Abstract:
The invention is a protective container for transporting an enclosed object such as a flat screen television or other flat screen monitor. The protective covering includes two flaps and a base having soft padding material on their inner surfaces. An open configuration is essentially flat, allowing a monitor to be easily positioned on the covering. The flaps fold up to transform the protective container into a closed configuration, with straps or other connectors holding the flaps in place. The protective container has various features making it convenient to move manually and to transport in a delivery truck. The protective container is more convenient to use than the prior art, and can be manufactured from relatively inexpensive materials.

Description:
FIELD OF THE INVENTION  
       [0001]    The present invention relates generally to a method and apparatus for protecting a flat screen television or other fragile object. More specifically it is directed to a protective container that folds around the object to enclose it on three sides. 
       BACKGROUND OF THE INVENTION 
       [0002]    All their benefits notwithstanding, flat screen televisions are cumbersome, fragile, expensive objects. A television with a screen diagonal of 42 inches (107 cm) might have dimensions of 42×28×5 inches (width×height×depth), weigh 160 pounds (68 kg), and cost possibly exceeding a thousand dollars. Larger sets (e.g., with screen diagonals of 60 inches (152 cm) or more) are not uncommon. The television has a screen section containing a screen in a plastic case that encloses its electronics. Often, the screen section is mounted on a stand. The screen and the (usually plastic) stand are particularly fragile components. 
         [0003]    Repair of an flat screen television or monitor often requires that it be taken from its place of installation (e.g., a family room in a home) to a remote service center in a delivery truck. Safe transport of the television to and from the service center can present a challenge to the one or two delivery persons that are sent to pick up the set. In the recent past, commercial delivery persons would often simply wrap the flat screen television in a blanket to carry it to the truck. Once in the truck, the television might be loose and in danger of being damaged, not attached to the inner walls of the truck. Needless to say, this approach might not inspire confidence in the observant customer/television owner. For the service center, the bulkiness, fragility, and expense combined to produce high risk of loss. 
         [0004]    In the prior art, at the opposite extreme in terms of protectiveness are cases made of rigid plastic or metal, lined with foam material. These cases enclose the monitor on all sides. Because monitors come in a wide variety of shapes and sizes, a given rigid case fits only one or a very limited number of particular television models. The service center and delivery trucks would need an extensive suite of differently sized cases to accommodate the numerous possibilities. In addition to this inflexibility, these cases are very expensive to manufacture. Because of their great weight, which can approach 100 pounds (45 kg), these cases are usually equipped with casters to allow them to roll. On some surfaces the casters are helpful, but they mostly hinder rather than facilitate progress when negotiating stairways and the rough surfaces, gaps, dips and lips often encountered when such a large object is being loaded onto a truck. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention is an apparatus and method for protecting a fragile object that eliminates the principal disadvantages of the current technologies. It is easy to use, inexpensive, adaptable, and lightweight. 
         [0006]    The protected object in the preferred embodiment is a flat screen television or computer monitor because the invention arose in the context of handling such devices, but the invention applies to protection of other types of objects as well. Henceforth, we will use the more generic term flat screen monitor, or simply monitor, to include flat screen televisions, and flat screen computer monitors, and other similar devices. While the remainder of the description of the invention will deal primarily with protecting a flat screen monitor, the reader should remember that is only an exemplary embodiment, and that protection of other objects is also contemplated by the invention. 
         [0007]    The protective container includes a base and two flaps, which flank and are rotationally attached to the base, each along a respective fold axis. The base is generally rectangular in shape and generally two-dimensional (i.e., flat). The flaps are also generally two-dimensional; in some embodiments they are generally rectangular, but in others they could resemble a semi-circle or a semi-oval or other shape. The protective container has an inner surface and an outside surface; it also has an open configuration and a closed configuration. The monitor is usually placed onto the inner surface of the base when the protective container is in its open configuration and its outside surface lies flat in contact with the ground. The width, or longest dimension of the monitor, is oriented parallel to the fold axes. In some embodiments, the entire protective container in its open configuration is generally rectangular when viewed from above. In some embodiments, the flaps and base are fabricated from a single piece of material; in this case, the fold axis is along a bend in the material. In other embodiments, the flaps and base are separate, but are joined along the fold axis. 
         [0008]    To change from the open configuration to the closed configuration, each flap is folded upward along its fold axis toward the opposite flap. The flaps are then attached to each other by one or more straps, cords, ropes, or other closure devices. Some or all of the inner surfaces of the base and flaps is covered with a cushioning material, such as a compressible foam, (for example, one fabricated from plastic polymer). 
         [0009]    When a monitor is positioned as has been described on the base and the protective device is in the closed configuration, the bottom, front, and back sides of the monitor are enclosed by the protective container. The protective container is essentially open along the sides and top of the monitor, although one or more connectors may extend between the sides across those openings. In the closed configuration, some or all of the cushioning material included in the sides of the protective device will be in contact with the front and back of the monitor. 
         [0010]    In some embodiments, the panels of the protective container (i.e., the base and flaps) are fabricated from polypropylene plastic. In the preferred embodiment, the polypropylene is ? thick and contains flutes (thin hollow cavities) that are oriented perpendicular to the fold axes and, in each panel, are parallel to the plane of the panel. The flutes help to keep the protective device lightweight and reduce its cost. The orientation of the flutes stiffens the flaps in the upward direction when the protective container is in its open configuration. The material is not, however, entirely rigid in the upward direction; a certain amount of flexibility is useful in allowing the flap cushioning material to be adjusted with the connecting apparatuses (i.e., usually straps or belts) to be contoured into better contact with the monitor. 
         [0011]    The base of the protective device may have integrated components to provide additional protection to the monitor. In some embodiments, the base has two integrated support blocks that are separated from each other by a distance D. The screen of the monitor rests on the support blocks, which have a cushioned upper surface, while the stand is suspended between the support blocks. As mentioned previously, stands are a relatively fragile component of a flat-screen monitor. While such suspension is preferred to protect the stand, sometimes a technician will place a monitor having width less than D into the protective device. In this case, the weight of the monitor will rest directly on its stand between the two support blocks. To minimize the risk of breakage in this situation, the upper surface of the portion of the base between the two support blocks is also padded. Typically, the support blocks will extend across the base from one fold edge to the other. The support blocks prevent the monitor from slipping along the base in a direction parallel to the sides of the protective device. 
         [0012]    In some embodiments, the support blocks will be hollow to help reduce the weight of the protective device. In some embodiments, the support blocks will be closed on all sides. In others, they will be open on two sides, such as the sides of the support blocks that face the flaps when the protective container is in the closed configuration. 
         [0013]    Typically, there will be two top straps or belts across the top of the protective device to keep it in the closed configuration. Each of these belts will have a section attached to the opposite flaps of the protective container. The two sections join with a connector; typically one section ends in a female connector part and the other in a matching male connector part. The length of the strap can be adjusted to make the sides fit the monitor snugly. 
         [0014]    Also typically, two sets of end straps configured similarly to the top straps extend from flap to flap across each open end of the protective container. On each end, these two sets of straps are essentially horizontal and parallel to each other when their two sections are connected and the strap is appropriately tightened. These straps can be adjusted to bring the flap padding close to the monitor, thereby taking advantage of the slight flexibility of the flaps. They also serve to keep the monitor between the ends of the flaps. 
         [0015]    The protective container also has apparatuses (e.g., handles) at each end adapted to lifting and carrying it and the enclosed monitor. Preferably, the upper end strap can be used as the handle. If two people are available, one person can lift the device from each end by the respective handle. 
         [0016]    Alternatively, one person can move the protective device and enclosed monitor using a two-wheeled hand truck. In some embodiments, a grip attached to one side near its top can be grasped by the hand-truck operator to hold the side of the protective device firmly as the hand truck is tilted around the axis of its wheels to lift and move the protective device and monitor. In some embodiments, the grip is a small strap loop. 
         [0017]    If the protective device enclosing a monitor is being taken in a service vehicle to a repair facility, it should be secured to the side of the truck to keep it from being crushed by other contents or overturning. A clip attached to one flap of the protective device, typically by a strap or belt, is adapted to connecting to a bracket mounted to the inner wall of the vehicle. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of a protective container embodying the invention, in its open configuration. 
           [0019]      FIG. 2  is a perspective view of a protective container embodying the invention, in its closed configuration. 
           [0020]      FIG. 3  is a cross-sectional view through the base of a protective container embodying the invention, the view illustrating how the support blocks eliminate stress on the stand of a large monitor set. 
           [0021]      FIG. 4  is a cross-sectional view through the bottom of a protective container embodying the invention, the view illustrating how a small monitor set fits between the support blocks, resting on foam padding. 
           [0022]      FIG. 5  is a top view of a protective container embodying the invention, in its closed configuration, with dashed lines indicating the position of a monitor. 
           [0023]      FIG. 6  is an end view of a protective container embodying the invention, in its closed configuration, with dashed lines indicating the position of a monitor. 
           [0024]      FIG. 7  is an end view of a protective container embodying the invention, in its closed configuration, with dashed lines indicating the position of a monitor, showing the assembly being lifted by an end strap. 
           [0025]      FIG. 8  is a end view of a protective container embodying the invention, in its closed configuration, with dashed lines indicating the position of a monitor, showing a hand truck grip being used to load the assembly onto a hand truck. 
           [0026]      FIG. 9  is an end view of a protective container embodying the invention, in its closed configuration, with dashed lines indicating the position of a monitor, showing the hand truck grip securing the assembly as it is being moved on a hand truck. 
           [0027]      FIG. 10  is a perspective view of a retaining clip adapted to attaching the assembly to the inner side wall of a vehicle. 
           [0028]      FIG. 11  is a front view of a retaining clip adapted to attaching the assembly to an inner wall of a delivery vehicle. 
           [0029]      FIG. 12  is a perspective view of a protective container embodying the invention, in its closed configuration, with dashed lines indicating the position of a monitor, showing the retaining straps and retaining clips securing the assembly to an inner wall of a delivery vehicle. 
           [0030]      FIG. 13  is a flowchart depicting an embodiment of the method of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]      FIG. 1  illustrates an embodiment of the invention, a protective container  100  for a flat screen monitor. The protective container  100  includes two flaps  105  and a base  110 . The flaps  105  each contain a flap panel  106  and the base includes a base panel  110 . The base panel  110  is essentially rectangular. The flaps  105  and base  110  are essentially flat, but in some embodiments of the invention are fabricated from a plastic material that makes them somewhat flexible. The two flap panels  106 , which are also essentially rectangular, are attached to the base panel  110  along opposite edges of the base panel  110 . In the open configuration  101  shown in  FIG. 1 , the three panels are essentially flat and coplanar, and each has a an upper surface and a lower surface. The lower surface rests on a rigid essentially horizontal surface (not shown) such as the floor of a building or truck, or the ground. 
         [0032]    Each flap  105  can fold upward along a fold axis  180  that is coincident with the edge of the base  110  to which the flap is attached. Folding the two flaps  105  toward each other along respective fold axes  180 , as indicated by arrows in  FIG. 1 , transforms the protective container  100  from the open configuration  101  shown in  FIG. 1  to the closed configuration  102  illustrated by  FIG. 2 . In the embodiment shown, the flap panels  106  and base panel  110  form a unitary outer shell of the protective container  100 , consisting of a single sheet of plastic bent along the fold axes  180 . The upper surfaces of the flaps  105  and base  110  shown in  FIG. 1  become inner surfaces of the protective container  100  when it is in the closed configuration  102 . In  FIG. 2 , the viewer sees the entire outside surface of one flap  105 . 
         [0033]    Attached to and covering some portion of the inner surface of each flap  105  is cushioning material that is used to protect an enclosed object, such as a flat screen monitor. In the particular embodiment of  FIG. 1 , the cushioning material is provided by a rectangular piece of compressible foam flap panels  106 , one flap panel  106  attached to and covering about 75% of each flap  105 . In some embodiments, the compressible foam is of a type fabricated from plastic polymer 
         [0034]    In some embodiments, the panels of the protective container (i.e., the base panel and flap panels) are fabricated from polypropylene plastic. In the preferred embodiment, the polypropylene is standard commercial 6 mm thick corrugated polypropylene material, although a range of thicknesses from 4 to 8 mm will work reasonably well. In some embodiments, the material contains flutes (tubes describing thin hollow cavities) that have axes oriented perpendicular to the fold axes and, in each panel, are parallel to the plane of the panel. The hollowness of the flutes helps to keep the protective container  100  lightweight and to reduce its cost. The orientation of the flutes stiffens the flaps  105  in the upward direction when the protective container is in its open configuration. In other words, the flaps  105  resist sharp bending along lines parallel to the fold axes  180 . However, the material is still somewhat flexible, so that tightening straps or belts that connect the flaps  105  can result in gentle contours that bring the flap cushioning material into good contact with the monitor. Thus, while the embodiments shown in the figures (e.g.,  FIG. 2 ) illustrate flap panels  106  that are exactly flat in the closed configuration  102 , it should be noted that in other embodiments they will be somewhat curved. Also, in some embodiments, the angle between each flap panel  106  and the base panel  110  may be less than the 90 degree angle shown in the figures displaying the closed configuration  102 . 
         [0035]    In the embodiment shown in  FIG. 1 , two support blocks  120  are incorporated into the base  110  of the protective container  100 . The purpose of the support blocks  120  is discussed below in connection with  FIG. 3  and  FIG. 4 , which present cross-sections through the base  110  and support blocks  120  in the direction indicated by the section symbols designated ‘A’. Between the support blocks  120 , the base  110  is covered with a cushioning material on its inner surface. The support blocks  120  themselves are also covered on top with cushioning material. 
         [0036]    In the closed configuration  102 , the flaps  105  are held together by straps. Within the scope of the invention, the number of straps and their positions are variable. In the particular embodiment shown, there are two top straps  135  and two end straps  139 . Each top strap  135  has a female portion  136  ending in a female connector and a male portion  137  ending in a male connector. There are two end straps  139  on each end of the protective container  100 , an upper end strap  140  and a lower end strap  145 . Each upper end strap  140  has a female portion  141  and a male portion  142 . Similarly, each lower end strap  145  has a female portion  146  and a male portion  147 . When the protective container  100  is in its open configuration  101 , the pairs of male and female connectors are disconnected. 
         [0037]    In the closed configuration  102 , the protective container  100  describes two essentially open end spaces that are essentially perpendicular to the flap panels  106  and the base panel  110 , and an essentially open top space that is essentially parallel to the base panel  110 . 
         [0038]    As discussed previously, flat screen monitors are large, heavy, cumbersome delicate, and expensive. Consequently, they are difficult to move and to position. When the protective container  100  of the invention is its open position, it lies flat on the ground or floor. Two people carrying a flat screen monitor, one from each end, can easily position the monitor onto the bottom section of the protective container  100 , either suspended from the support blocks  120  as illustrated by  FIG. 3 , or between the support blocks  120  as illustrated by  FIG. 4 . Preferably, the support blocks  120  are hollow to act to some extent as shock absorbers to protect the monitor from vertical jostling. The materials and construction of the protective container  100  are sufficiently rugged that those people can even walk on the sides if necessary to more easily place the monitor onto the protective container  100 . 
         [0039]      FIG. 2  is a perspective view of an embodiment of the invention protective container  100  in its closed configuration  102 . Outlined with dashed lines is a flat screen monitor  200 , neatly sandwiched between the flaps  105  and cushioned by the flap panels  106  and the support block pads  121 . As will be discussed below, for smaller monitors, the base panel  110  also plays a cushioning role. All female connectors are coupled to their male counterparts, holding the sides upright and in place. This  FIG. 2  shows a feature that was not present in the embodiment illustrated by  FIG. 1 , namely, a hand truck grip  150 , which in the illustrated embodiment is a hand truck strap  150 . The hand truck strap  150  is adapted to loading the assembly, including the protective container  100  and the flat screen monitor  200  onto a hand truck, and will be described in connection with  FIG. 8  and  FIG. 9 . Also shown in  FIG. 2  are a pair of retainers  155 , which are adapted to attaching the assembly to the inner side wall of vehicle. The retainers  155  are discussed in more detail in connection with  FIGS. 10 through 12 . In some embodiments, the hand truck strap  150  and the retainers  155  will be on the same flap  105  of the protective container  100  as shown in  FIG. 2 , while in other embodiments, they are on opposite flaps  105 . 
         [0040]      FIG. 3  is a cross-section through a protective container  100  in the direction indicated by the arrows labeled ‘A’ in  FIG. 1 . It shows a flat screen monitor  200  suspended from the support blocks  120 , cushioned by the support block pads  121 . The monitor  200  includes a stand  210 , upon which it can rest when installed in a home or business. These stands  210  can be rather fragile. It is the purpose of the support blocks  120  to keep the weight of the screen portion of the monitor  200  off from its stand while it is being transported inside the protective container  100 . To emphasize this point, the stand  210  of the monitor  200  in the figure is depicted as not touching the base panel  110 . Because of compressibility of the base panel  110 , however, in some cases the stand  210  can be in contact with the base panel  110  while still bearing little of the weight of the screen. The height of the support blocks  120  and the distance between them are chosen to accommodate a range of the most commercially popular models of monitors  200 . This adaptability is a significant advantage over the rigid suitcase-like containers of the prior art. 
         [0041]    While the protective container  100  is intended primarily to handle monitors  200  in the suspended position illustrated by  FIG. 3 , retail and delivery and servicing staff can be expected to misuse the protective container  100  by using it to transport a monitor  200  that, because of its small width, cannot be suspended between the support blocks  120 . This situation is shown in  FIG. 4 . It is primarily to mitigate this common misuse that embodiments of the invention shown include a base panel  110 . 
         [0042]      FIG. 5  is a top view of an embodiment of a protective container  100  of the invention, showing a flat screen monitor  200  outlined with a dashed line. Like the one in  FIG. 3 , this monitor  200  is large enough to be properly suspended from the support blocks  120 . 
         [0043]      FIG. 6  is an end view of a an embodiment of a protective container  100  of the invention. The features of this figure have already been discussed. 
         [0044]      FIG. 7  illustrates the usefulness of the upper end strap  140  as a grip for a human hand  710  to lift and carry the one end of the assembly. Because of the size and weight involved, two people are required to carry the assembly, one on each end. The upper end strap  140  can also be used for a single person to drag the assembly across a horizontal surface. Note that the end straps in the unit shown in the figure can alternatively be crisscrossed, which increases the sturdiness of the unit at some expense in portability. In this configuration, the male portion of the top strap would be connected to the female portion of the bottom one, and conversely. 
         [0045]    Sometimes only one person may be available to move the assembly of protective container  100  and monitor  200 . As shown in  FIG. 8 , affixed proximate to the top of one flap  105  is a grip adapted to keeping the assembly from falling over as the flat bed of a hand truck  800  is slid underneath the assembly. A hand truck  800  is a two wheeled vehicle for manually moving large objects. In this particular embodiment, the grip is a hand truck strap  150 . At indicated by the arrow  800 , the hand truck strap  150  is adapted to being pulled by the hand  710  of a delivery person  720  to position it on the hand truck  800 . At this point, as shown in  FIG. 9 , the assembly can be moved by a single delivery person  720 . Over many surfaces where the casters of the prior art are impracticable, including many stairways and loading ramps, a hand truck  800  can move freely. 
         [0046]    Some embodiments of the invention incorporate a retainer  155  strap or cord for securing the assembly to the inner side wall of a delivery vehicle, such as a truck, resting on the floor. One such embodiment is shown in  FIG. 10 , which has a retainer clip  156  attached to the end of a retainer strap  157 .  FIG. 11  is a front view that corresponds to the perspective view of  FIG. 10 . 
         [0047]      FIG. 12  shows how the assembly might be attached to the inner side wall of a vehicle, such as a delivery truck. The base  110  of the protective container  100  rests on the floor  1200 , with one flap  105  of the protective container  100  essentially flush against a side wall  1210  of the vehicle. The retainer clips  156  are clipped into a bracket  1220  that is mounted on the side wall  1210 . The retainers  155  keep the protective container  100  and its contents from toppling over and from sliding around while the vehicle is in motion. 
         [0048]      FIG. 13  is a flowchart showing a particular embodiment of the method of the invention. After the method starts  1300 , the protective container  100  of the invention is placed  1305  on an essentially horizontal surface such as the ground or the floor of a building or a vehicle. The protective container  100  will be in its open configuration  101  as illustrated for one embodiment in  FIG. 1 . A flat screen monitor  200  is placed  1310  (usually carried) onto the protective container  100 . Preferably, the size of the monitor  200  will be such that it can be suspended on the two support blocks  120  that are included in the base  110  of the protective container  100 . If the monitor  200  has a stand  210 , the stand  210  will be suspended between the support blocks  120 . The protective container  100  is transformed  1315  into its closed configuration  102 , illustrated for one embodiment in  FIG. 2 , by folding the flaps  105  upward along the two fold axes  180 , and then connecting the flaps  105  using six straps, two across the top and two across each end of the protective container  100 . Typically, each of these straps will have two portions, one ending in a female connector and the other ending in a matching male connector. If  1325  two delivery persons will move the assembly (i.e., the protective container  100  enclosing the flat screen monitor  200 ), then each of them lift  1335  the assembly from the upper end straps  140 . Otherwise, the assembly will be loaded  1330  onto a hand truck  800  with the assistance of the hand truck grip  150 . The hand truck grip  150  might also be used to keep the assembly from changing position as the hand truck  800  is rolled. One embodiment of a hand truck grip  150  is shown in  FIG. 2 , namely a loop of strapping material attached to a flap  105 . The assembly is positioned  1340  on a delivery vehicle, resting on the floor  1200  against a side wall  1210 . retainer clips  156  attached by straps to the protective container  100  are then engaged into a bracket  1220  mounted on the side wall  1210  of the delivery vehicle. 
         [0049]    Of course, many variations of the above method are possible within the scope of the invention. Certain embodiments, for example, do not include some or all of steps  1325  through  1345 . Also for example, the flaps  105  might be joined by a rope wrapped around the protective container  100  rather than by straps. If straps are used, their number and locations are variable. The protective container  100  might have more formal lifting handles proximate to each end rather than just providing the upper end straps  140  for lifting. 
         [0050]    The present invention is not limited to all the above details, as modifications and variations may be made without departing from the intent or scope of the invention. Consequently, the invention should be limited only by the following claims and equivalent constructions.