Product insert and shipper

An article can include a panel member folded to form a collapsible sleeve comprising a first panel layer and a second panel layer, the panel member movable between a first configuration and a second configuration, the first and second panel layers defining a product-receiving portion. Each of the first panel layer and the second panel layer can comprise a pivotable edge portion and an extension portion coupled to the pivotable edge portion and received in an opening defined in a respective first and second panel layer. The edge portions of the first panel layer and the second panel layer are pivotable together to form a double-layered support member extending at an angle to the product-receiving portion on a first side of the product-receiving portion and the extension portions are pivotable out of their respective openings on an opposite, second side of the product-receiving portion by motion of the pivotable edge portions.

FIELD

The present disclosure pertains to expandable and collapsible inserts defining a pouch configured to receive a product, and which include support members which can be folded into place such that when the insert is disposed inside a shipping container or box, the product is suspended in the pouch within the container by the support members and spaced apart from the container walls.

BACKGROUND

It can be important to protect certain types of products (e.g., fragile items, liquid-filled containers, electronic components, etc.) from high acceleration events such as impacts, drops, etc., and/or compressing events, all of which can occur during shipping. Existing packaging systems for such products can typically include plastic filler materials such as expanded polystyrene “foam peanuts” or “packing peanuts,” plastic air bladders such as bubble wrap, and/or trays on which the product is secured by a plastic film such as shrink wrap. Such packaging systems have a number of drawbacks, including the inability to restrain movement of the product within the box. For example, polystyrene peanuts and bubble wrap can shift during handling of the box and shrink wrap films can plastically deform as the product shifts within the box, degrading their ability to hold the product in place. Further, such materials may not be recyclable and/or may be harmful to the environment. Accordingly, a need exists for containers or boxes, or inserts for such containers, that can protect a product during shipping, while also being more environmentally friendly.

SUMMARY

Disclosed herein are examples of articles that can be configured to retain an object within a portion of the article and, when received within a container or box, suspend the object within the container, away from interior sidewalls of the container. For example, the articles disclosed herein can be configured as inserts, configured to be received in a container or box. In some embodiments, the articles disclosed herein can comprise a first panel layer and a second panel layer that form a double-layered panel member when the article is in a planar, first configuration. The article can be configured to move into a functional, second configuration where a product-receiving portion and support members extending outward from the product-receiving portion are formed. The support members can be configured to interface with the interior sidewalls of the container to suspend the product-receiving portion within the container, away from at least a portion of the interior sidewalls.

In one representative embodiment, an article comprises a panel member folded to form a collapsible sleeve comprising a first panel layer and a second panel layer, the panel member being movable between a planar, first configuration and a folded, second configuration, the first and second panel layers defining a product-receiving portion. The first panel layer comprises a pivotable edge portion and an extension portion coupled to the pivotable edge portion and received in an opening defined in the first panel layer. The second panel layer comprises a pivotable edge portion and an extension portion coupled to the pivotable edge portion and received in an opening defined in the second panel layer. The edge portion of the first panel layer and the edge portion of the second panel layer are pivotable together to form a double-layered support member extending outward, at an angle to the product-receiving portion from a first side of the product-receiving portion. The extension portions are pivotable out of their respective openings to extend outward from an opposite, second side of the product-receiving portion by motion of the pivotable edge portions.

In some embodiments, the pivotable edge portions of the first panel layer and the second panel layer are first pivotable edge portions, the extension portions of the first panel layer and the second panel layer are first extension portions, and each of the first and second panel layers comprises a second pivotable edge portion and a second extension portion on the opposite side of the product-receiving portion from respective first pivotable edge portions.

In some embodiments, the panel member is a rectangular panel member comprising two open ends and two closed ends, the first pivotable edge portions of the first and second panel layers are located at a first open end of the two open ends, and the second pivotable edge portions of the first and second panel layers are located at a second open end of the two open ends.

In some embodiments, when the panel member is in the second configuration and the first and second pivotable edge portions are pivoted relative to the product-receiving portion, the two open ends of the panel member are closed such that a volume within the product-receiving portion is enclosed.

In some embodiments, the extension portion of the first panel layer extends a greater distance beyond the product-receiving portion than the extension portion of the second panel member when the extension portions are pivoted out of their openings and the panel member is in the second configuration.

In some embodiments, edges of the panel member are secured together to form the collapsible sleeve.

In some embodiments, the first panel layer and the second panel layer comprise slits such that the first and second panel layers can expand to a convex shape when an object is received between the first and second panel layers, in the product-receiving portion.

In some embodiments, the article comprises a cellulosic fiber-based material.

In some embodiments, the article is plastic-free.

In some embodiments, the angle is between 60 and 100 degrees.

In another representative embodiment, a system comprises: a box including a plurality of internal walls and an article configured to be moved from a planar, first configuration, to a folded, second configuration and arranged within the box in the second configuration such that a product-receiving portion of the article is suspended within and spaced away from at least a portion of the plurality of internal walls. The article comprises: the product-receiving portion formed by main body portions of a first panel layer and a second panel layer of the article and a plurality of support members formed by pivotable edge portions and extension portions of the first panel layer and the second panel layer. The plurality of support members extends outward from the product-receiving portion, where at least a portion of the plurality of support members are configured to contact one or more of the internal walls of the box.

In some embodiments, support members of the plurality of support members extend outward, at an angle, from the product-receiving portion and wherein the angle is between 60 and 100 degrees.

In some embodiments, support members of the plurality of support members extend outward from opposite sides of the product-receiving portion relative to a horizontal plane defined by the product-receiving portion, and from opposite ends of the product-receiving portion relative to a central longitudinal axis of the product-receiving portion.

In some embodiments, the plurality of support members includes: a first support member that is formed by first pivotable edge portions of the first and second panel layers disposed on a first end of the product-receiving portion and a second support member that is formed by first extension portions of the first panel layer and the second panel layer that extend from respective first pivotable edge portions of the first and second panel layers. The first support member and the second support member are disposed on the first end of the product-receiving portion and extend outward, in different directions, from the opposite sides of the product-receiving portion when the article is in the second configuration.

In some embodiments, the plurality of support members includes: a third support member that is formed by second pivotable edge portions of the first and second panel layers disposed on a second end of the product-receiving portion, the second end disposed opposite the first end, relative to the central longitudinal axis; and a fourth support member that is formed by second extension portions of the first panel layer and the second panel layer that extend from respective second pivotable edge portions of the first and second panel layers. The third support member and the fourth support member are disposed on the second end of the product-receiving portion and extend outward, in different directions, from the opposite sides of the product-receiving portion when the article is in the second configuration.

In some embodiments, the first support member and the fourth support member extend outward from a first side of the opposite sides of the product-receiving portion and the second support member and the third support member extend outward from a second side of the opposite sides of the product-receiving portion.

In some embodiments, the product-receiving portion comprises a cavity defined between the first panel layer and the second panel layer, the cavity configured to receive a product therein.

In some embodiments, the main body portions of the first panel layer and the second panel layer comprise a plurality of slits configured to allow the main body portions to expand to a convex shape when the product is received within the cavity.

In another representative embodiment, an article comprises a double-layered panel member comprising a first panel layer and a second panel layer, the panel member being movable between a planar, first configuration and a folded, second configuration, the first and second panel layers defining a product-receiving portion. The first and second panel layers comprise pivotable edge portions and extension portions coupled to the edge portions, the extension portions having free ends, the extension portions extending inwardly toward a center of main body portions of the first and second panel layers from the edge portions when the panel member is in the first configuration. The edge portions and the extension portions of the first and second panel layers are pivotable to form support members extending from opposite, first and second sides of the product-receiving portion when the panel member is in the second configuration.

In some embodiments, the double-layered panel member comprises corrugated board comprising corrugations extending in a first direction and the first panel layer and the second panel layer comprise a plurality of slits extending in a second direction that is perpendicular to the first direction such that the first panel layer and the second panel layer can flex to accommodate an object in the product-receiving portion.

In some embodiments, the first and second panel layers form a cavity of the product-receiving portion that is configured to receive an object, the cavity defined by a space between the first and second panel layers.

DETAILED DESCRIPTION

As introduced above, it can be important to protect certain types of products from high acceleration events (e.g., impacts, drops, etc.) and/or compression events (e.g., crushing from applied inward pressure), all of which can occur during shipping. Existing packaging systems for such products typically include plastic filler materials such as expanded polystyrene “foam peanuts” or “packing peanuts,” plastic air bladders such as bubble wrap, and/or trays on which the product is secured by plastic film such as shrink wrap. Such packaging systems have a number of drawbacks, including the inability to restrain movement of the product within the box and being harmful to the environment (e.g., non-recyclable and/or non-biodegradable).

The present disclosure pertains to packaging systems including an expandable, double-layered article configured as an insert, sleeve, receptacle, or holder that is configured to receive an object, such as a product to be shipped. The article (e.g., insert) can comprise a first panel layer and a second panel layer which together define a container portion or product-receiving portion. Each of the first panel layer and the second panel layer comprise edge portions that can be folded or pivoted relative to the product-receiving portion to form integral, double-layered support members that extend from the product-receiving portion at an angle. The pivotable edge portions of the first panel layer and the second panel layer can also comprise respective extension portions coupled to the panel layers on the opposite side of the axis or fold line about which the edge portions pivot. The extension portions can be received in corresponding openings or recesses defined in the first and second panel layers. When the pivotable edge portions are pivoted relative to the product-receiving portion, the extension portions can be pivoted out of the openings such that they extend away from the product-receiving portion at an angle, and on the opposite side of the product-receiving portion from the pivotable edge portion to which they are connected. Thus, in certain embodiments, the insert can be folded into an H-shaped (or I-shaped) member with only two folding actions. When inserted into a shipping container or box, the double-layered support members, the extension portions, and the edges of the product-receiving portion can contact the walls of the box to prevent translation of the insert in all three axes, as well as rotation about any axis.

FIGS.1-8illustrate an article configured as a product-receiving insert, sleeve, receptacle, or holder10, according to one embodiment. The insert10can comprise a panel member12having a first end portion14and a second end portion16. Referring toFIGS.1,4, and5, the first and second end portions14and16overlap and can be secured together (e.g., using adhesive, fasteners, or other securing means) such that the panel member12forms a band or a loop of material. In certain embodiments the first end portion14and second end portion16can be secured together using a hot-melt adhesive or glue. In this way, edges of the double-layered panel member12, which may be configured as the first end portion14and the second end portion16, can be secured together to form a collapsible tube or sleeve (e.g., a collapsible rectangular tube or sleeve).

As described further herein, the insert10is movable between a relatively planar, first configuration (FIGS.1-3,6, and7) and a folded or functional, second configuration (FIGS.8,9, and11-13). The insert10can also be manipulated into an intermediate, expanded configuration (e.g.,FIGS.4,5,10, and16) when positioning a product inside the insert. When the insert10is in the first configuration, the panel member12is a double-layered panel member12(FIG.1). When the insert10is in the intermediate configuration (which can also be referred to as a third configuration), a space or cavity (e.g., cavity87, as described further below) is formed between the panel layers of the panel member12and configured to receive an object (e.g., product). The portion of the insert that defines the cavity87is referred to hereinafter as the product-receiving portion84of the insert10and is described further below. When the insert10is in the folded, second configuration, edge portions and extension portions of the insert10are pivoted, relative to the product-receiving portion84, to form support members configured to suspend the product-receiving portion84within a container or box into which the insert10is inserted. As a result, the product-receiving portion84and the object arranged within the cavity87can be spaced away from at least a portion of the internal walls (e.g., internal sidewalls) of the container (e.g., as shown inFIG.13).

Referring toFIGS.1-5, the panel member12can comprise a first fold line18(FIGS.2-5), a second fold line20(FIGS.2,4, and5), a third fold line22(FIGS.2-5), and a fourth fold line24(FIGS.3,4, and5). The fold lines18,20,22, and24can extend parallel to a first axis (e.g., the x-axis of the coordinate axes shown inFIGS.2and3). Accordingly, the insert10can be movable between the flat, substantially flat, or planar, first configuration (FIGS.1-3) and the expanded, intermediate configuration in which the panel member12forms a tube with an internal space (e.g., cavity87). In some embodiments, in the intermediate configuration, the panel member12can be expanded into a rectangular tube, as shown inFIGS.4and5.

In the planar, first configuration, the panel member12is folded about the fold lines18and22such that the panel member12forms a first panel layer or wall26(FIG.2) and an overlapping or coextensive second panel layer28(FIG.3). Thus, the panel member12can be referred to herein as a double-layered panel member12. The relatively flattened insert10can also comprise two closed ends and two open ends. For example, in the first configuration, the insert10can comprise a first closed end portion30corresponding to the fold line18, a second closed end portion32corresponding to the fold line22, a first open end portion34and a second open end portion36.FIG.6is a side elevation view illustrating the closed end portion30andFIG.7illustrates the open end portion34.

In certain embodiments, the fold lines18,20,22, and24can be creases, perforations, scores, or combinations thereof. For example, in the illustrated embodiment the first fold line18and the third fold line22can comprise perforations, and the second fold line20and the fourth fold line24can comprise creases. In other embodiments, the first fold line18and the third fold line22can comprise creases and the second fold line20and the fourth fold line24can comprise perforations.

The first panel layer26and the second panel layer28can also comprise additional fold lines proximate to the first fold line18and the third fold line22to allow the panel layers to move away from each other in the z-axis (out of the plane of the page inFIG.2) in order to receive a product between them (e.g., receive a product in a space, volume, or cavity87formed between the first panel layer26and the second panel layer28, as described further below with reference toFIGS.10-12and16). For example, referring toFIG.2, the first panel layer26can comprise a perforated fold line23proximate to the first fold line18and a perforated fold line25proximate to the fold line22. The second panel layer28can comprise similar fold lines on the opposite side of the insert, such as a fold line29and fold line31, as shown inFIG.3.

Referring again toFIGS.2and3, each of the first panel layer26and the second panel layer28can comprise a plurality of fold lines and cutouts arranged to form foldable or pivotable support members. For example, as shown inFIG.2, the first panel layer26can comprise a fold line38proximate to the open end portion34and a fold line40on the opposite side of the first panel layer26, proximate to the open end portion36. The fold lines38and40can extend parallel to the y-axis. The fold line38can define a flap42(also referred to herein as a pivotable edge portion or edge portion) pivotable relative to a main body portion44of the first panel layer26, about the fold line38(FIG.2). The fold line40can define a flap46(also referred to herein as a pivotable edge portion) pivotable relative to the main body portion44about the fold line40.

Beginning at the closed end portion30(FIG.2) and moving in a direction along the positive y-axis, the fold line38can comprise a slit portion48followed by a perforated portion50extending between the slit portion48and an opening52(which is described in greater detail below). Continuing from the opposite side of the opening52in the positive y direction, the fold line38can further comprise another perforated portion54, followed by a cut or slit portion56extending to the edge of the second closed end portion32. In the illustrated embodiment, the fold line40can be configured similarly to the fold line38(e.g., including the same or similar slit and perforated portions).

In some embodiments, the slit portions48and56can be configured as cuts or slits through the first panel layer26and the perforated portions50and54can include one or more perforations or cuts that are spaced apart from one another (e.g., not continuous with one another) and extend through an entirety or at least a portion of the first panel layer26.

As noted above, the first panel layer26can define an opening52(FIG.2). The opening52can be configured to receive an extension portion (e.g., extension member)58coupled to and/or extending from the flap42and movable therewith relative to the main body portion44into and out of the opening52. The extension portion58can extend inwardly toward the center of the main body portion44, from the flap42, along the positive x-axis. In some embodiments, edges of the extension portion58can be spaced apart from edges of the opening52, thereby creating clearance, space, or a gap33between the opening52and extension portion58(FIG.2).

The first panel layer26can further comprise a second opening60on the opposite side of the insert from the opening52(FIG.2). The opening60can be configured to receive an extension portion configured as a bracing member62extending inwardly toward the center of the main body portion44from the flap46, and movable with the flap46into and out of the opening60. In some embodiments, edges of the bracing member62can be spaced apart from edges of the opening60, thereby creating a gap (e.g., spaced or clearance)35between the opening60and the bracing member62.

In the illustrated embodiment, a length dimension (length37shown inFIG.2) of the extension portion58along the x-axis is greater than the length dimension (length39shown inFIG.2) of the bracing member62, although in other embodiments they may be the same. The extension portion58and bracing member62can have the same or similar lengths along the y-axis, as shown inFIG.2, although in other embodiments these dimensions can also be different. Additionally, although the extension portion58and bracing member62, and the corresponding openings52and60, are illustrated as having rounded corners, in other embodiments the corners may be angled (e.g., right-angled), chamfered, or another shape.

At least the main body portion44of the first panel layer26can further comprise a plurality of scores or relief cuts referred to herein as slits64spaced apart from each other along the x-axis and along the y-axis. The slits64can extend parallel to the y-axis and can have the same or different lengths. The slits64can be configured to allow the main body portion44to flex and expand to a convex shape when a product is received in the insert, as explained in greater detail below.

In some embodiments, the slits64can be configured as narrow scores or cuts in the first panel layer26. In some embodiments, the slits64can extend through an entire thickness of the first panel layer26. In other embodiments, the slits64can extend through at least a portion of the thickness of the first panel layer26.

In embodiments in which the insert10comprises a corrugated board material, such as corrugated paperboard, the slits64can extend perpendicular to the longitudinal axes (indicated by double-headed arrow53shown inFIG.2) of the corrugations51(shown inFIG.5). For example, as illustrated inFIG.2the corrugations51can extend along the x-axis, and the slits64can extend along they-axis. This can improve the ability of the insert10to flex in directions at an angle to the corrugations.

In the illustrated embodiment, the main body portion44can also comprise an opening66at or near the center of the main body portion44(FIGS.1and2). In some embodiments, the opening66can be rectangular, although in other embodiments the opening66can have any shape, size, and/or location. The opening66can allow a user to view the object in the cavity87(FIGS.10,11, and16) of the product-receiving portion84(which can be a pouch/pocket formed by the main body portion44, as described further below). The opening66can also allow a user to manipulate the object within the product-receiving portion84to position it at a desired or specified position after the support members have been folded into place. Certain embodiments need not include an opening such as the opening66, or may include more than one opening66, depending upon the particular application. Further, in some embodiments, the second panel layer28can include additional openings, similar to the opening66(FIG.3).

Turning now toFIG.3, the second panel layer28can be configured similarly to the first panel layer26.FIG.3illustrates the second panel layer28as viewed by rotating the insert10inFIG.2by 180° about the x-axis. The second panel layer28can comprise a pivotable edge portion or flap68foldable about a fold line70from and relative to a main body portion45of the second panel layer28. The second panel28can further comprise an extension portion72coupled to the flap68. The extension portion72can be configured similarly to the extension portion58, as described above. The second panel layer28can define an opening79that is configured to receive the extension portion72(e.g., similar to opening52, as described above).

The second panel layer28can further comprise a pivotable edge portion or flap74foldable about a fold line76from the main body portion45, and an extension member configured as a bracing member78extending from the flap74(FIG.3). The bracing member78can be configured similar to the bracing member62of the first panel layer26. The second panel layer28can define an opening61that is configured to receive the bracing member78(e.g., similar to opening60, as described above).

In some embodiments, the fold line70and the fold line76can be configured similar to the fold line38and the fold line40, respectively. For example, each of the fold line70and the fold line76can comprise a first slit portion71, a first perforated portion73, a second perforated portion75, and a second slit portion77(FIG.3).

In the illustrated embodiment, when looking at the first panel layer26(FIG.2) the bracing member78of the second panel layer28can be positioned beneath the extension portion58of the first panel layer26and the extension portion72of the second panel layer28can be positioned beneath the bracing member62of the first panel layer26.

Additionally, similar to the first panel layer26, the second panel layer28can include a plurality of slits64in the main body portion45of the second panel layer28. The slits64in the second panel layer28can be configured the same or similar to the slits64in the first panel layer26.

Each of the extension portion58, bracing member62, extension portion72, and bracing member78(which can all be referred to herein as extension portions) can have a free end19and an attached end21(FIGS.2,3, and8), where the attached end21is coupled to or continuous with the respective flap (e.g., edge portion)42,46,68, and74, and the free end19is configured to move freely within the respective opening52,60,79, and61.

Referring toFIGS.1,8, and9, and as introduced above, the insert10can be movable or foldable between the flat, planar, or collapsed, first configuration (FIG.1) and a folded or functional, second configuration (FIG.8). In the second configuration, the panel member12(e.g., the first and second panel layers26and28) can also define a main body portion configured as a pouch that defines the product-receiving portion84(FIG.8). For example, the main body portion44of the first panel layer26and the main body portion45of the second panel layer28, together, can form the product-receiving portion84. The product-receiving portion84can have a first side11and second side13(which can also be referred to as surfaces) that are arranged opposite one another across a horizontal axis98of the product-receiving portion84(FIG.9), and a first end15and a second end17that are arranged opposite one another across a central longitudinal axis97of the product-receiving portion84(FIG.9).

Further, in the functional configuration, the panel member12can further define two or more support members configured to support the insert10when arranged within a container or box (e.g., as shown inFIG.13, as described in greater detail below) and suspend the product-receiving portion84within the container and away from two or more interior side walls of the container. In some embodiments, as described above, in the functional configuration, the insert can include four support members. However, in other embodiments, the insert10can include another number of support members, such as two or three support members.

More particularly, with reference toFIGS.8and9, in some embodiments, the flaps42and74can be moved, folded, pivoted, or erected along the respective fold lines38and76(FIGS.2and3) in the direction of arrow27(FIG.8) to form a double-layered first support member80. As used herein, a “layer” can be a sheet of material (e.g., paper), and/or a composite material construction (e.g., corrugated paperboard or fiberboard) that is movable/pivotable as a unitary body. Thus, in the illustrated example the flap42is a first layer of the double-layered first support member80and the flap74is a second layer of the double-layered first support member80. In certain embodiments, the first support member80can extend at an angle94(e.g., in a range of 60° to 100°, in a range of 80° to 100°, perpendicular or 90°, or substantially perpendicular or 90°±5°) relative to a horizontal plane (e.g., the x-y plane inFIG.8) defined by the product-receiving portion84(FIGS.8and9). In the configuration illustrated inFIG.8, the first support member80is oriented downwardly along the negative z-axis. Moving, folding, or pivoting the flaps42and74can cause the extension portions58and78to pivot upwardly simultaneously such that they extend above the product-receiving portion84in the y-z plane and form a second support member81. In some embodiments, as shown inFIGS.8and9, the second support member81can extend outward, at an angle41(e.g., in a range of 60° to 100°, in a range of 80° to 100°, perpendicular or 90°, or substantially perpendicular or 90°±5°) from the product-receiving portion84. In some embodiments, the angle41can be the same as the angle94. In other embodiments, the angle41and angle94can be different.

In the illustrated embodiment, the extension portion58extends further in the z-direction than (e.g., past) the bracing member78, although other configurations are possible. Said another way, the extension portion58can extend a greater distance beyond (in the z-direction) the bracing member78. In certain embodiments, the bracing member78can extend beyond the location where the extension portion58is coupled to the flap42in order to support or brace the extension portion58against counterclockwise rotation (e.g., in a direction shown by arrow96inFIG.8) or buckling about they-axis. In this way, the first support member80and the second support member81are arranged on the same, second end17and on opposite sides (e.g., first side11and second side13) of the product-receiving portion84. For example, the first support member80and the second support member81can extend outward, in different directions (e.g., along the z-axis), from the opposite first and second sides11and13of the product-receiving portion84.

Still referring toFIG.8, the flaps46and68can also be movable, foldable, or pivotable along the respective fold lines40and70(FIGS.2and3) to form a double-layered third support member82on the opposite end (e.g., the first end15) of the product-receiving portion84from the first support member80(which is located at the second end17). The third support member82can extend outward (e.g., upwardly inFIG.8) from the product-receiving portion84in the y-z plane (e.g., a plane of the third support member82is in the y-z plane), and can form an angle43with the product-receiving portion84(e.g., in a range of 60° to 100°, in a range of 80° to 100°, perpendicular or 90°, or substantially perpendicular or 90°±5°). In some embodiments, the angle43can be the same or similar to the angle94. In other embodiments, the angle43can be different from the angle94.

For example, the third support member82and the first support member80can be arranged on opposite sides of the product-receiving portion84relative to the horizontal axis98, and opposite ends of the product-receiving portion84relative to the central longitudinal axis97of the product-receiving portion84(FIG.9).

The extension portion72and the bracing member62can simultaneously pivot downwardly such that they extend generally along the z-axis below the product-receiving portion84to form a fourth support member83(FIGS.8and9). The bracing member62can support or brace the extension portion72to reduce the tendency of the extension portion72to rotate or buckle in the counterclockwise direction about the y-axis, as shown by arrow96(FIGS.8and9). In some embodiments, as shown inFIGS.8and9, the fourth support member83can extend outward, at an angle47(e.g., in a range of 60° to 100°, in a range of 80° to 100°, perpendicular or 90°, or substantially perpendicular or 90°±5°) from the product-receiving portion84. In some embodiments, the angle47can be the same as the angle43. In other embodiments, the angle47and angle43can be different.

In this way, the third support member82and the fourth support member83are arranged on the same, first end15and on opposite sides (e.g., first side11and second side13) of the product-receiving portion84. For example, the third support member82and the fourth support member83can extend outward, in different directions (e.g., along the z-axis), from the opposite first and second sides11and13of the product-receiving portion84.

When the support members80-83are erected or folded into position, the insert10can be in the functional, second configuration and have an H-shaped profile when viewed edge-on from the closed end portions30and32.FIG.9schematically illustrates the H-shaped profile formed by, from top to bottom and left to right, the third support member82, the fourth support member83(and/or the extension portion72), the product-receiving portion84, the second support member81(and/or the extension portion58), and the first support member80. When the first and third support members80and82are erected and the insert10is in the functional, second configuration, the product-receiving portion84can also be closed on all four edges49by the closed end portions18and22, and by the walls of the flaps42and68(FIG.8).

With reference toFIG.10, in use and when the insert10is in the intermediate configuration, a product (e.g., object)86can be inserted into the cavity (e.g., space)87defined by the product-receiving portion84between the first and second panel layers26and28through, for example, the flaps42and74(FIGS.2and3) of the open end portion34(FIG.7) or the flaps46and68of the open end portion36. The panel member12can be at least partially opened by folding the panel member about the fold lines18,20,22, and24(FIGS.4and5) into a parallelogram or rectangular shape.

FIG.16is an open end-view (e.g., from open end portion36) of the insert10with another product99arranged within a central portion of the cavity87and wedged between the first panel layer26and the second panel layer28. Thus, as discussed further below and shown inFIGS.10and16, products of different sizes and shapes can be received in the cavity87of the product-receiving portion84of the same insert10.

Referring toFIG.11, after arranging the product86inside the cavity87, the insert10can be folded into the functional, second configuration and the support members80-83can be erected by folding or pivoting the flaps or edge portions42and74in a first direction (e.g., downwardly inFIG.11) and folding the flaps or edge portions46and68in an opposite, second direction (e.g., upwardly inFIG.11). The first and second panel layers26and28can expand, curve, or flex to conform to the shape and size of the product86aided by the slits64(e.g., by forming a convex surface67).

Referring toFIG.12, the folded insert10, in the second configuration, can then be disposed or inserted into a container or box88comprising internal height, width, and length dimensions configured to accommodate the insert10in the second, functional configuration shown inFIGS.8and12. In the illustrated embodiment, the container88comprises an open end90and a closed end92. The insert10can also be dimensioned to fit into particular containers.

FIG.13illustrates the shipping insert10received inside the container88, from the open end90of the container88. When closed, the container88can comprise six interior walls, including side walls89,91,93, and95, and end walls85(at the closed end92) and65(formed when the flaps at the open end90of the box are closed). Surfaces, edges, and/or projections or extensions of the insert10can brace the insert10against the interior surfaces of the walls of the container88such that the product-receiving portion84is suspended in the x-z plane away from or spaced apart from at least the side walls89,91,93, and95of the container88. In some embodiments, at least a portion of the support members80-83are configured to contact one or more of the sides walls89,91,93, and95.

For example, the first support member80and the extension portion72(e.g., the support member83) can contact the wall95, and the third support member82and the extension portion58(e.g., the support member81) can contact the side wall91such that the product-receiving portion84is spaced apart from (and not in direct contact with) each of the side walls91and95. The product-receiving portion84can also be spaced apart from the side wall89by at least the combined thickness of the flaps42and74(FIG.8) of the first support member80, and spaced apart from the side wall93by the combined thickness of the flaps46and68of the third support member82. The closed end portions30and32of the insert10can contact the end walls85, and87of the container88when the container88is closed.

As shown inFIG.13, the first and second panel layers26and28of the insert10can deform, flex, or bulge into a convex shape (e.g., to form the convex surface67) to conform to the shape of the product received in the product-receiving portion84.

In certain embodiments, the insert10can be constructed, folded, or assembled from a single piece of material, such as corrugated paperboard having one or more face sheets with a corrugated or fluted layer therebetween.FIG.14shows a representative example of a corrugated paperboard blank100from which the insert10can be assembled. The blank100can comprise a one-piece, unitary construction wherein each of the walls, extension portions, tabs, fold lines, knife cuts, score lines, and/or perforations, etc., are integrally formed with the blank. For example,FIG.14shows the first panel layer26and the second panel layer28, which can be continuous with one another, and their various extension portions, fold lines, slits, openings, and the like, as previously described above with reference toFIGS.1-13.

As used herein, the terms “unitary construction” and “integrally formed” refer to a construction that does not include any welds, fasteners, or other means for securing separately formed pieces of material to each other. In other embodiments, any of the various panels, extension portions, tabs, etc., can be separately formed and secured to the main body of the insert. In certain embodiments, the cuts, fold lines, score lines, etc., of the blank100can be formed in an in-line, streamlined manufacturing process such that the blank can be produced without requiring that the production equipment be stopped.

The insert embodiments described herein can also be made from any of various cellulosic fiber-based materials/cellulose-based sheet materials, such as paperboard, linerboard, kraft paper, solid or fluted sheet materials, multi-ply or single ply sheet materials, and the like. The insert embodiments can also comprise any of various non-cellulosic materials, such as polymeric or petroleum-based sheet materials including plastic sheets, films, walls, and/or layers. Such non-cellulosic materials may comprise structural and/or non-structural elements of the insert. The inserts can also comprise metal foils, metalized films, metal or plastic screening, rigid or semi-rigid webbing, or any other flexible or pliable sheet material. The inserts can also comprise any combination of the materials recited herein.

The insert embodiments described herein can also include one more surface treatments/coatings/films (e.g., such as on surfaces which may contact the object/goods contained in the insert). Such treatments may include anti-abrasion coatings, water resistance coatings, grease/oil-resistant coatings, vapor/odor-trapping coatings, release/non-stick/friction-reducing coatings (e.g., polytetrafluoroethylene), friction-enhancing/slip-resistant coatings, electrostatic discharge (ESD) coatings, flame or fire-resistant coatings, any of various dyes or colorants, and any combination thereof. Any of these materials may also be incorporated into the cellulosic or polymer-based materials forming the structure of the insert (e.g., into the pulp from which the cellulosic fiber-based sheet material is made).

FIG.15illustrates a representative embodiment of a blank200from which the container88ofFIG.12can be constructed.

One or more of the embodiments of the present disclosure can provide significant advantages over known packaging configurations. For example, because the support members and/or extension portions of the insert10contact the side walls89,91,93, and95of the container88, and the closed end portions30and32of the insert10contact the end walls85and65, a product disposed at or near the center of the product-receiving portion84can be spaced apart from all six walls of the container88(e.g., spaced inwardly from the walls of the container along three axes), or suspended at or near the volumetric center of the container. Additionally, the space or volume defined between the first and second panel layers26and28(e.g., the cavity87) can taper or narrow toward the edges of the product-receiving portion84. Accordingly, although products may be free to move slightly near the center of the product-receiving portion84, they will become wedged between the first and second panel layers26and28at the corners and/or edges of the product-receiving portion84, thereby limiting further movement and preventing contact with the walls of the container88. The first and third support members80and82, along with the extension portions58and72, can also prevent rotation of the insert10inside the container88about any axis. Thus, a product received in the insert10can be protected from impacts, and from displacement toward the walls of the box, thereby also preventing potential damage from inward (e.g., compression) forces against walls of the container88. Additionally, because certain embodiments of the insert10are plastic-free, or substantially plastic-free, the insert10and the container88are recyclable, unlike existing packaging systems including gas bladders, plastic film, and other polymer-based cushioning or restraints.

One or more of the insert embodiments described herein can also provide significantly improved consumer usability. For example, once a product is inserted into the product-receiving portion84, the first and second support members80and81can be simultaneously erected by folding the flaps42and74into place, and the third and fourth support members82and83can be simultaneously erected by folding the flaps46and68into place. Thus, with only two folding actions, the insert10can provide stability and impact resistance in six directions, along all three axes.

The ability of the product-receiving portion84to conform to the shape of the product also allows a wide variety of products to be accommodated, including all manner of shapes, sizes, and weights (e.g., as shown inFIGS.10and16). For example, the product-receiving portion84can accommodate relatively flat, rectangular objects, as well as round or cylindrical objects having any aspect ratio and dimensions which fit within the product-receiving portion. Additionally, because movement of a product in any direction will cause it to eventually become wedged between the first and second panel layers26and28at the edges and/or corners of the product-receiving portion, the insert10can accommodate relatively heavy products (e.g., liquid-filled containers, glass or metal objects, etc.) which traditionally require significant quantities of plastic material to adequately cushion and restrain.

Certain embodiments of the insert disclosed herein are formed substantially (99% or greater) of biodegradable materials. Certain embodiments of the insert disclosed herein are formed completely from biodegradable materials. Certain embodiments are plastic-free, or substantially plastic-free (i.e., less than 1% plastic). Certain embodiments of the insert are free of or substantially free of polyethylene (PE) and/or other synthetic polymers, which materials are typically found in conventional inserts in the form of liners, membranes, walls, shock-absorbing means such as gas bladders, etc. For example, in certain embodiments at least 90%, 92%, 95%, 97%, 98%, or more of the total mass of the insert is biodegradable. As used herein, “biodegradable” means that the referenced article can be substantially (at least 95%) or completely decomposed by microorganisms (e.g., bacteria, fungi, etc.) or other natural processes in one year or less from the time the article is placed in the trash, a landfill or the like. Certain of the disclosed inserts can also be produced using certain percentages by weight of renewable plant-based fiber materials and/or recycled materials. As used herein, cellulosic or paper material, especially such material treated with water-resistant coatings or additives, is “recyclable” if it can be processed into new paper/paperboard/cardboard/corrugated or other plant-based fiber material using the process defined in the Fibre Box Association's Voluntary Standard for Repulping and Recycling Corrugated Fiberboard Treated to Improve its Performance in the Presence of Water and Water Vapor. The containers or boxes into which the inserts are placed can also be biodegradable and/or recyclable, and can comprise cellulosic fiber-based materials.

In alternate embodiments, instead of having four support members that result in the insert having an H-shaped profile when in the folded or functional configuration and viewed edge-on from the closed end portions30and32(e.g., as shown inFIG.9), the insert can have less then four support members resulting in a differently-shaped profile. For example, the insert may include two support members disposed at one end of the product-receiving portion, resulting in a T-shaped profile. In other examples, the insert can include a different number of support members, such as three support members.

Explanation of Terms

As used herein, the terms “box” and “container” refer to an article that is capable of holding one or more products or other physical articles. As used herein, the term “cardboard box” refers to a box formed from any of a variety of heavy paper-like materials (e.g., cellulosic fiber-based materials), including, for example, cardstock, corrugated fiberboard, and/or paperboard. As used herein, the term “corrugated paperboard” refers to a fluted corrugated medium with one or more flat liner layers coupled thereto, such as a central corrugated layer with a first liner layer on one side and a second liner layer on another side of the central corrugated layer.

As used herein, the term “blank” refers to a flat sheet of material that is formed into an article (such as an insert) or a container, such as a flat sheet of corrugated paperboard. As used herein, the term “flat-formed” refers to an article that is manufactured from one or more flat pieces, such as a blank, that is manipulated into a different shape, such as by folding. As used herein, the terms “hingedly coupled” and/or “pivotably coupled” refers to any manner of engagement between a first part of a blank relative to a second part of the blank which allows the first part to travel relative to the second part without the first part becoming disengaged from the second part, such as by one or more fold lines, one or more cut lines, and/or some combination thereof. As used herein, the term “cut line” refers to an area that includes a cut that extends at least partially through the blank to facilitate folding, tearing, and/or some other structural advantage. Cut lines can be straight, curved, or some other shape, and can include perforation lines in which the cut is not continuous along the length of the cut line (i.e., a perforated line is a cut line that is discontinuous).

Although there are alternatives for various components, parameters, operating conditions, etc., set forth herein, that does not mean that those alternatives are necessarily equivalent and/or perform equally well. Nor does it mean that the alternatives are listed in a preferred order unless stated otherwise.

In view of the many possible embodiments to which the principles of the disclosed technology may be applied, it should be recognized that the illustrated embodiments are only examples and should not be taken as limiting the scope of the disclosure. Rather, the scope of the disclosure is at least as broad as the following claims. We therefore claim all that comes within the scope and spirit of these claims.