Abstract:
A packaging system and method that can be used to protect a display device. The packaging system includes a front foam panel, a base foam panel and a back foam panel, and two different types of foam for the panels. The base foam panel supports the weight of the display device and absorbs vibrations. The front foam panel protects the screen of the display device by spreading loads over a wider area and reducing the risk of the screen cracking. A back foam panel is made of a lower density foam and supports the display device rear panel in position while taking up the different shapes of the rear panels and allows for variation in thicknesses between different models.

Description:
BACKGROUND 
     Flat screen display devices such as televisions and computer monitors are fragile. The screens and other portions of these display devices can be damaged during shipment or other transport, as well as during storage, unless protective measures are taken. To protect such display devices during transport, various packaging and transport containers are known in the art. Complicating the protection of display devices during transport is that the rear sides of the display devices come in a number of different shapes, and display devices of similar screen sizes may have different thicknesses depending upon manufacturer and model. 
     SUMMARY 
     A packaging system and method are described which can be used to protect a flat screen display device including, but not limited to, during transport and shipment, storage, and the like. The packaging system is designed to accommodate different shapes of the rear sides of the display devices as well as to accommodate different thicknesses of display devices. 
     The packaging system uses at least three panels of foam material including a front foam panel, a base foam panel, and a back foam panel. Two different types of foam material are used for the panels. In one embodiment, the front foam panel and the base foam panel are made from a foam material, such as, but not limited to, closed-cell polyethylene foam having a higher density than the density of the foam material used to form the back foam panel. The base foam panel supports the weight of the display device and absorbs vibrations during transit. The front foam panel can be the same foam material as the base material because the display screen, the most vulnerable part of the display device, is substantially flat and requires protection from impacts particularly of a point loading nature. The higher density foam of the front foam panel can spread the load over a wider area and can reduce the risk of the display screen cracking. 
     The back foam panel is made of a foam material having a lower density than the foam material of the front foam panel and the base foam panel. An example of a suitable foam material for the back foam panel includes, but is not limited to, convoluted foam. The foam material for the back foam panel is selected to support the display device in position while accepting the different shapes of the rear sides of display devices and to allow for variation in thicknesses between different models. 
     The foam panels can be located on a suitable supporting wrap member, such as corrugated cardboard. In one embodiment, the foam panels are positioned off-center to one side of the wrap member to allow positioning of accessories such as the display device stand, cables, and other accessories. 
     In one embodiment, the packaging system can include a wrap member having a generally rectangular shape including opposite side edges perpendicular to opposite end edges; an open, flat configuration; a closed, folded configuration; an interior surface; and an exterior surface. A back foam panel constructed of a first type of foam material is fixed to the interior surface of the wrap member. A base foam panel is fixed to the interior surface of the wrap member and is spaced from and not directly connected to the back foam panel. The base foam panel is constructed of a second type of foam material that is different from the first type of foam material. In addition, a front foam panel is fixed to the interior surface of the wrap member and is spaced from and not directly connected to the back foam panel or to the base foam panel. The front foam panel is constructed of the second type of foam material. The wrap member is constructed so that it is foldable from the open, flat configuration to the closed, folded configuration. At the closed, folded configuration the wrap member forms a generally rectangular structure with the front foam panel facing the back foam panel, and the back foam panel and the front foam panel are generally perpendicular to the base foam panel. 
     In use, when the display device is disposed within the wrap member when in the closed, folded configuration, a display screen of the display device faces the front foam panel, a rear side of the display device faces the back foam panel, and an edge of the display device can rest on the base foam panel. 
     In one embodiment, the wrap member can be provided with suitably located hinges or fold lines along which the wrap member is designed to fold in order to surround the display device when in the closed, folded configuration. 
     In another embodiment, the packaging system includes a support substrate having opposite side edges perpendicular to opposite end edges; an open, flat configuration; a closed, folded configuration; an interior surface; and an exterior surface. A back foam panel is fixed to the interior surface of the support substrate, with the back foam panel being constructed of one type of foam. A base foam panel is fixed to the interior surface of the support substrate and is spaced from and not directly connected to the back foam panel. The base foam panel is constructed of a type of foam different than the one type of foam. In addition, a front foam panel is fixed to the interior surface of the support substrate and is spaced from and not directly connected to the back foam panel or to the base foam panel, and the front foam panel is constructed of the same type of foam as the base foam panel. The support substrate is foldable from the open, flat configuration to the closed, folded configuration, and in the closed, folded configuration the support substrate forms a generally rectangular structure with the front foam panel facing the back foam panel, and the back foam panel and the front foam panel are generally perpendicular to the base foam panel. 
     A method of packaging a display device using the packaging system includes disposing the wrap member on a support surface in the open, flat configuration with the interior surface thereof facing upward. The display device is laid display screen-side down on the front foam panel. The wrap member is then folded over the display device to form a generally rectangular structure with the back panel and the back foam panel facing the front panel and the front foam panel, and the upper panel facing the base panel and the base foam panel. The upper panel is then secured to an exterior surface of the back panel, for example using a double-sided adhesive tape that is secured to the interior surface of the upper panel. 
    
    
     
       DRAWINGS 
         FIG. 1  is a perspective view of the packaging system described herein in an open configuration, according to an embodiment. 
         FIG. 2  is a top view of the packaging system of  FIG. 1  in the open configuration, according to an embodiment. 
         FIG. 3  illustrates the packaging system at an initial stage of a process of packaging a flat screen display device, according to an embodiment. 
         FIG. 4  illustrates the next stage of the packaging process where the flat screen display device is disposed on the packaging system, according to an embodiment. 
         FIG. 5  is a top view of  FIG. 4  also showing placement of a display stand and accessories, according to an embodiment. 
         FIG. 6  illustrates the next stage of the packaging process including folding the packaging system around the display device, according to an embodiment. 
         FIG. 7  illustrates another stage of the packaging process including closing the packaging system around the display device, according to an embodiment. 
         FIG. 8  illustrates wrapping material being wound around the ends of the packaging system of  FIG. 7  to close the open ends of the packaging system, according to an embodiment. 
         FIG. 9  illustrates a method of packaging a display device using the packaging system as described herein, according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A packaging system and method are described that can be used to package a flat screen display device to protect the display device during transport and shipment, storage, and the like. The packaging system is designed to accommodate different shapes of the rear sides of display devices as well as accommodate differing thicknesses of display devices. The packaging system can also accommodate accessories used with the flat screen display device including, but not limited to, a display device stand, mechanical fasteners, cables, and the like. 
     As used herein, the phrase “flat screen display device” or just “display device” is intended to encompass any flat screen electronic display device including, but not limited to, flat screen televisions, flat screen computer monitors, and the like. In some embodiments, the packaging system can also be used to package other objects, whether electronic or non-electronic, that may have a shape similar to a flat screen display device. 
     The language “flat screen” as used herein is intended to encompass display screens that are substantially flat and encompass display screens that may deviate slightly from substantially flat but which are nonetheless considered flat. A display device includes a substantially flat panel display screen on one or a front side thereof, and a rear side opposite the display screen. The shapes and structures of rear sides of display devices typically vary based on the model and/or manufacturer of the display device. Likewise, the thicknesses of each display device measured between the front side and the rear side also typically vary based on the model and/or manufacturer of the display device. 
       FIGS. 1-2  illustrate an embodiment of a packaging system  10  described herein that is configured for packaging a display device. In general, the packaging system  10  is designed to package a display device  12  (see  FIG. 4 ) to protect the display device  12  from damage during transport and shipment, storage, and the like. The packaging system  10  is designed to accommodate different shapes of the rear sides of different models of display devices as well as accommodate differing thicknesses of different models of display devices. 
     The display device  12  can be any flat screen electronic display device including, but not limited to, a flat screen television, a flat screen computer monitor, and the like. In some embodiments, the packaging system  10  can also be used to package other objects, whether electronic or non-electronic, that may have a shape similar to a flat screen display device. 
     As best seen in  FIG. 2 , the packaging system  10  includes a wrap member  20  (also referred to as a support substrate) having a cushioning means. The cushioning means generally encase the display device  12  when the wrap member is folded from an open, flat configuration (shown in  FIGS. 1-2 ) to a closed, folded configuration (shown in  FIG. 7 ). In some embodiments, the cushioning means can include one or more foam panels. In some embodiments, the cushioning means can be formed of any material that is suitable for performing the functions described herein. 
     The wrap member  20  has a generally rectangular shape with opposite, parallel side edges  22   a ,  22   b , opposite end edges  24   a ,  24   b  that are perpendicular to the side edges  22   a ,  22   b , an interior surface  26 , and an exterior surface  28 . In the open configuration during use, the interior surface  26  is designed to face upwardly while the exterior surface  28  is designed to lay generally flat on a floor or other supporting surface. The wrap member  20  can be formed of any material that is suitable for performing the functions of the wrap member  20  that are described herein or are implicit in the operation of the packaging system  10 . In one non-limiting example, the wrap member  20  can be formed from corrugated cardboard. 
     The wrap member  20  is separated into a number of different sections or panels that optionally are an integral, one-piece construction with one another. In particular, the wrap member  20  includes a rectangular base panel  30  that extends from the side edge  22   a  to the side edge  22   b , and from a back edge  32  to a front edge  34 , the back edge  32  and the front edge  34  extending from the side edge  22   a  to the side edge  22   b  parallel to the end edges  24   a ,  24   b  and perpendicular to the side edges  22   a ,  22   b.    
     The wrap member  20  further includes a rectangular back panel  40  that is integrally joined to the back edge  32  of the base panel  30  along a hinge  42  defining a hinge axis that extends from the side edge  22   a  to the side edge  22   b  parallel to the end edges  24   a ,  24   b  and perpendicular to the side edges  22   a ,  22   b . The hinge  42  defines a fold axis or line along which the base panel  30  and the back panel  40  can fold relative to each other while still maintaining the integral connection between the base panel  30  and the back panel  40 . The back panel  40  includes the end edge  24   a.    
     Optionally, another hinge  44  can be provided between the base panel  30  and the back panel  40  that defines another fold axis or line, different than the fold axis defined by the hinge  34 , along which the base panel  30  and the back panel  40  can fold relative to each other while still maintaining the integral connection between the base panel  30  and the back panel  40 , according to an embodiment. The hinge  44  is spaced from the hinge  42 , with the hinges  42 ,  44  permitting the wrap member  20  to fold along the different axes to accommodate different thicknesses of the display device  12 . 
     Still referring to  FIG. 2 , the wrap member  20  further includes a rectangular front panel  50  that is integrally joined to the front edge  34  of the base panel  30  along a hinge  52  defining a hinge axis that extends from the side edge  22   a  to the side edge  22   b  parallel to the end edges  24   a ,  24   b  and perpendicular to the side edges  22   a ,  22   b . The hinge  52  defines a fold axis or line along which the base panel  30  and the front panel  50  can fold relative to each other while still maintaining the integral connection between the base panel  30  and the front panel  50 , according to an embodiment. 
     The front panel  50  also includes an upper edge  54  where it is integrally joined to an upper panel  60  along a hinge  62  defining a hinge axis that extends from the side edge  22   a  to the side edge  22   b  parallel to the end edges  24   a ,  24   b  and perpendicular to the side edges  22   a ,  22   b . The hinge  62  defines a fold axis or line along which the upper panel  60  and the front panel  50  can fold relative to each other while still maintaining the integral connection between the upper panel  60  and the front panel  50 , according to an embodiment. The upper panel  60  can also include additional spaced hinges  64 ,  66  that define fold axes or lines permitting the upper panel  60  to fold over the exterior surface of the back panel  40  as best seen in  FIGS. 6-7 . The spacing of the hinges  64 ,  66  can accommodate different thicknesses of the display device  12 . As evident from  FIG. 2 , the upper panel  60  includes the end edge  24   b.    
     The overall size of the wrap member  20  from the side edge  22   a  to the side edge  22   b  (D in  FIG. 2 ), and from the end edge  24   a  to the end edge  24   b , can be selected based on the size of the display device  12  to be packaged. In one embodiment, the overall size of the wrap member  20  can also be selected based on the size of a pallet on which the packaging system  10  will be placed for transport. In such an embodiment, the wrap member  20  may be sized to accommodate a range of display device sizes (e.g., having a display screen ranging from 32 inches to 42 inches) and fit onto a standard pallet (e.g., a pallet dimensioned 48 inches by 40 inches) without extending beyond the pallet. 
     A back foam panel  70  is fixed to the interior surface  26  of the back panel  40 . In the illustrated embodiment, the foam panel  70  covers a majority of the surface area of the interior surface  26  of the back panel  40 , and includes two edges  72   a ,  72   b  thereof that are contiguous with the side edge  22   b  and the end edge  24   a . An edge  72   c  of the foam panel  70  is spaced from the hinges  42 ,  44  and an edge  72   d  is spaced from the side edge  22   a . The foam panel  70  has a dimension D 3  between the edges  72   a  and  72   d . The dimension D 3  is generally less than the dimension D of the wrap member  20 . The foam panel  70  also has a thickness T 3  ( FIG. 1 ), which can vary depending on, for example, the type of foam selected and the particular embodiment. It is to be appreciated that the thickness T 3  can be the same as or different from the thicknesses T 1  and T 2 . 
     In use, the foam panel  70  is designed to be engaged with a backside of the display device  12 . The backsides of display devices tend to have differing shapes and sizes based on the manufacturer and model. The foam material of the foam panel  70  is selected to support the display device  12  in position while taking up the different shapes of the different back panels of different display devices and to allow for variation in thicknesses between different models. In one embodiment, the foam panel  70  is a lower density foam than the foam panels  80 ,  90  such as, but not limited to, a convoluted foam of a type known in the art. 
     A base foam panel  80  is fixed to the interior surface  26  of the base panel  30 . In the illustrated embodiment, the foam panel  80  covers a majority of the surface area of the interior surface  26  of the base panel  30 , and includes two edges  82   a ,  82   b  thereof that are contiguous with the side edges  22   a ,  22   b . An edge  82   c  of the foam panel  80  is spaced from the hinge  42  and an edge  82   d  is spaced from the hinge  52 . As illustrated in  FIG. 2 , the foam panel  80  has a dimension D 2 , which is about the same as the dimension D of the support member  20  as described above. The foam panel  80  also has a thickness T 2  ( FIG. 1 ), which can vary depending on, for example, the type of foam selected and the particular embodiment. It is to be appreciated that the thickness T 2  can be the same as or different from the thicknesses T 1  and T 3 . 
     In use, the foam panel  80  is designed to support the weight of the display device  12  when the packaged display device is stood upright and to absorb vibration during transit. The foam material of the foam panel  80  is of a different type than, and has a higher density than, the foam material of the foam panel  70 . The foam material of the foam panel  80  can be for example, but not limited to, closed-cell polyethylene foam of a type known in the art. 
     A front foam panel  90  is fixed to the interior surface  26  of the front panel  50 . In the illustrated embodiment, the foam panel  90  covers a majority of the surface area of the interior surface  26  of the front panel  50 , and includes an edge  92   a  thereof that is contiguous with the side edge  22   b , an edge  92   b  that is spaced from and parallel to the hinge  52 , an edge  92   c  that is spaced from the side edge  22   a , and an edge  92   d  that is spaced from the hinge  62 . As illustrated in  FIG. 2 , the foam panel  80  has a dimension D 1  between the edges  92   a  and  92   c . The dimension D 1  is generally less than the dimension of the wrap member D. In one embodiment, the dimension D 1  of the foam panel  90  can be greater than the dimension D 3  of the foam panel  70 . The foam panel  90  also has a thickness T 1  ( FIG. 1 ), which can vary depending on, for example, the type of foam selected and the particular embodiment. It is to be appreciated that the thickness T 1  can be the same as or different from the thicknesses T 2  and T 3 . 
     In use, the foam panel  90  is designed to face the display screen of the display device  12  which is the most vulnerable part of the display device  12 , and is typically flat and requires protection from impacts particularly of a point loading nature. In one embodiment, the foam material of the foam panel  90  is of the same type of foam as the foam panel  80 , for example, but not limited to, closed-cell polyethylene foam of a type known in the art. The higher density foam of the front foam panel  90  can spread loads over a wider area and can reduce the risk of the screen cracking. 
     Each of the foam panels  70 ,  80 ,  90  can be secured to its respective panel  40 ,  30 ,  50 , respectively, in any suitable manner in order to fixedly attach the foam panels  70 ,  80 ,  90  to the wrap member  20  so that the foam panels  70 ,  80 ,  90  do not shift positions prior to or during use. Examples of suitable attachment mechanisms include, but are not limited to, glue, tape, and the like, along with suitable combinations thereof. 
     As evident from  FIG. 2 , the foam panels  70 ,  90  are not centered on the interior surface of the wrap member  20  so that the foam panels  70 ,  90  are positioned closer to the side edge  22   b  than they are to the side edge  22   a . This leaves space between the edges  72   d ,  92   c  and the side edge  22   a  for positioning of miscellaneous items such as a display device stand  94   a  and accessories  94   b  to be packaged with the display device  12 , for example (shown in  FIG. 5 ). 
     As illustrated in  FIG. 2 , a strip of adhesive material  100  is disposed on the interior surface  26  of the upper panel  60  near the end edge  24   b . The adhesive material  100  can be any adhesive material that can adhere to the exterior surface  28  of the back panel  40  when the wrap member  20  is in the closed, folded configuration to retain the wrap member  20  in the closed, folded configuration. The adhesive material  100  can be for example, but not limited to, double-sided adhesive tape. However, other techniques for retaining the wrap member  20  in the closed, folded configuration can be used in addition to or separately from the adhesive material  100 , for example exterior straps that are fixed to or separate from the wrap member  20 , exterior tape or wrapping material, metal staples, and other fastening elements known in the art. 
     As evident from  FIG. 7 , when the wrap member  20  is folded, ends  110   a ,  110   b  of the packaging will be open. To close the ends  110   a ,  110   b , stretch wrapping material  200  (shown in  FIG. 8 ) can be optionally wound around the folded wrap member  20  including around the ends  110   a ,  110   b . Other techniques for closing the ends  110   a ,  110   b  can be used. For example, exterior straps can be deployed around the wrap member including around the ends  110   a ,  110   b , or flap panels can be integrally formed on the side edges  22   a ,  22   b  of the wrap member  20  such that when the wrap member  20  is in the closed, folded configuration, the flap panels can be folded over the opens ends  110   a ,  110   b  and suitably secured to the wrap member  20  to close the open ends  110   a ,  110   b.    
     With reference to  FIGS. 3-7  together with  FIG. 9 , operation and use of the packaging system  10  is as follows. In an initial step  120 , the wrap member  20  is disposed on a support surface, such as on a floor or a table, in the open, flat configuration with the interior surface  26  facing upward as shown in  FIG. 3 . The particular packaging system  10  selected can be based, for example, on the size of the display device  12 . In some embodiments, the packaging system  10  can include markings to indicate what size of display devices  12  can be stored therein. In some embodiments, a user may have to remove components of the display device  12  prior to step  122 . For example, the user may have to remove the display device stand  94   a  and/or accessories  94   b . In other embodiments, the display device stand  94   a  and/or accessories  94   b  may already be removed. 
     In step  122 , the display device  12  is then laid screen-side down on the foam panel  90  as shown in  FIG. 4 . It is to be appreciated that the display device  12  can alternatively be laid screen-side up on the foam panel  70 , according to an embodiment. Optionally, if there is the display device stand  94   a  and/or accessories  94   b , the accessories can be wrapped (e.g., in bubble wrap, or the like) and placed on the interior surface  26  of the front panel  50  at step  124 . It is to be appreciated that optional step  124  can alternatively be performed after steps  126  and/or  128 . The wrap member  20  is then folded over and around the display device  12  as shown in  FIG. 6  to the closed, folded configuration (step  126 ), forming a generally rectangular structure with the back panel  40  and the foam panel  70  facing the front panel  50  and the foam panel  90 , and the upper panel  60  facing the base panel  30  and the foam panel  80 . The wrap member  20  is then closed in step  128  as shown in  FIG. 7 , for example by folding the upper panel  60  over the exterior surface  28  of the back panel  40  and securing the upper panel  60  to the back panel  40  using the adhesive material  100 . Optionally, in step  130 , the open ends  110   a ,  110   b  can be closed, for example by stretch wrapping material  200  wound around the folded wrap member  20  including around the ends  110   a ,  110   b  or by other techniques as discussed above. The packaging system  10  can then, for example, be placed onto a pallet or other similar shipping container for transport, storage, or the like. In some embodiments, the packaging system  10  with the display device  12  can be set onto a pallet such that the base panel  30  is rested on the pallet surface. 
     The described embodiment(s) may be embodied in other forms without departing from the spirit or novel characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.