Abstract:
The present invention relates generally to a collapsible shipping container utilizing standard box making equipment manufactured from material such as paper, corrugated board, and corrugated plastic, and in particular, to a package that employs a tensioned film system, that holds a product hammock style, between two layers of film and/or between a film and a wall of the package. To use the box, the formed box which has been stored in a flat configuration, is unfolded to a substantially rectangular or square configuration by folding at least one flap panel about its fold line to a position superadjacent a central panel and conforming the container to a hexagonal cross-section. In this configuration the box retains its hexagonal cross-section and can be self-supporting in a vertical position, in order to facilitate the filing operation. The container has retaining means for securing a pair of plastic films at their ends to opposing sides of the container.

Description:
[0001]    This patent application is a continuation-in-part of copending patent application Ser. No. 12/570,755, filed Sep. 30, 2009, which application claims the benefit of provisional patent application 61/194,663, filed Sep. 30, 2008, and having the title “Suspension Packaging”, the disclosures of which are incorporated by reference, as though recited in full. 
     
    
     BACKGROUND 
       [0002]    1. Field of Invention 
         [0003]    The present invention relates generally to a collapsible shipping container utilizing standard box making equipment manufactured from material such as paper, corrugated board, and corrugated plastic, and in particular, to a package that employs a tensioned film system, that holds a product hammock style, between two layers of film and/or between a film and a wall of the package. 
         [0004]    2. Brief Description of Prior Art 
         [0005]    The prior art includes numerous variations of boxes that employ a hammock like structure to cradle a product within the box. However, there is still a need to design a box that provides the combination of low cost, ease of manufacture, ease of transport to an end user, ease of use from the end user&#39;s standpoint, and which provides a required level of cushioning. 
       SUMMARY 
       [0006]    The present invention relates to a typical box having four sides and bottom and top flaps when erected. 
         [0007]    In accordance with an embodiment of the invention, a box comprises a first blank having a first center panel with four edges and four flap panels. Each of the four flap panels is contiguous with one of the center panel four edges and separated therefrom by a flap panel fold line. The center panel has a first central fold line extending parallel to the flap panel fold line separating the opposing first and third panels. The central fold line extends from an edge of the center panel to an outer edge of at least one contiguous opposing flap panel. The second flap panel is divided into two sub-panels by a slot and the fourth panel is divided into two sub-panels by a fold line. The first and third opposing flap panels have an elongated slot that are parallel to one another and to the center panel central fold line. 
         [0008]    A second blank is dimensioned to coordinate with the first blank when the two blanks are in their folded configuration with the second blank overlying the first blank. The second blank has a second center panel with four edges and four flap panels contiguous with each edge that are separated from the center panel by an edge fold line. A first and a third of the flap panel have a contiguous pair of opposing end flaps that are separated from a neighboring flap panel by a slot. 
         [0009]    A second central fold line of the second blank extends parallel to the central fold line of the first blank when the first and second blanks are in their assembled configuration with the second blank overlying the first blank. The second central fold line extends from one edge of the center panel to an outer edge of at least one of its contiguous opposing flap panel. Each contiguous end flap and flap panel is separated by a fold line, and each flap panel is separated from said second center panel by a fold line. 
         [0010]    The second blank flap panels have a peripheral edge that is longer than half the distance between the central fold line and a parallel fold line, with the peripheral edge being an edge not parallel with the central fold line. 
         [0011]    In accordance with an embodiment of the invention, a box is formed and filled using the above blanks. The first blank first and second flap panels are rotated about their fold lines, from the plane of the first blank toward a position in which the first flap panel&#39;s peripheral edge and the second flap panel&#39;s peripheral edge are separated by a distance equal to or less that the distance between the first flap panel fold line and the second flap fold line. A support film member is secured to the first and second flap panels in a position and dimensioning to be taut when the container is in a rectangular or square cross-sectional configuration and flaccid when said container is in a hexagonal configuration. The second blank&#39;s first flap panel is then fixed to the first blank&#39;s first flap panel and the second blank&#39;s second flap panel to the first blank&#39;s second flap panel. The second blank&#39;s second flap panel having its fold line parallel to the first blank&#39;s central fold line. This places the central fold line of the second blank parallel to the central fold line of the first blank when in the assembled configuration. The container is then folded to a substantially flat configuration for transportation to a user. 
         [0012]    In accordance with an embodiment of the invention, to use the box, the formed box is unfolded to a substantially rectangular or square configuration by folding at least one flap panel about its fold line to a position superadjacent a central panel and conforming the container to a hexagonal cross-section. 
         [0013]    In accordance with an embodiment of the invention, the support film member is secured to the first blank&#39;s first and second flap panels by passing each of two ends of the support film member through one of the elongated slots and fixing the two ends of the support film to its respective flap panel. 
         [0014]    In accordance with an embodiment of the invention, the support film member can be a pouch, and an article can be inserted into the pouch while the box is in a hexagonal cross-sectional configuration. The box can be supported in its hexagonal cross-sectional configuration on a substantially horizontal planar surface and positioned with its first blank center panel central fold line substantially vertical relative to horizontal planar surface. An article can then be inserted into the pouch while the support film of the pouch is flaccid. The pouch can also have a flap member and an adhesive containing region, with the flap member folding onto the adhesive containing region to secure the article product within the pouch. 
         [0015]    In accordance with another embodiment of the invention, the support film can be secured to the first blank&#39;s first and second flap panels by wrapping a first end of a first support film around a peripheral edge of the first blank&#39;s first flap panel and a second end of the support film around a peripheral edge of the first blank&#39;s second flap panel. A second support film can then be secured to the first blank&#39;s first and second flap panels by passing each of two ends of said support film through one of the elongated slots and fixing each of the two ends of to its respective flap panel. The second support film can be in the form of a pouch and the product inserted into the pouch while the box is in a form having a hexagonal cross-section. The pouch can have a flap member and an adhesive containing region with the flap member being folded onto the adhesive containing region to secure the product within the pouch. 
         [0016]    In accordance with a further embodiment of the invention, a box for retaining products, especially fragile products, for shipping comprises a first center panel with four flap panels contiguous with the edges of the first center panel. The four flap panels are separated from the center panel by a flap panel fold line. The first center panel has a central fold line extending parallel to two of the flap panel fold lines that extends from the edge of the center panel to an outer edge of at least one of its contiguous flap panels. The opposing first and a second flap panels have an elongated slot that are parallel to the other elongated slot and to the first center panel and second central fold lines. 
         [0017]    A second blank has a second center panel is contiguous with, and separated by a fold line, four flap panels, with a second central fold line extending parallel to the first central fold line. The second central fold line extends from an edge of the second center panel to an outer edge of at least one of its contiguous flap panels. At least one contiguous flap panel has one of the first or the second central fold line extending from its contiguous edge with the center panel to its outer edge. The flap panel is folded about its fold line to a position superadjacent to its contiguous central panel, and the box is conformed to a hexagonal cross-section. The box includes a support film having two ends is secured at each end to a panel contiguous with a center panel, along a line that is parallel to the central fold line. The support film is positioned and dimensioned to be taut when the box is in a rectangular or square cross-sectional configuration and flaccid when the box is in a hexagonal configuration. 
         [0018]    At least one end of said support film can pass through the elongated slot from the interior side of the elongated slot containing panel to the exterior side of the elongated slot containing panel, and then secured to the exterior side of the elongated slot containing panel. The support film can be a pouch with the elongated slots being substantially midway between the edges of the panel to which it is attached. The support film can also be secured to the panels at a position proximate one of the center panels for supporting an article between the support film and the center panel. 
         [0019]    In accordance with a further embodiment of the invention, a package is formed and filled by using at least one blank having a first blank center panel and four flap panels and a first central fold line extending parallel to two flap panel fold lines. The central fold line extends from an edge of the center panel to an outer edge of at least one of its contiguous flap panels. The first and a second of the four flap panels being on opposing sides of said first center panel. 
         [0020]    A second center panel is contiguous with a flap panel at each of its four edges, and separated therefrom by an edge fold line. At least one of the flap panels has a pair of opposing end flaps contiguous therewith and separated therefrom by a fold line. A second central fold line is parallel to the first central fold line and extends from an edge of the center panel to an outer edge of at least one of its contiguous flap panels. The pair of opposing end flaps are each separated from a neighboring flap panel by a slot, and each contiguous end flap and flap panel is separated by a fold line. 
         [0021]    In accordance with a still further embodiment of the invention the box is assembled by rotating the two flap panels contiguous with the first central panel about their fold lines, from the plane of the first central panel toward a position in which the two flap panels are separated by a distance equal to or less that the distance between the two flap panel fold lines with said first central panel. A support film is secured to the first two flap panels. A second center flap panel is fixed to a first center panel flap panel that has the support film secured thereto, forming a box. The box is folded to a substantially flat configuration, for transportation to a user. 
         [0022]    In accordance with a further embodiment of the invention a flattened box is unfolded to a substantially rectangular or square configuration, and at least one flap panel is folded about its fold line with a center panel to a position superadjacent to the center panel. The box is then conformed to a hexagonal cross-section and supported in its hexagonal cross-sectional configuration on a substantially horizontal planar surface. The box is positioned with its first blank center panel central fold line substantially vertical relative to said substantially horizontal planar surface. An article is then insert into the box for support by the support film member while said support film member is flaccid. The support film can be a pouch, and inserting an article into the box for support by the support film while it is flaccid comprising inserting an article into the pouch. The at least one flap panel is folded about its fold line with a center panel from the position superadjacent to the center panel, to an end closure position and the box is restored to its square or rectangular cross-sectional configuration. The box is then sealed as for example, by applying an adhesive tape to the ends of the box. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0023]    The invention will be described with the accompanying drawings, in which: 
           [0024]      FIG. 1A  is a plan view of a blank for making a first half of the box of the present invention. 
           [0025]      FIG. 1B  is a plan view of a blank for making a second half of the box of the present invention. 
           [0026]      FIG. 2  is a perspective view of the first blank illustrating the first folds in accordance with an embodiment of the present invention. 
           [0027]      FIG. 3  is a perspective view of the box prior to the two blanks being affixed to each other, in accordance with an embodiment of the present invention. 
           [0028]      FIG. 4  is a perspective view of the assembled box folded flat, in accordance with an embodiment of the present invention. 
           [0029]      FIG. 4A  is a perspective view of the assembled box open to a rectangular cross-section, in accordance with an embodiment of the present invention. 
           [0030]      FIG. 5  is a perspective view of the erected box with end flaps and end panels folded superadjacent against the central panels and the side panels that are between the central panels, in accordance with an embodiment of the present invention. 
           [0031]      FIG. 6  is a perspective view of the box of  FIG. 5 , standing on end in its hexagonal configuration, in accordance with an embodiment of the present invention. 
           [0032]      FIG. 7  is a perspective view of a box similar to that of  FIG. 5 , but with both a pouch and a retention film and standing on end in its hexagonal configuration, in accordance with another embodiment of the present invention. 
           [0033]      FIG. 8  is a perspective view of a box being assembled and shown open to a rectangular cross-section similar to the box of  FIG. 3 , but with an additional fold over end flap for extra rigidity and strength, in accordance with an embodiment of the present invention. 
           [0034]      FIG. 9A  is a further design of a blank in accordance with an embodiment of the present invention. 
           [0035]      FIG. 9B  is an additional blank design in accordance with an embodiment of the present invention. 
           [0036]      FIG. 10  is a perspective view, partly in cross-section, of a one piece blank design and containing a retention film, in accordance with an embodiment of the present invention. 
           [0037]      FIG. 11  is a perspective view, partly in cross-section, of a one piece blank design and containing a support film, in accordance with a further embodiment of the present invention. 
           [0038]      FIG. 12  is a perspective view of the box on end in its hexagonal configuration, and having a pouch and an article being inserted into the pouch, in accordance with an embodiment of the present invention. 
           [0039]      FIG. 13  is a plan view of a support film prior to being folded into a pouch configuration, in accordance with an embodiment of the present invention. 
           [0040]      FIG. 14  is a perspective view, partly in cross-section, of a one piece blank design and containing a retention film, in accordance with a further embodiment of the present invention. 
           [0041]      FIG. 15  is a perspective view, partly in cross-section, of a two piece blank design and containing a retention film, in accordance with a further embodiment of the present invention. 
           [0042]      FIG. 16  is a plan view of a blank for making a one piece box, in accordance with a further embodiment of the present invention. 
           [0043]      FIG. 17  is a perspective view, partly in cross-section, of a support film wrapped around a retainer member, in accordance with a further embodiment of the present invention. 
           [0044]      FIG. 18  is a perspective view, partly in cross-section, of a one piece blank design with a support film wrapped around a retainer member, in accordance with a further embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
     Definitions 
       [0045]    It is advantageous to define several terms before describing the invention. It should be appreciated that the following definitions are used throughout this application. Where the definition of terms departs from the commonly used meaning of the term, applicant intends to utilize the definitions provided below, unless specifically indicated. 
         [0046]    For the purposes of the present invention, the term “box” refers to an enclosure of any size and shape formed from a single or multiple bonded corrugated sheet that has the appropriate score lines, as well known in the art. The terms package and container are used herein interchangeable with the term “box”. 
         [0047]    For the purposes of the present invention, the term “clearance space” as used herein, refers to the space between flap side edges and an adjacent side wall, when the box is in its erected configuration. 
         [0048]    For the purposes of the present invention, the term “slot” refers to the manufacturing method that makes a cut that can be approximately, 3/16 of an inch wide between adjacent bottom flaps, or wider. For example,  114 ,  180 ,  186 ,  184 ,  181 , and  182  represent slots as illustrated in  FIGS. 1A and 1B  and provide clearance space. 
         [0049]    For the purposes of the present invention, the terms “corrugated paper”, corrugated plastic, and the term “corrugated board” are used interchangeably, and are inclusive of single, double and triple wall corrugated materials for shipping boxes, as well known in the art. 
         [0050]    For the purposes of the present invention, the term “double wall” refers to corrugated material that has two corrugated layers separated by a flat sheet and two outer flat sheets. 
         [0051]    For the purposes of the present invention, the term “knock down” refers to the box when it is flattened as illustrated, for example, in  FIG. 4  herein. 
         [0052]    For the purposes of the present invention, the terms “opened”, “assembled”, and “erected” refers to the configuration of the box as illustrated for example, in  FIGS. 5 and 6  herein When erected, the box can be, or has been filled with product. 
         [0053]    For the purposes of the present invention, the term “score lines” may also be referred to as “fold lines” or “crush lines”. Forming fold lines in blanks from which boxes are made is well known in the art, and any desired one of the well known techniques can be used. As seen in  FIGS. 1A and 1B , reference numbers  108 ,  109 ,  110 ,  11 ,  158 ,  156 ,  159 ,  170 ,  171 ,  173 ,  174 ,  170 , and  177 , indicate typical score lines. 
         [0054]    For the purposes of the present invention, the term “score” refers to the manufacturing method that linearly crushes the corrugated sheet to enable a fold line to be formed, as well known in the art. 
         [0055]    For the purposes of the present invention, the terms “side panels” the side wall panels of a rectangular box, as for example, panels  101 ,  102 ,  103 ,  152 ,  153 , and,  155  of  FIGS. 1 and 7 . In the case of a square box, two opposing sidewalls of the four sidewalls are referred to as end panels and the other two opposing side walls are referred to as side panels. 
         [0056]    The terms end panels and side panels are terms of convenience and are used to identify a first pair of opposing side walls and a second pair of opposing side walls. While generally, end panels, such as  104 ,  105 ,  105 A,  160 ,  161 ,  190 ,  192 ,  194 , and  196  of  FIGS. 1A and 1B , are narrower than side panels, the terms themselves have no criticality, and end panels can be wider than side panels. For the purposes of the present invention, the term “single wall” refers to corrugated material that has one corrugated layers separated by a flat sheet and two outer flat sheets. 
         [0057]    For the purposes of the present invention, the term “flap” and/or “flaps” may be used when referring to end panels. 
         [0058]    For the purposes of the present invention, the term “substantially”, as used herein means tolerance ranges normal used in the paper box industry. 
         [0059]    For the purpose of the present invention, the term “suspension layer” refers to the film structure that attaches to box panels for securing objects during shipping. Multiple suspension layers can be used and suspension layer can be used in combination with retention layer(s). 
         [0060]    For the purpose of the present invention, the term “pouch” refers to a film structure that encloses and forms a suspension layer. 
         [0061]    For the purpose of the present invention, the terms “pouch”, “film”, and “suspension layer” refers to structure that can be an anti-static/static dissipating material, and is preferably a material that will hold a product under tension when stretched. The material tends to return to its un-stretched form rather than to deform or elongated to a longer dimension, and thus, will hold a product firmly, and under tension. The product is accordingly not free to move, or rattle around in the box. The film is resilient and returns to its original shape when after being subjected to a vibration or jarring action. The film thus cushions and cradles the object being transported. The method in which films are joined to the walls of the box can include, by way of example, welding, heat activated adhesives, co-adhesives, pressure sensitive tapes, and hot melt glues. Epoxies and silicone adhesive can be used. Pressure sensitive tapes for the pouch structure are provided with a release film which is removed when the pouch is to be sealed closed. 
         [0062]    For the purpose of the present invention, the terms “fixing” and “securing”, when referring to the attaching of a panel of one blank to a panel of another blank, or the attaching of a retaining member such as  1164  of  FIG. 11 , or  1006  of  FIG. 10 , to a panel, means the attaching of two members together by an of the well known means, such as adhesives, including for example, a hot melt glue, heat activated adhesives, co-adhesives, or pressure sensitive adhesives, and by other known means such as staples, adhesive tapes and the like. 
         [0063]    For the purpose of the present invention, the term “void fill” refers to any material used to fill the empty space around an object being shipped inside a box. More commonly known to those skilled in the art it refers to stuffing popcorn/peanuts, Bubble Wrap, airbags, paper product, foam and Styrofoam. Void fill can be used in conjunction with suspension and retention packages, but preferable, the suspension and retention packages of the present invention negate the need for void fill. 
         [0064]    For the purpose of the present invention, the term “erected” refers to the box being unfolded as to have square corners and a closed bottom, as well known in the art. 
         [0065]    For the purpose of the present invention, the term “RSC” means regularly slotted cardboard, as well known in the industry. 
         [0066]    For the purpose of the present invention, the term “die cut panels” refers to the industry standard method of forming blanks such as illustrated in  FIGS. 1A and 1B . 
         [0067]    The term “substantially” as referred to herein indicates a near, close to relationship, not significantly departing from a particular quality. For example, while 50% would not be substantially 100%, but a value that provides the desired result though not exactly equal to the ideal or optimum value, would be considered to be substantially the exact, ideal, or optimum value. A substantially vertical article could depart from the perpendicular relationship with a horizontal plane, but would not depart to the extent that it begins to lose its stability or requires an external support to be self supporting. 
       Description 
       [0068]    There are four simple advantages to the suspension packaging system of the present invention. The product provides exceptional cushioning and vibration protection while greatly reducing warehouse space, eliminating inner cushioning materials, saving labor, and reducing material costs. 
         [0069]    In a preferred embodiment, the system uses a film pouch centered within a box that is secured in place by trapping the ends of the film between two layers of corrugated for exceptional strength. The film passes through the first corrugated layer utilizing a 3/6″ tall slit and is then turned 90 degrees to be glued between the corrugated panels. The corrugated layers are completely glued as well to create an exceptionally strong box in its own right. 
         [0070]    The firmly attached stretchable film can now be used for two purposes. First, as a pre-made pouch for loading items to be shipped in that is virtually indestructible. It requires the packer to keep both ends of the box open so that loading can be easily facilitated. Once the box is folded the film-pouch becomes taut and is ready for shipping. The design orients the box to be opened from the side so that the opening of the pouch is exposed to the user, thereby facilitating the insertion of an article or articles into the pouch. 
         [0071]    In another embodiment, the film cooperates with a side wall of the box to form the equivalent of a pouch. In this embodiment, the article is retained between the taut film and the box, and this style of a box is referred to as a retention pack. 
         [0072]    The box can be stood on end, that is, on its end flaps, to expose the pouch for easy insertion of an article into the pouch. The box is placed on a horizontal surface, as for example, a packing table, with the open end of the pouch. 
         [0073]    Additionally, the film can be used as a platform for a separate pouch to be attached with a pressure sensitive adhesive, either residing on the pouch or on the film. This design orients the box to be opened from the top so that the film&#39;s full length and width are exposed. 
         [0074]    A further aspect of the invention is that the film is trapped between two layers of corrugated that runs along the bottom of the box. The film starts from the left by having 1″ of material trapped between the layers of corrugated material, and then passes underneath the inner corrugated layer leading to the opposing corrugated layer and passing underneath to be trapped between those layers. Typically this box would be shallower or less tall than prior art boxes and to the other embodiments of the invention. 
         [0075]    The support film of the present invention is preferably a plastic which stretches up to about 40% with high load retention, that is, without distorting or deforming, or exceeding its yield point. In one embodiment anti-static/static dissipative films can be used. 
         [0076]    The pouch can be a folded sheet or two sheets can be heat welded to form a pouch. Additionally, multiple pouches can be provided, advantageously, in spaced, parallel rows. 
         [0077]      FIGS. 1A and 1B  illustrate an embodiment of the present invention in which a pair of blanks,  100  and  150  is employed to make a box of the type illustrated in  FIG. 4A . The first blank  100  has a central panel  101  which is bound by fold lines  108 ,  109 ,  110 , and  111 . The fold lines form the edges of the central panel  101  of the blank  100 . Panel flaps  102 ,  103 ,  104 ,  105 , and  105 A are contiguous with the center panel  101 . 
         [0078]    The panels  102  and  103  can be provided with elongated slots  112  and  113  respectively, for use in securing the support film to the panels  102  and  103 . The film  200  is centered within the box by passing it through the first corrugated layer utilizing a 3/6″ tall slit and is then turned 90 degrees to be glued between the corrugated panels  102  and  152 , and  103  and  153 . The corrugated layers are completely glued as well to create an exceptionally strong box in its own right. 
         [0079]    The film used is advantageously a transparent urethane 3 mils thick. The urethane film&#39;s unique properties of stretch ability and memory make film always return to original shape. These properties enable the film to absorb repeated shock and vibration. 
         [0080]    The center panel  101  is provided with a central fold line  106  which extends across the center panel  101  and the flap panel  104 . In the embodiment of  FIG. 1A , the flap panels  105 A and  105  are separated by a slot which serves to facilitate the step of folding flap panels onto the center panel, as illustrated in  FIGS. 5 and 6 . 
         [0081]    With respect to  FIG. 1B , fold lines  171 ,  158 ,  170  and  159  form the edges of the central panel  155  of the second blank  150  and separate the center panel  155  from the flap panels  194 ,  153 ,  152 ,  190  and  198 . End flaps  160 ,  161 ,  192 , and  196 , are contiguous with flap panels  152 , and  153  and separated therefrom by fold lines  174 ,  175 ,  173 , and  177  respectively. Slots  180 ,  182 ,  184 , and  186  are employed to provide clearance between flap panels and end flaps during the assembly steps. 
         [0082]    The center panel  155  is noted to be bounded by fold lines  158 ,  159 ,  170 , and  171 , and is provided with a central fold line  156 . The central fold line is employed during the steps of folding the box flat, as illustrated in  FIG. 4 , and in forming the hexagonal configuration as illustrated, for example, in  FIGS. 6 and 7 . 
         [0083]    The attachment of a stretchable support film  200  to the blank  100  is most readily achieved by folding the flap panels  103  and  102  toward each other thereby bringing the elongated slots  112 , and  113  sufficiently close together to facilitate the insertion of one end of the support film  200  into the elongated slot  113  and the other end into the elongated slot  112 . The ends of the support film are folded against their respective flaps panels. The film is preferably formed of a plastic that is stretchable up to 20% and more preferably, up to 40% without exceeding its yield point. The film can be used as a platform for a separate pouch that is attached with a pressure sensitive adhesive, either residing on the pouch or the film. This design orients the box to be opened from the top so that the film&#39;s full length and width are exposed. 
         [0084]      FIG. 3  shows an inner blank having flap panels  301  and  305 , a central fold line  306  and a support film  300  secured through elongated slots  313  and  315  to side flap panels in the manner of the embodiment of  FIG. 2 . An outer blank having flap panels  394 ,  390 , and end flaps  361 ,  396 ,  392  and  360  contiguous with the flap panels, is moved toward the inner blank until the flap panel  380  is registered with the flap panel  386  and the flap panel  382  is registered with the flap panel  384 . The registered flap panels are secured to each other advantageously by means of an adhesive, such as hot melt glue. 
         [0085]      FIG. 4  shows the formed box knocked down to a flat configuration, and ready to be stacked with additional formed and flattened boxes. 
         [0086]      FIG. 4A  shows the box in a first stage of being opened for use by the person packing the box. The panels on one end of the box, (see for example panels E 1 , E 2 , and D, and D) are maintained in the same plane as the panels with which they are contiguous, whereas panels A, A, C 1 , C 2  and B, are rotated in the direction of arrows AA, AA, CC, CC, and BB, respectively. 
         [0087]      FIG. 5  shows the panels rotated to a position in which they lie against (are superadjacent to) their respective contiguous panels. Thus, panel A is flat against panel J, and B is flat against panel H. Panels E 1 , E 2 , and D are shown non-rotated, that is, they are maintained in their positions in-line with their contiguous panels, H and J respectively. 
         [0088]      FIG. 6  shows box after the center panels are forced outwardly at their central fold lines, as indicated by arrows  602  and  604 . The box is preferably on a normal, horizontal surface of a work table, as seen standing on flaps  606 ,  608 , and  609 . It should be understood that the dimensions of the panels  606 ,  608 ,  609 , and the panels that are not seen in the figure, serve as box support panels and advantageously are dimensioned such that their support edges lie in the same plane, which is the plane of the support surface. If one or more panels is longer than the others, the box can become unstable and cannot support itself in a vertical orientation. The term vertical orientation refers to the orientation of the central fold lines relative to the surface on which the box is standing. 
         [0089]      FIG. 7  illustrates an alternate embodiment in which the box is provided with a pouch member having two support films  200 A and  200 B, and a retentions support film  706 . The box, indicated generally as  710 , is shown with the panels  161 ,  198 , and  190  (visible in the view of  FIG. 7 ) having their outer edges lying in the same plane. The outermost edges are the lowermost edges of the box when the box is vertically oriented and standing on a work table. The term “vertically oriented” refers to the orientation of central fold lines  106  and  156 , relative to the horizontal plane of a work table (not shown). The support films  200 A,  200 B, and  706  are relaxed or flaccid, when the box is in the hexagonal configuration illustrated in  FIG. 7 . In this configuration, an article can be inserted into the open pouch and between the support film  706  and the adjacent box wall which is bent along fold lines  106  and  156 , that is, “V” shaped. The box is opened from its rectangular or square cross-section as seen in  FIG. 5 , for example, to the hexagonal cross-sectional configuration of  FIG. 7 , by apply pressure in the direction indicated by arrows  702  and  704 . The flap panel  194  when folded onto the center panel  155  tends to hold or lock the box in its hexagonal cross-section configuration. Similarly, the flap panel (not visible) folded against center panel  101 , tends to hold or lock the box in its hexagonal cross-section configuration. The use of one slotted panel and one full panel as illustrated in  FIGS. 1A and 1B  makes it easier to form the box into a hexagonal configuration, while the use of opposing unslotted panels serves to provide greater rigidity to the hexagonal configuration. 
         [0090]    In the embodiment of  FIG. 8  the flap panel  894  is provided with a reinforcing flap  895 . Flap  894  is folded over the end flaps  896  and flap panels  801 , and flap  895  wraps around the center panel  806  and is secured thereto by an adhesive, tape, staple, or other well known method. The central fold  856  is noted to extend to the flap panel  894  and the reinforcing flap  895 . In this embodiment, a pouch  800 , formed of two sheets of plastic film, and a retention support film  810  are employed to accommodate two different articles. 
         [0091]      FIGS. 9A and 9B  show an alternate embodiment which generally corresponds to the embodiment of  FIGS. 1A and 1B . However, the flap panels  904 ,  905 , and  905 A are shorter than the corresponding flap panels  104 ,  105 , and  105 A of  FIG. 1 . Additionally, the embodiment of  FIGS. 9A and 9B  do not employ slots between the flap panel sections  905  and  905 A. The reference numbers of  FIGS. 1A and 1B  are a one hundred series, whereas the reference numbers of  FIGS. 9A and 9B  are in a corresponding  900  series. Thus, slots  112  and  113  correspond to slots  912  and  913 , flap panels  102  and  103  correspond to flap panels  902  and  903 , etc. 
         [0092]      FIG. 10  illustrates another embodiment of a box indicated generally as  1000 , formed from a single blank. The box employs two central fold lines  1046  and  1056 , corresponding to central fold lines  906  and  956  of  FIGS. 9A and 9B . The center panel  1004  is formed contiguous with a flap panel  1006 , which in turn is contiguous with a second center panel  1008 , which in turn is contiguous with a flap panel  1010 . Contiguous panels should be understood as being separated by a fold line. The support film  1002  is secured around the upper edge of the flap panel  1010  and secured between a retainer member  1006  and flap panel  1012 . 
         [0093]      FIG. 11  illustrates a box indicated generally as  1100 , which corresponds generally to the box  1000  of  FIG. 10 , with a few exceptions, relating to the support film design. In this embodiment, a support film, which is advantageously in the form of a pouch, is wrapped over and around a retainer member  1162  and secured between the retainer member  1162  and the panel  1110 . Similarly, the support film has its other end wrapped over and around a retainer member  1162  and is secured between the retainer member  1164  and the panel  1114 . The panel  1104  is a center panel having a central fold line  1156  for the functions previously described. 
         [0094]      FIG. 12  show a box  1200 , having a pouch member  1201 , formed of two sheets of plastic film or a folded over single sheet. The article  1208  is inserted into the pouch and a fold over flap region  1202  of pouch  1201  is folded onto an adhesive section  1206  of the fold section  1204  of pouch  1201 . The adhesive can be a two sided adhesive tape bonded on one side to the sheet  1204  and bonded on the other side to the flap section of sheet  1202 . The adhesive tape is provided with a release film that is removed after the article is inserted into the pouch, thus exposing the adhesive layer. 
         [0095]      FIG. 13  is a plan view of a pouch member  1201  having an adhesive layer  1206  and a flap region  1202 . The pouch can alternatively be formed of two separate plastic sheets heat welded to form a pouch, as illustrated in  FIG. 12 . 
         [0096]      FIG. 14  shows an alternative embodiment of a one piece box  1410 , similar to one piece box  1000  of  FIG. 10 , except that the retention sheet  1406  is secured to the box using elongated slots as seen for example in the embodiments of  FIGS. 2 ,  4 A,  6 ,  8 , and  12 . The exposed ends  1407 , of the support film  1406 , are preferable cover over with a layer of corrugate material. 
         [0097]      FIG. 15  shows a box  1510  which is similar to the design of the boxes of  FIGS. 7 and 8  except that is only uses a single retention film  1506  for supporting and article. The box is opened to its hexagonal form by folding along central fold lines  1546  and  1556 . The film  1506  has a fold over region  1507  secured between two panels of the box, in the manner previously described in relation to the similar boxes. 
         [0098]      FIG. 16  illustrates an embodiment of a blank, indicated generally as  1600 , that corresponds generally to the embodiment of  FIG. 14 . It is noted that the elongated slot  1682  can preferably be positioned about midway between fold lines  1631  and  1632 , and slot  1680  are be correspondingly halfway between fold line  1630  and the outer peripheral edge of panel  1602 . In an embodiment of the invention, the suspension layer is two inches above the box floor and three inches from the top of the box. 
         [0099]    Alternatively, the elongated slot  1680  and  1682  can be positioned adjacent fold lines  1630  and  1631  respectively. In this later configuration, the support film can be used to retain an article between the film and the central panel  1604 . It should be understood that multiple layers of film can be used, and can be all pouch configurations, or combinations of pouches and single sheet of film. 
         [0100]      FIG. 16  shows a single blank which is similar to the two piece blank system of  FIGS. 9A and 9B . Essentially, panel  1602  and elongated slot  1680  of blank  1600  correspond to panel  902  and slot  912  of blank  900 . Central panel  1604  and central fold line  1620  of blank  1600  correspond to center panel  901  and central fold line  906  of blank  900 . Panel  1606  and elongated slot  1682  correspond to panel  903  and slot  913 . 
         [0101]    Center panels  1608  and central fold line  1622  of blank  1600  correspond to center panel  955  and central fold line  956  of the blank of  FIG. 9B . Panel  1610  and its fold line  1633  correspond to panel  940  and its fold line  959 . Panels  1662  and  1670 / 1672  correspond to panel  996  of  FIG. 9B  and its opposing panel. Panel  1674  and fold line  1640  correspond to panel  994  and fold line  970 . Panel  1692  corresponds to panel  992  of the embodiment of  FIG. 9B . 
         [0102]    It can be seen that panel  952  of  FIG. 9B  has no corresponding panel in the embodiment of  FIG. 16 , because an overlap panel is not required in a one piece design. Other corresponding panel relationships will be evident to one skilled in the art, even though not specifically noted herein. 
         [0103]    It is noted that  FIG. 16  illustrates an embodiment of a blank, indicated generally as  1600 , that corresponds generally to the embodiment of  FIG. 14 . It is noted that the elongated slot  1682  can preferably be positioned about midway between fold lines  1631  and  1632 , and slot  1680  are be correspondingly halfway between fold line  1630  and the outer peripheral edge of panel  1602 . 
         [0104]    Alternatively, the elongated slot  1680  and  1682  can be positioned adjacent fold lines  1630  and  1631  respectively. In this later configuration, the support film can be used to retain an article between the film and the central panel  1604 . It should be understood that multiple layers of film can be used, and can be all pouch configurations, or combinations of pouches and single sheet of film. 
         [0105]    In the pouch design, where a pair of flaps extends through each of the elongated slots, one flap can be folded upward from the suspension layer against the wall and the other folded downward going against the wall. These flaps are extensions of the suspension layer and are what secures it to the corrugated box. It should be noted that the middle section of the film, that is, the region between the points at which the film is secured to the walls of the box, is the same dimension as the interior box footprint, in order to provide a taut film configuration. 
         [0106]    Once the pouch(s) are filled the box can then be closed by bending in the top four box flaps over the scored fold lines and taping them down. The last step is to tape close the box flaps. With the box flaps closed and taped, the box is ready for shipment via any common carrier. 
         [0107]      FIG. 17  illustrates an embodiment in which the plastic films wrap a support member. A pouch  1700  is formed by an upper plastic support film  1702  and a lower plastic support film  1704 . The support films fit through inner panel  1750  via a slot  1751 . The upper plastic support film  1702  bends upwards after the slot  1751  while the lower plastic support film  1704  bends downwards after the slot  1751 . The upper plastic support film  1702  and the lower plastic support film  1704  are wrapped over and around a retainer member  1762 . The plastic support film wrapped retainer member  1762  is sandwiched between outer panel  1710  and the inner panel  1750 . Essentially, the embodiment of  FIG. 17  corresponds to the embodiments of  FIGS. 1-9  with the addition of the retaining members. 
         [0108]      FIG. 18  shows an embodiment in which the plastic films wrap a support member in a one piece blank design. A pouch  1800  is formed by an upper plastic support film  1802  and a lower plastic support film  1804 . An inner panel  1850  is held in place using a fastener  1808 , such as staples or rivets. The fastener  1808  connects the inner panel  1850  to the outer panel  1810 . The support films fit through inner panel  1850  via a slot  1851 . The upper plastic support film  1802  bends upwards after the slot  1851  while the lower plastic support film  1804  bends downwards after the slot  1851 . The upper plastic support film  1802  and the lower plastic support film  1804  are wrapped over and around a retainer member  1862 . The plastic support film wrapped retainer member  1862  is sandwiched between outer panel  1810  and the inner panel  1850 . Essentially, the embodiment of  FIG. 18  corresponds to the embodiments of  FIGS. 10 and 11 , with the addition of the retaining members. 
         [0109]    Rather than using mechanical means such as staples or the like, sealing of the two sheets of film  1802  and  1804  that form the pouch  1800  is preferably by means of a sealing technique such as disclosed in the following patents, the disclosures of which are incorporated herein by reference, as though recited in full:
   U.S. Pat. No. 5,931,581—Self-Sealable Packaging For Enclosing Articles (uses heat sealing, pressure-sensitive adhesives, co-adhesives, binary adhesives)   U.S. Pat. No. 5,722,585—Folding box with self-adhesive seal (folding box with self-adhesive seal and a method for sealing the folding box)   U.S. Pat. No. 3,614,914—Box Sealing Machine (heat sealing cardboard boxes)   U.S. Pat. No. 4,379,008—Method and apparatus for sealing cardboard containers (sealing plastic or synthetic coated sealing surfaces of cardboard containers to each other)   U.S. Pat. No. 5,942,058—Co-adhesive system for bonding wood, fibers, or agriculture based composite . . .   U.S. Pat. No. 6,571,953—Printed-thermoplastic tamper-resistant package (rf, UV, ultrasonic, heat)   
 
         [0116]    The bonding type of sealing serves to seal the first leg of the “U” of film  1802  to slotted member  1850  and to the retainer member  1862 , and the second leg of the “U” of film  1802  to the retainer member  1862  and outer panel  1810 . The sealing procedure is applied to both ends of the film  1804  and the film  1802 . The sealing procedure is essentially the same for the one piece package of  FIG. 18  and for the two piece package of  FIG. 17 . 
         [0117]    Although the present invention has been fully described in conjunction with several embodiments thereof with reference to the accompanying drawings, it is to be understood that various changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as described by the appended claims, unless they depart there from. 
       BROAD SCOPE OF THE INVENTION 
       [0118]    While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” In this disclosure and during the prosecution of this application, means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects and embodiments), and should not be improperly interpreted as limiting the scope of the application or claims. In this disclosure and during the prosecution of this application, the terminology “embodiment” can be used to describe any aspect, feature, process or step, any combination thereof, and/or any portion thereof, etc. In some examples, various embodiments may include overlapping features. In this disclosure, the following abbreviated terminology may be employed: “e.g.” which means “for example.”