily pulled through the opening114of the end walls. For example, in some embodiments, each of the straps202,204can be stitched to itself in a manner that allows the straps to be pulled through the openings114in only one direction.

In some such embodiments, distal portions of the first and second strap elements202,204releasably couple with one another. As shown inFIGS. 5A, 6A, and 6B, in some embodiments, a distal portion of the first strap element202includes a hook/loop material208and a distal portion of the second strap element204includes a corresponding loop/hook material206so that the first strap element202and the second strap element204are releasably coupled.

In some embodiments, as shown inFIGS. 5A, 5B, 7, 8A, and 8B, the first end wall110comprises a pull tab opening114and a pull tab118extends outside the material storage tray100through the pull tab opening114. In some embodiments, a pull tab strip116extends through the pull tab opening114to form the pull tab118. As shown inFIGS. 5A, 7A, and 8A, in some embodiments, the first strap element202(e.g., a proximal portion) is the pull tab strip116.

In some embodiments, as shown inFIGS. 5A, 5B, 7A, 7B, and 8A, the walls106further comprise a first side wall120and a second side wall122opposite the first side wall120. In some embodiments, the first side wall120comprises the pull tab opening114and the pull tab118extends outside the material storage tray110through the pull tab opening114. In some such embodiments, the first and second strap elements202,204are attached to the first and second end walls110,112, respectively, and the pull tab118is formed from a pull tab strip116other than the first or second strap element202,204. Although the FIGS. show the end walls110,112as being shorter than the side walls120,122, the end walls110,112and the side walls120,122could be the same length or the end walls110,112could be longer than the side walls120,122. In some embodiments, the perimeter108has a shape selected from a square, a rectangle, a hexagon, or an octagon.

In some embodiments, as shown inFIG. 8AandFIG. 8B, each strap202,204can extend out from a lower half of the end wall110,112to which it is attached. In some embodiments, as shown inFIG. 8AandFIG. 8B, each strap202,204can extend out from a lower third or lower half of the end wall110,112to which it is attached. In some embodiments, as shown inFIG. 8A, when the straps202,204are pulled tight and secured together, the straps202,204contact the bottom104. In some embodiments, each strap202,204can extend out from under the end wall free edge130,138of the end wall110,112to which it is attached. In some such embodiments, each strap202,204can extend under the end wall free edge130,138between the end wall lip tabs132,140. In some embodiments, as shown inFIG. 8B, when the straps202,204are pulled tight and secured together, the straps202,204extend across the storage volume without contacting the bottom104. As would be appreciated by one of ordinary skill in the art, the releasable strap200inFIG. 6Ais configured to be attached to the embodiment shown inFIGS. 5A, 7A, and 8A, having a pull tab opening114on end wall112; whereas the releasable strap200inFIG. 6Bis configured to be attached to the embodiment shown inFIGS. 5B, 7B, and 8B, having a pull tab opening114on each of end walls110and112.

In some embodiments, as shown inFIG. 5A, the first end wall110is formed by a first end lip124and the second end wall112is formed by a second end lip126. In some embodiments, a first end fold line128is located between the bottom104and the first end lip124, and a first end free edge130includes at least one first end lip tab132, and at least one first end tab slot134is located adjacent to the first end fold line128. In some embodiments, a second end fold line136is located between the bottom104and the second end lip126, and a second end free edge138includes at least one second end lip tab140, and at least one second end tab slot142is located adjacent to the second end fold line136. In some such embodiments, the at least one first end tab slots134are adapted for receiving the at least one first end lip tabs132when the first end lip124is folded up then in half toward the bottom104, and the at least one second end tab slots142are adapted for receiving the at least one second end lip tabs140when the second end lip126is folded up then in half toward the bottom104. In such embodiments, the first end fold line128and the second end fold line136define a portion of the perimeter108of the bottom104.

In some embodiments, as shown inFIG. 5A, the walls106further comprise a first side wall144and a second side wall146opposite the first side wall144. In some embodiments, the first side wall144is formed by a first side lip145and the second side wall146is formed by a second side lip147. In some embodiments, a first side fold line148is located between the bottom104and the first side lip145and a first side free edge150includes at least one first side lip tab152, and at least one first side tab slot154is located adjacent to the first side fold line148. In some embodiments, a second side fold line156is located between the bottom104and the second side lip147and a second side free edge158includes at least one second side lip tab160, and at least one second side tab slot162is located adjacent to the second side fold line156. In some embodiments, the at least one first side tab slots154are adapted for receiving the at least one first side lip tabs152when the first side lip1445is folded up then in half toward the bottom104, and the at least one second side tab slots162are adapted for receiving the at least one second side lip tabs160when the second side lip147is folded up and in half toward the bottom104.

In some embodiments, as shown inFIG. 5A, the first side lip145comprises two opposing first side wing tabs155extending outward from edges of the first side lip145, and the second side lip147comprises two opposing second side wing tabs163extending outward from edges of the second side lip147. In some such embodiments, one first side wing tab155aand one second side wing tab163aare adapted to fit within a void formed when the at least one first end lip tabs132are received by the at least one first end tab slots134, and the other first side wing tab155band the other second side wing tab163bare adapted to fit within a void formed when the at least one second end lip tabs140are received by the at least one second end tab slots142.

In some embodiments, as shown inFIGS. 5B and 11-14, the hinged lid178can be integrally connected to at least one of the side walls (120or122) or one of the end walls (110or112). The hinged lid178can also include a first lid portion180, a second lid portion184and a third lid portion188, wherein the second lid portion184is connected to the first lid portion180along a first edge of the second lid portion184, and the second lid portion184is connected to the third lid portion188along a second edge of the second lid portion184, opposite the first edge. In some embodiments, the second lid portion184can be integrally connected to the first lid portion180along a fold line182at the first edge, and the second lid portion184can be integrally connected to the third lid portion188along a fold line186at the second edge. In some such embodiments, the first lid portion180can be integrally connected to at least one of the side walls (120or122) or one of the end walls (110or112). The first lid portion180can be integrally connected to the wall (110,112,120, or122) along a fold line181. In such embodiments, the hinged lid is configured to convert between a folded-in position, an opened position, and a closed position.

In some embodiments, as shown inFIGS. 11-14, the hinged lid178includes a first lid portion180that is integrally connected to the second side wall122at fold line181, a second lid portion184that is integrally connected to the first lid portion180at fold line182, and a third lid portion188that is integrally connected to the second lid portion184at fold line186.

In some embodiments, as shown inFIGS. 11, 13, and 14, the third lid portion188includes a through hole190. In such embodiments, a user can easily convert the hinged lid178from a folded-in position, as shown inFIGS. 11, 12A, and 12B, to an opened position, as shown inFIG. 13, by inserting a finger or other object through the though hole190to grip an opposing surface of the third lid portion188or an edge of the through hole190, and lift the hinged lid178up to expose the bottom104. The through hole190can include a hole, cut out, notch or other opening through a portion of the third lid portion188. In some embodiments, the through hole has a shape selected from a circle, oval, square, a rectangle, triangle, a hexagon, or an octagon. In some embodiments, the through hole190has a width that is less than a width of the third lid portion188.

In some embodiments, e.g., such as in the folded-in position, the total width of the hinged lid178can be approximately equal to the total of the width of the side wall122plus the width of the bottom104. In such embodiments, the total width of the second and third lid portions (184and188) can be approximately equal to the width of the bottom104. In other embodiments, the total width of the hinged lid178can be greater than the total of the width of the side wall122plus the width of the bottom104. In one example, a width of the first lid portion180is approximately equal to a width of the side wall122and the total width of the second and third lid portions (184and188) is greater than the width of the bottom104. In such embodiments, the difference in the respective total widths can be 6 inches or less, or 4 inches or less, or 2 inches or less, or 1 inch or less, or 0.5 inch or less. In other embodiments, the total width of the hinged lid178can be less than the total of the width of the side wall122plus the width of the bottom104. In one example, a width of the first lid portion180is approximately equal to a width of the side wall122and the total width of the second and third lid portions (184and188) is less than the width of the bottom104. In such embodiments, the difference in the respective total widths can be 6 inches or less, or 4 inches or less, or 2 inches or less, or 1 inch or less, or 0.5 inch or less.

In other embodiments, e.g., when the hinged lid178is in the closed position, the total width of the hinged lid178can be approximately equal to the total of the width of the side wall122plus the width of the bottom104plus the width of the other sidewall120. In such embodiments, the width of the first lid portion180can be approximately equal to the width of the sidewall122, the width of the second lid portion184can be approximately equal to the width of the bottom104, and the width of the third lid portion188can be approximately equal to the width of the other sidewall120.

In some embodiments, as shown inFIGS. 13 and 14, the hinged lid178includes side flaps192,193. In such embodiments, the side flaps192,193are integrally connected to the ends of the second lid portion184. In some embodiments, when the hinged lid178is in a folded-in position to form a tray structure, as shown inFIGS. 11 and 12, the side flaps192,193can be folded under the second lid portion184before the hinged lid178is pressed down toward the bottom104. As shown inFIG. 12, the hinged lid178is integrally connected to the second side wall122, and when folded in toward the bottom104, the first lid portion180is in contact with the second side wall122, and the second and third lid portions184,188are in contact with the bottom104. The material storage and transport system10can function as a tray when the hinged lid178is in such a position.

As shown inFIG. 13, when the hinged lid178is in an opened position, the storage volume102, along with the releasable strap200, are accessible. From the opened position, the side flaps192,193and the third lid portion188can be extended outward from the second lid portion184, and the hinged lid178can be converted from the opened position inFIG. 13to the closed position inFIG. 14. In some embodiments, when in the closed position, the side flaps192,193, and the third lid portion188can be folded down toward the first end wall110, the second end wall112, and the first side wall120, respectively. In some embodiments, the side flaps192,193, and the third lid portion188can be fixed to the first end wall110, the second end wall112, and the first side wall120, respectively, in any suitable manner, including, for example, adhesive, tape (e.g., double-sided tape), hook and loop material (e.g., Velcro®), etc. For example, inFIG. 13, the side flaps192,193, and the third lid portion188have an adhesive strip191. The material storage and transport system10can function as a sealed container (e.g., box) when the hinged lid178is in such a position.

In some embodiments, the hinged lid178, the bottom104, the second side wall122are formed from a unitary piece of material. In some embodiments, the hinged lid178, the bottom104, the first side wall120, the second side wall122, the first end wall110, and the second end wall112are formed from a unitary piece of material.

In some embodiments, the material storage and transport system10can be sized to fit snuggly within a sealable box (e.g., a shipping box). As used herein, snuggly refers to having at least two of thickness, width, and length of the material storage tray10within 0.5 inches or less than the corresponding interior dimensions of the shipping box, or within 0.25 inches of less than the corresponding interior dimensions of the shipping box.

This provides an added layer protection during shipping and, in combination with the compression strap200, limits movement of the samples500during transport. The pull tab also facilitates removal of the material storage and transport system10from the sealable box, once the box has been opened. The walls of the tray can be formed of two layers of corrugated cardboard (e.g., one folded back against the other) for durability. These folds create a concealed location for attaching the strap to the walls of the material storage tray. In some embodiments, as shown inFIGS. 6A, 7A, and 8A, the pull tab opening114allows the strap200to extend out of the material storage tray100to create a pull tab118and be attached to the inside of the wall106on both sides of the pull tab opening114. The thinness of the cardboard allows a user to use a small pull tab opening114and receive the pull tab strap116.

From an aesthetic point, the material storage and transport system is as useful as a display object as it is functional for shipping. Constructing the Sample Tray out of corrugated cardboard allows a user to get crisp edges while maintaining stiffness. The user can write on the outside of the walls106to indicate what project or type of samples are contained within. In some embodiments, a shipping label can be printed on an outside surface (e.g., the outside surface of184or the outside surface of bottom104) of the material storage tray.

The informational materials600can be folders containing two dimensional materials samples such as, but no limited to, textiles, leather, laminates, wallcoverings, window treatments, paints, coatings, as well as, information regarding the materials/samples in the material storage tray. The folders provide an organizational system for these types of samples both in terms of packaging and in the customer's environment. Folders are sized to be compatible with the material storage stray allowing for scalable fulfillment depending on the size of a customer's order. The folders600can accommodate all typical two-dimensional sample sizes without folding or creasing.

Although the subject matter has been described in terms of various embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.