Abstract:
An insert and packaging system for a box may include a pliable body defining a void. The void is dimensioned to receive an end of a portable computer. The void is characterized by a height and a width. The body that defines the void has at least two removable portions, such that removal of the portions alters the height and width of the void, thereby permitting the void to receive a portable computer of varying dimensions.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates generally to packaging schemes for portable consumer electronics, and more particularly to an improved box and set of inserts for packaging of portable consumer electronics, such as a portable computer. 
       BACKGROUND 
       [0002]    Consumer electronics, such as personal computers, are typically purchased at a commercial outlet, where knowledgeable employees of the outlet may assist an individual in understanding the product offerings, and in deciding which particular product to purchase. At the time of purchase, customers may be offered a warranty for purchase that supplements the warranty offered by the manufacturer of the product. For example, a purchaser of a portable computer may be offered a multi-year warranty for a price that is determined as a given fraction of the purchase price of the computer. Commercial outlets often maintain a service department to handle warranty claims or other service claims that their customers may have. Thus, for example, when an owner of a portable computer returns his or her computer to the commercial outlet for service, the service department may attempt to remedy the problem exhibited by the portable computer. If the service department is unable to remedy the problem, the service department may ship the computer to a central location for servicing. 
         [0003]    As a necessary condition of shipping the computer from the outlet to the service center (and vice versa), the personal computer must be properly packaged within a cardboard box. To protect the computer during shipping, the box may include foam inserts that surrounds and suspends the computer, so that if the box were to be dropped, a surface of one or more of the foam inserts absorbs the impact and generally “cushions” the blow. Therefore, the computer is spared damage from the occasionally harsh handling incurred during the shipping process. 
         [0004]    One particular problem encountered during boxing a personal computer for shipping is that personal computers come in different dimensions, which generally necessitates the need for different sized boxes and different sized inserts to accommodate the various possible dimensions of portable computers. In ad hoc shipping environments, such as outlets for consumer electronics, maintaining an inventory of various sized boxes and inserts for boxes is cumbersome and expensive. 
         [0005]    An opportunity for improvement of the packaging scheme used during shipping of portable electronics, such as portable computers exists. An improved scheme may reduce the need for different size boxes and/or inserts for different sized computers. It is desirable that such a scheme be relatively inexpensive and easy to use. 
       SUMMARY 
       [0006]    Against this backdrop, the present invention was developed. According to one embodiment, an insert for a box may include a pliable body defining a void. The void is dimensioned to receive an end of a portable computer. The void is characterized by a height and a width. The body that defines the void has at least two removable portions, such that removal of the portions alters the height and width of the void, thereby permitting the void to receive a portable computer of varying dimensions. 
         [0007]    According to another embodiment, an insert includes a body of foam having a first surface and an opposed second surface. The insert also includes a first plurality of incisions extending from the first surface to second surface. The insert further includes a second plurality of incisions extending from the first surface and stopping short of the second surface. The first and second pluralities of incisions cooperate to form first and second legs that are foldably joined to the second surface of the body of foam, and a third detachable leg. The first, second, and third legs abut one another, so that when the first and second legs are unfolded, and when the third leg is detached, a void is created. The void is dimensioned for receiving an end of a portable computer. 
         [0008]    According to another embodiment, a packaging system for a portable computer includes a box and a means for suspending a portable computer within the computer. The suspending means is adjustable to permit suspension of a portable computer of varying dimensions. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  depicts an exemplary embodiment of a pair of inserts suspending a portable computer. 
           [0010]      FIG. 2  depicts the embodiment of the pair of inserts of  FIG. 1  within an exemplary embodiment of a box. 
           [0011]      FIG. 3A  depicts a frontal view of the insert of  FIG. 1 . 
           [0012]      FIG. 3B  is another depiction of a frontal view of the insert of  FIG. 1 . 
           [0013]      FIG. 4A  is another depiction of a frontal view of the insert of  FIG. 1 . 
           [0014]      FIG. 4B  is a frontal depiction of the insert of  FIG. 1  with removable portions thereof withdrawn from the insert. 
           [0015]      FIG. 5  depicts an exemplary embodiment of a foam body exhibiting incisions that cooperate to form the insert of  FIG. 1 . 
           [0016]      FIG. 6  is another depiction of an exemplary embodiment of a foam body exhibiting incisions that cooperate to form the insert of  FIG. 1 . 
           [0017]      FIG. 7  depicts the foam body of  FIG. 5  with its pair of foldable legs extended from the body. 
           [0018]      FIG. 8A  is a frontal depiction of the foam body of  FIG. 7 . 
           [0019]      FIG. 8B  is a frontal depiction of the foam body of  FIG. 8B  with a removable portion withdrawn. 
           [0020]      FIG. 9A  is a rear view of an exemplary embodiment of the foam body of  FIG. 8B . 
           [0021]      FIG. 9B  is a top view of an exemplary embodiment of the foam body of  FIG. 9A . 
           [0022]      FIG. 10A  is a frontal view of an exemplary embodiment of the foam body of  FIG. 9B . 
           [0023]      FIG. 10B  is a frontal depiction of the foam body of  FIG. 10A  with removable portions withdrawn. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Various embodiments presented herein will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments should not be construed as limiting the scope of covered subject matter, which is limited only by the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments. 
         [0025]      FIG. 1  depicts an improved packaging scheme that includes a pair of inserts  100  and  102 . According to some embodiments, each insert  100  and  102  is a foam body, such as packaging foam or other foam used for creation of packaging inserts or in the packaging field generally. (Each of the various inserts disclosed herein may be made of foam, although this is not essential to practice of the invention. The inserts may be made of any material suitable for use in connection with packaging and for serving the purpose of securing and/or protecting an article during transport.) Each body defines a cavity or void that is dimensioned to receive opposite ends  105  and  107  of a portable electronic device, such as a portable computer  104 . Each insert  100  and  102  includes a pair of legs  106 ,  108 ,  110 , and  112  that project outwardly from the insert. According to some embodiments, the legs  106 ,  108 ,  110 , and  112  are composed of the same materials of which the bodies of the inserts are composed. Although the inserts  100  and  102  of  FIG. 1  are shown as including two legs apiece, in principle, each insert  100  and  102  may include any number of legs, including a single leg, two legs, three legs, or more. 
         [0026]      FIG. 2  depicts a box  200  into which the inserts  100  and  102  have been introduced. As can be seen from  FIG. 2 , the inserts  100  and  102  rest upon the bottom surface of the box  200 , and suspend the portable computer  104  therein. According to some embodiments, the box  200  is composed of cardboard, as is commonly known in the art of packaging. As shown in the particular embodiment of  FIG. 2 , each insert  100  and  102  has three legs  106 ,  108 ,  110 ,  112 ,  202 , and  204  protruding therefrom. (In  FIG. 1 , each insert  100  and  102  was shown with only two legs  106 ,  108 ,  110 , and  112  protruding therefrom; center legs  202  and  204  are optional, and provide for better support and rigidity.) The legs  106 ,  108 ,  110 ,  112 ,  202 , and  204  extend outwardly from the body of each insert  100  and  102 , and abut opposite sides  201  and  203  of the box  200 . The legs  106 ,  108 ,  110 ,  112 ,  202 , and  204  serve to stabilize the inserts  100  and  102  and computer  104  within the box, so that they do not move within the box when the box is being handled during shipping, for example. According to the embodiment shown in  FIG. 2 , the side of the box identified by reference numeral  203  is actually the side of a compartment that may be used to contain items such as electrical cords, etc. 
         [0027]      FIGS. 3A and 3B  depict side views (as viewed from a vantage identified by the dashed line presented in  FIG. 2 ) of the insert  100 . According to the embodiments described with reference to  FIGS. 1 and 2 , the inserts  100  and  102  are substantially identical. Therefore, the ensuing description of insert  100  serves as a description of insert  102 . Of course, the inserts  100  and  102  need not be identical, but for the sake of manufacturability, the inserts  100  and  102  may often be substantially identical. As can be seen from  FIG. 3A , the body of the insert  100  defines a void or cavity  300  generally characterized by a height, h, and a width, w. The void  300  is partially defined by surfaces  302 ,  304 ,  306 , and  308 , and during use, the computer makes contact with these surfaces  302 ,  304 ,  306 , and  308 . According to some embodiments, one or more of the surfaces  302 ,  304 ,  306 , and  308  may exhibit a sawtooth shape. For example, as shown in  FIG. 3A , surface  302  exhibits a sawtooth shape. The sawtooth shape allows the insert  100  to receive an end of a portable computer having a range of heights. For example, the insert  100  may receive an end of a portable computer having a height as great as h 1 , and as little as h 2 . Although not depicted, surface  304  may exhibit a sawtooth shape, according to some embodiments, thereby achieving an even greater flexibility in terms of the range of heights of portable computers that may be received by the insert  100 . Further, as shown in  FIG. 3B , surfaces  306  and  308  also exhibit a sawtooth shape. Consequently, the insert  100  may receive an end of a portable computer having a width as great as w 1 , and as little as w 2 . Although  FIG. 3B  depicts surfaces  306  and  308  as exhibiting a sawtooth shape, according to some embodiments, only one of the surfaces  306  or  308  exhibits a sawtooth shape. Still further, according to some embodiments, none of the surfaces  302 ,  304 ,  306 , and  308  exhibit a sawtooth shape. 
         [0028]    To provide still greater flexibility in the range of heights and widths of computers receivable by the insert  100 , one or more of the surfaces  302 ,  304 ,  306 , and  308  that partially define the void or cavity  300  may be removable. For example, surfaces  304 ,  306 , and  308  may be removable along the dashed lines depicted in  FIG. 4A . By “removable,” it is meant that the portions of the insert body identified by the aforementioned dashed lines may be separated from the insert body without resort to any tool, such as a cutting tool or the like. For example, the insert body may be scored along the dashed lines, in order to permit easy removal of the portions  304 ,  306 , and  308 . When those portions  304 ,  306 , and  308  are removed, the cavity or void  300  grows in width (if portions  306  or  308  are removed) and in height (if portion  304  is removed). Therefore, as shown in  FIG. 4B , the width of the void  300  grows to a dimension w 3 , where w 3 &gt;w 2 , and the height grows to a dimension as great as h 3 , where h 3 &gt;h 2 . Note that removal of portion  304  causes the newly-created surface  400  to exhibit a sawtooth shape, thereby providing even greater flexibility in height, as described previously. 
         [0029]      FIG. 5  depicts a foam body  500  that includes various incisions that cooperate to form an insert like that described with reference to  FIG. 1-4 . The body  500  has a first surface  502  (the surface that is viewed from the vantage presented in  FIG. 5 ), and an oppositely disposed second surface that is not visible, given the vantage presented in  FIG. 5 . The body  500  includes three different types of incisions: (1) incisions that extend all they way from the first surface  502  to the opposed second surface, which are indicated in  FIG. 5  by solid lines; (2) scoring, i.e., incisions that intermittently extend from the first surface  502  to the opposed second surface to permit for removable portions of the body  500 , which are indicated by dashed lines; and (3) incisions that extend from the first surface  502  but not to the second opposed surface, which are indicated by dotted lines (e.g., incisions that extend about 80% or 90% of the way through the body). 
         [0030]    The aforementioned incisions cooperate to create the various features of the insert described previously. For example, portions  600  and  602  may be rotated about the dotted lines (one of which has been identified by reference numeral  604 ), which represent incisions extending through about 90% of the foam body, to form legs projecting outwardly from the body. The legs formed by such rotation correspond to the legs  106 ,  108 ,  110 , and  112  described with reference to  FIGS. 1 and 2 .  FIG. 7  depicts a front view of the insert after having performed such a rotation operation. 
         [0031]    Next, as shown in  FIG. 8A , the portion identified by reference numeral  800  may be removed. As a consequence of such removal, the insert appears as shown in  FIG. 8B . As can be seen from  FIG. 8B , the void described with reference to  FIGS. 1-4B  is created by unfolding of the legs  600  and  602  and removal of the central portion  800 . The legs  801  and  803  of the removed central portion may then be inserted into the slots  802  and  804  in the foam body, creating a central leg. The leg formed by such insertion corresponds to the central legs  202  and  204  depicted in  FIG. 2 . A rear view of the insert after having inserted portion  800  to form a central leg is depicted in  FIG. 9A . A top view is shown in  FIG. 9B . 
         [0032]    It should be noted, that the distal portions  900  and  902  of legs  600  and  602  are removable, by virtue of the scoring indicated by the dashed lines (this scoring is also shown in  FIG. 5 ). Removal of the distal portions  900  and  902  of the legs, shortens the distance by which the body of the inserts are offset from the edge of the box, and therefore lengthens the span of space between the two inserts, thereby allowing for the inserts to accommodate a longer computer. 
         [0033]    Turning to  FIG. 10A , it should also be noted that the portions identified by reference numerals  1000 ,  1002 , and  1004  are removable, by virtue of the scoring indicated by the dashed lines (this scoring is also depicted in  FIG. 5 ). Removal of the portions identified by reference numerals  1000 ,  1002 , and  1004  extends the length and width of the void, as discussed previously, and therefore permits for reception of a larger computer.  FIG. 10B  depicts the insert with the portions identified by reference numerals  1000 ,  1002 , and  1004  removed. 
         [0034]    The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. Those skilled in the art will readily recognize various modifications and changes that may be made to the present invention without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims.