Abstract:
A packaging assembly for protecting a fragile article comprises a fragile article, packaging material around the fragile article, an outer carton containing the packaging material and the fragile article, and at least one cavity within the outer carton. The cavity is outside of the packaging material.

Description:
FIELD OF THE INVENTION 
   The present invention relates to a shipping carton and insert for use in packaging breakable or fragile articles. 
   BACKGROUND 
   Flat, fragile products such as framed glass mirrors, are highly subject to breakage during shipping and handling. Protective packaging that is sufficient for normal handling often does not withstand more aggressive handling. While known rectangular shipping cartons have been used to protect products during shipping and handling, experience has shown that the geometry of these packages makes it convenient for handlers to lay them flat at the base of, or within a stack of goods. The crushing which results from this stacking often damages the fragile products within the rectangular shipping carton despite the use of protective packaging, and is responsible for a significant amount of the breakage realized with such goods. Experience has also demonstrated that warning statements on the package such as “do not lay flat” or “this end up” are frequently ignored during shipping and handling. 
   With the parcel shipment of fragile items such as mirrors and the like, a reduction in breakage reduces the cost of addressing dissatisfied customer complaints, processing replacement orders and stocking and handling replacement items. The reliable delivery of undamaged, unbroken items improves customer satisfaction. Known methods for avoiding breakage include strapping Masonite to a package, this however is expensive and cumbersome. 
   SUMMARY OF THE INVENTION 
   The invention described herein is a packaging system and method to protect the shipping and handling of a fragile flat product that is packed in its own container or carton. Unlike most conventional methods of shipping fragile items, the method described herein does not require any additional packing material and/or strapping in order to protect the fragile product boxed in its own container. 
   A packaging assembly is disclosed for protecting a fragile article which comprises a fragile article, packaging material around the fragile article and an outer carton containing the packaging material and the fragile article. The outer carton in turn comprises a base, a first wall extending up from the base, and a second wall extending up from the base. The base rests on a horizontal plane, at least one of the first wall and second wall forms an acute angle with the horizontal plane, and the sum of the angles formed by the first wall and second wall with the horizontal plane is not equal to one hundred and eighty degrees. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a perspective view of an assembled shipping carton; 
       FIG. 2  is a planar view of a complete, unfolded, shipping carton; 
       FIG. 3  shows two embodiments of the present invention wherein the shipping carton has an “A” shape, and a triangular shape, respectively, when viewed from the side. 
       FIG. 4  shows a side view of an alternative embodiment of the present invention; and 
       FIG. 5  shows a further alternative embodiment wherein a shipping carton contains an inner carton and inserts provided to stabilize the inner carton within the shipping carton. 
   

   Before any embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangements of components set forth in the following description, or illustrated in the drawings. The invention is capable of alternative embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the terminology used herein is for the purpose of illustrative description and should not be regarded as limiting. 
   DETAILED DESCRIPTION OF THE INVENTION 
   Known shipping cartons used for transporting fragile packaged materials such as glass have a relatively flat geometry making it convenient for handlers to lay them flat and stack them with other goods. When these cartons are stacked together with or underneath of other items, deformations are caused in the structure of the shipping carton, putting excess pressure on the packaged materials contained within. These packaged materials, which may be panes of glass, mirrors, or sheets of some other fragile material, are susceptible to breakage when subjected to shear forces across their thinnest dimensions produced by crushing or bending of the shipping carton. 
     FIGS. 1 and 3  show a perspective view and a side view of a first embodiment of an assembled shipping carton embodying one or more features of the present invention. In  FIG. 1 , a shipping carton  600  includes a pair of matching main panels  601 . One main panel  601  comprises the front, and the other the rear, of the shipping carton  600 . In one embodiment the main panels  601  are rectangular in shape. Likewise, the shipping carton  600  has a pair of matching side panels  602 , disposed on either side of the shipping carton  600  and connecting the main panels  601 . In one embodiment of the present invention, the side panels  602  are trapezoidal in shape. The side panels  602  may or may not be isosceles trapezoids. They may also be triangular in shape as shown with dashed lines in  FIG. 3 , or any other suitable shape. 
   In  FIG. 3  a shipping carton  400  is shown enclosing an inner carton  410 , and wherein the shipping carton  400  has an “A” shape when viewed from the side. The shipping carton  400  is supported on a surface  450  and has a top panel  403  and a bottom panel  404 , and at least one cavity  430  within the shipping carton  400  but without the inner carton  410 . 
   In addition, in  FIG. 1 , a top panel  603  is provided connected to both the main panels  601  and the side panels  602 . In one embodiment the top panel  603  is rectangular in shape. In another embodiment of the present invention, the top panel  603  meets the side panels  602  at a perpendicular angle. In a further embodiment, the top panel  603  meets one or both of the main panels  601  at an angle interior to the shipping carton  600  which is an obtuse angle. 
   Furthermore, the shipping carton  600  is also provided with a bottom panel  604 . The bottom panel  604  is also connected to both the main panels  601  and the side panels  602 . In one embodiment the bottom panel  604  is rectangular in shape. In another embodiment of the present invention, the bottom panel  604  meets the side panels  602  at a perpendicular angle, and meets one or both of the main panels  601  at an angle interior to the shipping carton  600  which is an acute angle. 
   In the event that the bottom panel  604  meets only a first main panel  601  at an acute angle θ′, then the angle θ″ the bottom panel  604  makes with a second main panel  601  is not the supplement of the angle θ′. In this manner the main panels  601  are constrained in that they may not lie in parallel planes; in the vicinity of the bottom panel  604  they are a maximum distance apart and in the vicinity of the top panel  603  they are a minimum distance apart. It is also contemplated however, that in an alternative embodiment, the main panels are parallel to each other. 
   The acute angle θ′ or θ″ made by the intersection of the bottom panel  604  and at least one of the main panels  601  at the base of the shipping carton  600  provides an increased rigidity and resistance to crushing of the shipping carton  600 , and can deflect forces created when the shipping carton  600  strikes or is struck by another surface. 
   In one embodiment, the shipping carton  600  has an “A” or trapezoidal shape similar to a conventional “A” frame used from transporting glass when viewed from the side. The appearance of the reinforced shipping carton  600  is distinctive; the overall shape of an isosceles trapezoid mimics the “A frame” that is the universal standard in handling glass or other flat, fragile materials. This appearance makes a shipper&#39;s products easily identifiable, and makes the fact that the shipper has taken extra effort to protect the product evident to a recipient. 
   The shape of the shipping carton  600  discourages a handler from laying the shipping carton  600  flat on either of the main panels  601  and stacking other goods on top of the shipping carton  600 ; a practice that has led in the past to breakage of the packaged materials within the shipping carton. Were a handler to attempt this, the fact that the main panels  601  do not lie in parallel planes has the result that a sloped main panel  601  would be the only surface available for stacking other packages on top of the shipping carton  600 . This sloped surface would cause the other stacked goods to slide off of the shipping carton  600 , thus discouraging this practice. 
   Furthermore, the broad bottom panel  604  and lower center of gravity of the shipping carton  600  encourages a handler to store it on the bottom panel  604 . This orientation minimizes the footprint of the shipping carton  600  on a horizontal surface and avoids the problems associated with stacking the shipping carton  600  beneath other packages. 
   Because the shipping carton  600  is smaller at the top when stored on end (i.e. on the bottom panel  604 ), and because the center of gravity of the shipping carton  600  is below the vertical center of the shipping carton  600 , it is easier to manipulate during shipping and handling than are known packages. These same handling advantages are also available to a customer at his warehouse or job site. 
   The shipping carton  600  may in one embodiment be constructed from corrugated cardboard. It may also be used to enclose an inner carton  610  occupying an area within the shipping carton  600  denoted by the dashed lines  605 . This inner carton  610  may furthermore be secured within the shipping carton  600  by a series of fasteners  620  such as staples, or other appropriate fasteners for securing shipping containers known to one skilled in the art. In one embodiment of the present invention, the inner carton  610  is provided to enclose packaged materials  611 , which may be panes of glass, mirrors, or sheets of some other fragile material. The inner carton  610  may also be constructed from corrugated cardboard, and need not fill the entire interior of the shipping carton  600 ; in the event that it does not, one or more cavities  630  are left within the shipping carton  600  and without the inner carton  610 . 
   In one embodiment, the inner carton  610  is a standard rectangular shipping carton. The packaged materials  611  in the inner carton  610  may be selectively combined with the shipping carton  600  only for parcel shipments where the experienced incidence of damage is high. As such, costs associated with these shipments do not have to be borne by products expected to receive less aggressive handling, which may be shipped alone in a standard rectangular shipping carton. 
     FIG. 2  is a planar view of a complete, unfolded shipping carton  500 , which may be assembled to become the shipping carton  600  of  FIG. 1 . As mentioned above, the unfolded shipping carton  500  has a pair of main panels  501 , multiple side panels  502 , multiple top panels  503 , and a bottom panel  504 . 
   In one embodiment the main panels  501  are rectangular in shape. Likewise, the shipping carton  500  has two pair of matching side panels  502 , disposed on either side of the main panels  501 . In one embodiment of the present invention, the side panels  502  are trapezoidal in shape. The side panels  502  may or may not be isosceles trapezoids, and they may, in a further alternative embodiment, be triangular in shape, as well as being another suitable shape. 
   In addition, at least one top panel  503  is provided connected to at least one of the main panels  501 . In one embodiment the top panel  503  is rectangular in shape. Furthermore, the shipping carton  500  is provided with a bottom panel  504 . The bottom panel  504  connects the two main panels  501 . In one embodiment the top panel  503  is rectangular in shape. 
   The side panels  502  are each provided with a series of angles  591  through  594 . In an embodiment of the present invention, the angles  591  through  594  measure 85°, 93°, 83° and 99°, respectively. In an alternative embodiment, the angles  591  through  594  measure 83°, 96°, 85° and 94°, respectively. These measurements are understood to be purely exemplary, and could vary by ±4 degrees, or in some cases more. 
   The panels of the shipping carton  500  are designed to fold along the fold lines  505  so that the flat, unfolded shipping carton  500  may be assembled into the shipping carton  600  of  FIG. 1 . Accordingly, the main panels  501  may be brought towards each other, allowing top panels  503 , as well as two pair of side panels  502 , to fold and overlap each other. 
   These overlapping panels may be secured to each other by fasteners  620  (see  FIG. 1 ) such as staples, tape, adhesive, or any other appropriate method known to one skilled in the art. In one embodiment, the use of non-asphaltic tape in addition to staples to secure the overlapping panels will better secure the panels. In another embodiment, the shipping carton  500  is constructed at the time of use; it is normally stored unused in its flat state, resulting in savings of storage space. 
   In alternative embodiments of the present invention, the specific number of top panels  503  and side panels  502  may be altered. For example, a single top panel  503  and a single pair of side panels  502  (disposed to either side of only one of the main panels  501 ) could be used. These embodiments, while simpler, lack the added rigidity of the overlapping panels discussed in the previous embodiment. 
   The dimensions of the various panels of the shipping carton  500  are denoted by the dimensions  560 ,  564 ,  565  and  568 . In one embodiment, the dimension  560  is 38.68 inches, the dimension  564  is 70.85 inches, the dimension  565  is 27.91 inches and the dimension  568  is 21.04 inches. 
     FIG. 4  shows an embodiment of the present invention having only 1 angled main panel instead of the two angled main panels (with respect to the bottom panel) of  FIG. 1 . A shipping carton  200  is employed with an inner carton  210  and has a top panel  203  and a bottom panel  204 . These panels run in planes parallel to one another. The shipping carton also has a pair of main panels  281  and  282  running in nonparallel planes between the top panel  203  and bottom panel  204 . In an alternative embodiment, the two main panels  281  and  282  may be of different lengths from one another. Thus, the top panel  203  and bottom panel  204  together with the main panels  281  and  282  form a non-rectangular convex quadrilateral, or trapezoid. 
   In a further embodiment, to prevent the inner carton  210  and the products contained within from being loose and unstable within the shipping carton  200 , one or more fasteners  220  are inserted through a plurality of sides (e.g. such as one of the main panels  281  and  282 ) of the shipping carton  200  to the inner carton  210 , making the combination one integral package. The fasteners  220  fortify the protection around products contained within the inner carton  210  by fastening two cartons together; in essence a double-walled carton is provided. In another embodiment, fasteners  220  are inserted through the bottom panel  204  as well as two side panels  202  lying in the plane of the page and connecting the main panels  281  and  282 , securing the shipping carton  200  to the inner carton  210  on three sides. 
   The dimensions of the inner carton  210  may be varied to match the alternate sizes  215  of an alternative inner carton. These alternate sizes  215  are merely exemplary; the inner carton  210  may be of any dimensions which fit within the shipping carton  200 . The inner carton  210  may or may not contact the interior of the shipping carton  200  on more than one of its panels. 
   In one embodiment of the shipping carton  200 , a recipient opens the top of both the shipping carton  200  and the inner carton  210  for safe and convenient removal of a product contained within. In a further embodiment, the top panel  203 , as well as the top surface of the inner carton  210  comprise overlapping flaps that may be unfolded to allow a recipient of the shipping carton  200  access to the products contained within. 
   Because the main panels  281  and  282  of the shipping carton  200  are not parallel to one another, and because in one embodiment the inner carton  210  comprises an ordinary rectangular solid, a cavity  230  remains within the shipping carton  200  regardless of the size and orientation of the inner carton  210 ; i.e. the inner carton  210  does not take up all the interior space within the shipping carton  200 . 
   The cavity  230  creates an acute angle on the shipping carton  200  resulting in an increased rigidity and resistance to crushing of the shipping carton  200 . This angle can deflect a force otherwise applied to a product contained within the shipping carton  200  when the carton strikes the surface  250 , or another surface. 
     FIG. 5  shows another alternative embodiment wherein a shipping carton  300  contains an inner carton  310 . As in  FIG. 4 , at least one cavity  330  is present creating an acute angle in the shipping carton  300 , as well as providing the shipping carton  300  with a broad base on the surface  350  and a lower center of gravity. An insert  340  is provided to stabilize the inner carton  310  within the shipping carton  300 . In a further embodiment, the inner carton  310  contacts both a top panel  303  and a bottom panel  304 . In yet another alternative embodiment, fasteners  320  may be used in addition to the inserts  340  to stabilize the inner carton  310  within the shipping carton  300 . 
   The invention is not limited in the choice of material from which the box can be made. It could be made from corrugated cardboard, or any other appropriate box making material. Furthermore, the shape of the shipping carton is not limited to the “A” or wedge shapes described herein and shown in the drawings. The shipping carton could also be any shape that is substantially non-rectangular so that it makes it difficult to stack, unlike shaped cartons on top of each other while shipping and handling a fragile product. 
   The reduction in breakage afforded by the proposed packaging system and method not only results in cost savings for replacement goods and handling of replacement orders, but also addresses customer dissatisfaction issues that arise whenever a product experiences a high rate of breakage. Parcel carriers usually do not insure glass goods against such damage.