Abstract:
A packaging article constructed in accordance with the invention is provided which is formed and shipped in a flat shape, and which may be converted into a rigid L-shaped, U-shaped, triangular or square/rectangular shipping or storage container for the protection of articles during shipping and storage. The packaging article is constructed using a rigid but pliable member to allow for ease in formation and handling, but after formation into an L-shaped, U-shaped or other shaped shipping or storage container, to produce a rigid storage structure or tube.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to an improved packaging item for securing materials and, more specifically, elongated articles, such as glass rods, pipes, lumber, Venetian blinds and the like for transporting, storing or shipping, and, in particular, to a space-saving packaging article container which may be shipped to a user in a flat position and then formed into a U-shaped, L-shaped, triangular or other shaped container.  
         BACKGROUND OF THE INVENTION  
         [0002]    Packaging and other shipping containers are typically constructed of corrugated materials and the like. In the prior art, typically, a preformed U-shaped angle board is used. The angle board material may be formed by layering paperboard that is formed around a mold to give the board the U-shaped appearance. Layer after layer of this paperboard is applied to the U-shaped mold to form a U-shaped, rigid, multi-layer paperboard packaging product.  
           [0003]    Using such a method, a rigid packaging article is produced, which will protect the contents inside. Such articles may be formed in any length, and for that matter, can be formed in any size and, therefore, can accommodate contents of many varied lengths and sizes. Of course, the larger the U-shaped board, the less rigid the final packaging article.  
           [0004]    While such rigid U-shaped packaging articles have been sufficient, they have also had a number of drawbacks. For instance, because the U-shaped packaging article is rigid, like sized packaging articles will not easily nest within each other, thereby increasing the shipping volume. As such, the packaging articles take up as much space empty as they do fully loaded. This exacts an unnecessary added expense, because warehouse space and space on a shipping vessel is costly.  
           [0005]    Other known packaging articles include those having a tri-sectional structure that can be shipped in a flat configuration and later formed into a U-shaped structure. A major drawback of such tri-sectional packaging articles is that the side-walls of the packaging article must be held in a jig to keep the side-walls erect during loading of the materials or the structures must be constructed with an intricate array of layers in order to hold the sides up. The former process adds expense and complication during the loading phase, while the latter adds expense during manufacturing of the packaging article. In either case, the expenses incurred are eventually passed to the consumer. It is, thus, desirable to provide a strong and pliable container that can be shipped in a flat configuration, so as to take up less space, and that can more easily and effectively be formed into a multi-shaped container for shipping or storing a variety of materials.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention is directed to a packaging article which is formed so as to be shipped and stored in a flat state, thereby minimizing the space used by said article, and then be converted into a rigid multi-shaped shipping or storage container for the protection of various articles during transport or storage. The packaging article is constructed to allow for ease in formation and handling, and offers strength and flexibility in that it may be formed into a vast variety of shapes to accommodate various sized and shaped materials for shipping or storage.  
           [0007]    In an exemplary embodiment of the invention, the packaging article is formed with a plurality of support layers disposed between a pair of sealing layers. Each support layer is formed using a plurality of reinforcement layers which are preferably adhesively bonded together to add strength to the support layer structure. Preferably, at least three such support layers are positioned in a plane and spaced apart so as to form a collapsible channel therebetween.  
           [0008]    The support layers are positioned in spaced apart relation and bound together by overlaying one of the pair of sealing layers on each side of the support layers on each side of the support layers. In the exemplary embodiment presently being described, two collapsible channels are formed on both sides of the middle support layers. Thus, the collapsible channels are defined by, on the one hand, the first and second support layers, and on the other, two of the support layers. Each collapsible channel is reinforced by a strong, but pliable, shaping member to add strength and support to the packaging article. The collapsible channel further functions to permit the two outer support members to articulate about an axis passing through the collapsible channel, such that a user can shape the packaging article depending on the user&#39;s packaging needs. As will be described in greater detail below, the pliable support members allow the packaging article to maintain a defined shape as desired by the user.  
           [0009]    During use, the outer support layers may be articulated so as to form a corner at the collapsible channel which acts as a hinge, to form an acute angle, a right angle or an obtuse angle depending on the desired shape of the final packaging article. As the support layers articulate, the pliable reinforcement members become angled to substantially match the angle of the outer support members in relation to the middle support member. Thus, the structure maintains its shape due to the pliable nature of the shaping member. After use, the packaging article is easily flattened for storage, thereby minimizing the amount of space required for storage.  
           [0010]    In another exemplary embodiment, the packaging article structure comprises a support layer that is formed using a single layer of material, having desired strength and weight properties, disposed between the coupling layer and the sealing layer and adhesively bonded thereto. The support layers are situated so as to form a collapsible channel therebetween; each collapsible channel being reinforced by a strong but pliable shaping member to add strength and support to allow the packaging article to maintain a defined shape as desired by the user.  
           [0011]    Other objects and features of the present invention will become apparent from the following detailed description, considered in conjunction with the accompanying drawing figures. It is to be understood, however, that the drawings, which are not to scale, are designed solely for the purpose of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    In the drawing figures, which are not to scale, and which are merely illustrative, and wherein like reference numerals depict like elements throughout the several views:  
         [0013]    [0013]FIG. 1 is a perspective view of a portion of a U-shaped paperboard structure constructed in accordance with the invention;  
         [0014]    [0014]FIG. 2 is a side elevational view of a portion of the paperboard structure constructed in accordance with the invention in a flat position;  
         [0015]    [0015]FIG. 3 is a side elevational view of the paperboard structure constructed in accordance with the invention in a U-shaped orientation;  
         [0016]    [0016]FIG. 4 is a side elevational view of a portion of the paperboard structure constructed in accordance with the invention; and  
         [0017]    [0017]FIG. 5 is a side view of a packaging article having four support member structures each articuable so as to form a closed packaging article. 
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0018]    The present invention is directed to a packaging article  10  that can be manipulated into a variety of shapes for storing, shipping or transporting a variety of materials.  
         [0019]    Referring now to the drawings in detail, FIG. 1 depicts a packaging article product  10  in a U-shaped configuration for storing or shipping materials, as constructed in accordance with an exemplary embodiment of the invention. Packaging article  10  generally comprises at least three support members  28  positioned in spaced apart relation and bound together by first and second sealing layers  30 ,  34 . The relative position of the support members  28  and the sealing layers  30 ,  34  define a collapsible channel  24 , which permits the two outer support members  28 ″ and  28 ″ to articulate about an axis (X) passing longitudinally through the collapsible channels  24 . Thus, as depicted in FIG. 1, the packaging article  10  can be formed to take a U-shape. A strong, but pliable, reinforcement member  26  (shown in FIG. 2) is preferably positioned and fixed between other first sealing layer  30  and the support members  28  so as to overlie and further define the collapsible channels  24 . In an exemplary embodiment, as shown in FIGS. 3 and 5, the reinforcement member  26  is positioned such that, when the packaging article  10  is bent into the U-shape, the member  26  is nearest the outer sealing layer  34 . Of course, in an alternate embodiment, the reinforcement member  26  can be positioned nearer the inner sealing layer  30 . Although a pair of reinforcement members  26  are shown in the FIGS., one skilled in the art will recognize that a single reinforcement member  26  that extends through both collapsible channels may be used. The reinforcement member  26  also preferably extend throughout the packaging so as to substantially overlie the whole of the collapsible channels  24 , as shown in FIG. 2.  
         [0020]    Preferably, the support members  28  are formed by layering a plurality of paperboard sheets, which are adhesively bound. However, the packaging article may also be constructed of a strong resilient material such as plastic, corrugated paper, or a similar suitable material.  
         [0021]    The packaging article product  10  as shown in FIG. 1, includes a base  12 , a first section  16  and a second section  18  which are unitarily formed into a single structure. The packaging article product  10  also includes first and second sealing layers  30 ,  34  which are unitary layers that cover the first section  16 , the base  12  and the second section  18 . The sealing layers have opposed surfaces, a sealing layer first surface  31 ,  33  and a sealing layer second surface  32 ,  35 .  
         [0022]    The first section  16 , the base  12  and the second section  18  each include a support member  28  disposed therein. Each support member  28  has opposing surfaces, a support member first surface  27  and a support member second surface  29 . The support member  28 , in a preferred embodiment, includes one or more reinforcement member  36  which are adhesively bonded together to form a unitary structure. This reinforcement member  26  adds strength to the packaging article  10  to allow it to accommodate a variety of materials. The reinforcement member  26  overlies the collapsible channel  24 , which when one of the sections  16 ,  18  is articulated, collapses to form along with the reinforcement member  26  an elbow joint  22  therein. The elbow joint  22  allows the sections  16 ,  18  and the base  12  to be bent into a configuration sweeping through any angle from 0 degrees to 180 degrees depending on the requirements of a user of packaging article product  10 .  
         [0023]    Referring to FIG. 2, the collapsible channel  24  formed by two of the support members and the sealing layers  30 ,  34  is shown from a side elevation view. The support layers  28  are situated so as to leave a gap therebetween which defines the collapsible channel  24 . Each support layer  28  is further comprised of a plurality of reinforcement layers  36  which are adhesively bound into a unitary structure. The collapsible channel  24  is shown to be reinforced by a shaping member  26  which is made of a strong but pliable material such as steel, although any pliable material importing strength to the article  10  may be used. The composition of the material of the shaping member  26  allows the shaping member to be bent into a variety of shapes, and to hold the desired shape. The shaping member  26  is shown traversing the collapsible channel  24  and is held in place using a form of adhesive between the support layer  28  and the sealing layer  30  whereby forming a reinforced, unitary structure. The benefit of the present invention is that the packaging article product  10  may be bent into various angles, and due to the strength and pliability of the shaping member  26  it will maintain the angle into which it is bent without the assistance of any other devices.  
         [0024]    [0024]FIG. 2 further illustrates the packaging article product  10  in a flat configuration. The flat configuration is desired when the packaging article product is being shipped in bulk or stored because in a flat configuration the packaging article product  10  will take up much less space than if it were in a U-shaped, an L-shaped or other configuration shape. This is desirous because space savings typically equates to costs savings for the user of the packaging article product  10 .  
         [0025]    Referring now to FIG. 3, the packaging article product  10  is depicted in a side elevational view. The packaging article product  10  is shown in FIG. 3, in a U-shaped configuration. This configuration is achieved by bending the shaping member  26  into a 90 degree orientation. The presence of the collapsible channel  24  allows the shaping member  26  to collapse the collapsible channel  24  whereby allowing the base  12  and the second section  18  to be placed in a substantially perpendicular orientation. The first section  16  and the base  12  are also placed into a perpendicular orientation by bending the shaping member  26  at the collapsible channel  24  which joins the first section  16  and the base  12  into a unitary structure. This U-shaped orientation is used to store or ship a variety of materials. However, the packaging article product  10  may also be shaped into a variety of configurations by bending the shaping members  26  into a variety of different acute or obtuse angles. For example, bending the shaping member  26  into a 45 degree angle would allow the packaging article product  10  to be formed into a triangular shape. Conversely, by bending the shaping members  26  into a 135 degree angle we create a completely different shape which would allow the storage or shipping of a larger amount of material due to the volume within the container being increased. This is a desirable feature for the users of the packaging article product because it adds an element of flexibility to the product because different sizes and shapes of materials can be inserted into the packaging article product  10  by bending the first section or the second section at different angles depending on the user&#39;s requirements.  
         [0026]    Referring now to FIG. 4, we see a side view of the collapsible channel  24  formed within the sealing layer  30  and the coupling layer  34 . The collapsible channel  24  is shown as being formed between the support layers  28  by orienting the support layers  28  with a gap therebetween. The shaping member  26  is shown disposed across the collapsible channel  24  and further disposed between the support layers  28  and the sealing layer  30  and being adhesively bonded thereto.  
         [0027]    In a second embodiment, we refer again to FIG. 2 which depicts the packaging article product  10  from a side elevational view. In the second embodiment, the support layer  28  is comprised of a single material support layer  28 , which is comprised of a single solid material such as plastic, foam or the like. In the second embodiment, the support layers  28  will be disposed between the sealing layer  30  and the coupling layer  34  and situated so as to leave a gap which creates a collapsible channel  24 . The shaping member  26  will traverse the collapsible channel  24  and will be adhesively bonded between the support layer  28  and the sealing layer  30 .  
         [0028]    In an alternate embodiment shown in FIG. 5, the packaging article  10  generally comprises four support members  28  positioned in spaced apart relation and bound together by first and second sealing layers  30 ,  34 . The relative position of the support members  28  and the sealing layers  30 ,  34  define a collapsible channel  24 , which permits the two outer support members  28  and  28 ′ to articulate about an axis (X) passing longitudinally through the collapsible channels  24 . Thus, as depicted in FIG. 1, the packaging article  10  can be formed to take a square or rectangular shape by articulating each support member  28  approximately 90° about axis (X). A strong, but pliable, reinforcement member  26  is preferably positioned and fixed between other first sealing layer  30  and the support members  28  so as to overlie and further define the collapsible channels  29 . Although a pair of reinforcement members  26  are shown in the FIGS., one skilled in the art will recognize that a single reinforcement member  26  that extends though both collapsible channels may be used. The reinforcement member  26  also preferably extend throughout the packaging so as to substantially overlie the whole of the collapsible channels  24 , as shown in FIG. 1.  
         [0029]    Thus, while there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the disclosed invention may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.