Abstract:
In a packaging cushion device, a base member has a base wall, and first and second sidewalls respectively perpendicular to two adjacent edges of the base wall. The base wall and first and second sidewalls define a receiving portion. A modular component has a base panel, two adjacent first and second side panels perpendicular to the base panel, a first projection extending from the first and second side panels, and a second projection extending from the base panel and the second panel. The first and second projections are matchable with and connectable to the receiving portion to form two interchangeable configurations of different heights, thereby satisfying the need of packing a computer housing in either folded or unfolded configuration, and saving packing materials.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims priority of Taiwanese Application No. 095131755 filed on Aug. 29, 2006. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The invention relates to a packaging cushion device, more particularly to a packaging cushion device for the protection of corners of an article. 
   2. Description of the Related Art 
   Articles, for instance, electronic articles such as central processing unit, and displays, are vulnerable to damage when subjected to squeezing, pressing or impacting forces. In order to minimize damage caused to such articles during transport from a manufacturing end to a user end, cushioning materials, such as Styrofoam® and sponge, are utilized to space the articles from walls of packaging boxes, such as cardboard boxes and plastic boxes. As such, the articles will not hit against the packaging boxes, and a buffering effect can be produced when the packaging boxes are subjected to external forces. The function of protecting the article can therefore be achieved. 
   Generally, the shape and size of an article are fixed after the manufacture thereof is finished. Therefore, a cushioning material for packaging the article must have a structure and size that are fixed in accordance with the shape of the article. However, due to different needs in application, some products are designed to have configurations and sizes that can be varied from a manufacturing end to a final user end. In that case, the fixed-type cushioning materials are unable to accommodate different configurations of such products. 
   Take a computer device as an example. The hardware of a computer device includes a motherboard, electronic cards, a power source, etc., in addition to a computer housing. As a current way of commercializing computer devices, various component parts of computer devices may be offered by different manufacturers. Therefore, the computer device may be assembled by an upstream assembly factory, a wholesaler, or a retailer, and may also be assembled by the user himself/themselves. When a computer housing has not been assembled with other hardware, it is hollow. In order to reduce the volume of a computer housing prior to assembly with other hardware that will occupy space upon transport, there has been provided a computer housing with a modular or foldable design by which the computer housing can be laid flat, thereby decreasing the volume of the computer housing and reducing transportation costs. Because a computer device may be assembled by an upstream assembly factory or a retailer, during assembly of the computer device, the computer housing needs to be assembled or unfolded to form a space for containing other hardware, and after assembly of the computer device, the computer housing has to be packed once again so as to be transported to the end user. Therefore, the computer housing must undergo packaging two times when delivered from an original manufacturer to a place of assembly and then to the end user after assembly. If a cushioning device having an invariable shape is used for packaging such a foldable computer housing, it cannot accommodate both the folded and unfolded configurations of the foldable computer housing. 
     FIG. 1  shows a typical computer housing  91  associated with cushioning members  92 ,  93 . The cushioning members  92 ,  93  are generally made of Styrofoam®, and are provided with structures matching the shapes of the front and rear sides  911 ,  912  of the computer housing  91  so as to cover corners at the front and rear sides  911 ,  912  and to protect the computer housing  91 . However, the cushioning members  92 ,  93  having invariable shape cannot fit a folded flat configuration of a foldable computer housing. 
   As mentioned above, when an article has a variable configuration, a cushioning device having a fixed shape cannot satisfy packaging requirements for different configurations of the article. 
   SUMMARY OF THE INVENTION 
   Therefore, the object of the present invention is to provide a packaging cushion device formable into interchangeable modular configurations that provide differently sized receiving spaces. 
   According to the present invention, a packaging cushion device comprises at least one base member, and at least one modular component. 
   The base member has a base wall, a first sidewall, and a second sidewall. The base wall has first and second edges forming a corner therebetween. The first and second sidewalls are perpendicular to the base wall and are connected respectively to the first and second edges. The first and second sidewalls are spaced apart from the corner so as to define a first receiving corner portion therebetween. 
   The modular component has a bottom panel, a first side panel, a second side panel, a first projection, and a second projection. The bottom panel has first and second lateral ends forming a corner therebetween. The modular component has a reference point at a juncture between the first and second lateral ends, a first direction that extends perpendicularly away from the base panel from the reference point, and a second direction extending along the second lateral end and away from the first lateral end. The first and second side panels extend respectively from the first and second lateral ends along the first direction. Each of the first and second projections has a shape complementary to that of the receiving corner portion. The first projection extends along the first direction from apart of the first side panel and a part of the second side panel both of which are adjacent to the reference point. The second projection extends along the second direction from the second side panel and from an edge of a part of the base panel adjacent to the second side panel. A distance of a distal end of the first projection from the reference point along the first direction is different from a distance of a distal end of the second projection from the reference point along the second direction. A first modular configuration is formed when the first projection of the modular component is inserted into the receiving corner portion of the base member. A second modular configuration is formed when the second projection of the modular component is inserted into the receiving corner portion. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiments with reference to the accompanying drawings, of which: 
       FIG. 1  is a perspective view illustrating a conventional cushion device for packaging a computer housing; 
       FIG. 2  is an exploded perspective view of the first preferred embodiment of a packaging cushion device according to the present invention for packaging the computer housing in a folded state; 
       FIG. 3  is a perspective view showing a base member of the first preferred embodiment; 
       FIG. 4  is a perspective view showing a modular component of the first preferred embodiment; 
       FIG. 5  shows an assembled state of the components of  FIG. 2 , wherein cushion units of the first preferred embodiment are in a first modular configuration, a box shown in  FIG. 2  being omitted; 
       FIG. 6  is an exploded perspective view showing that the first preferred embodiment is used in packaging the computer housing in an unfolded state; 
       FIG. 7  shows an assembled state of the components of  FIG. 6 , wherein cushion units of the first preferred embodiment are in a second modular configuration, a box shown in  FIG. 6  being omitted; and 
       FIG. 8  is an exploded perspective view showing cushion units of the second preferred embodiment according to the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   A preferred embodiment of the packaging cushion device according to the present invention is usable for packaging a housing of a computer device that can be folded and unfolded. Referring to  FIG. 2 , a packaging cushion device of the present invention is made from Styrofoam® and includes four sets of one-to-one assemblage cushion unit  2 . Each cushion unit  2  includes a base member  3  and a modular component  4 . As shown in  FIG. 3 , each base member  3  has a substantially rectangular base wall  31 , and first and second sidewalls  32 ,  33  proximate to each other and extending perpendicularly from first and second edges  311 ,  312  of the base wall  31 , respectively. The first and second edges  311 ,  312  of the base wall  31  form a right angle corner  313  therebetween. The first and second sidewalls  32 ,  33  are spaced apart from the right angle corner  313  by a predetermined distance so that a substantially L-shaped receiving corner portion  34  is defined therebetween. 
   As shown in  FIG. 4 , each modular component  4  has a bottom panel  41 , a first side panel  42 , a second side panel  43 , a first projection  44 , and a second projection  45 . The bottom panel  41  has adjacent first and second lateral ends  411 ,  412  forming a corner therebetween. A juncture between the first and second side panels  411 ,  412  is defined as a reference point. A direction that extends perpendicularly from the reference point and away from the bottom panel  41  is defined as a first direction (I). Another direction that extends along the second side panel  412  and away from the first side panel  411  is defined as a second direction (II). The first and second side panels  42 ,  43  are formed to extend respectively from the first and second lateral ends  411 ,  412  in the first direction (I). Each of the first and second projections  44 ,  45  has a shape complementary to that of the receiving corner portion  34 , and is to be assembled in the receiving corner portion  34 . The first projection  44  extends along the first direction (I) from a part of the first side panel  42  and a part of the second side panel  43  adjacent to the reference point. The second projection  45  extends in the second direction (II) from the second side panel  43  and a part of the bottom panel  41 . A distance of a distal end  441  of the first projection  44  from the reference point along the first direction (I) is smaller than a distance of a distal end  451  of the second projection  45  from the reference point along the second direction (II) so that the modular component  4  and the base member  3  can be assembled together to form two selective modular configurations that provide receiving spaces with different heights. 
     FIGS. 2 and 5  show a first modular configuration of the cushion units  2  which are used in packaging a lay-flat, folded computer housing  81 . The procedure of packaging is as follows: Firstly, the base members  3  are positioned respectively at four corners of a bottom of a box  83 . After the computer housing  81  is placed in the box  83 , the first projection  44  of each modular component  4  is assembled in the receiving corner portion  34  of the respective base member  3 . As a result, eight corner parts  811  at top and bottom of the computer housing  81  and four vertical edges  812  interconnecting adjacent top and bottom corner parts  811  are covered by the respective cushion units  2  to space the computer housing  81  from the walls of the box  83 . Aside from achieving cushioning and protecting effects, the modular components  4  and the base members  3  which are interlocked provide a support to reinforce the structure of the box  83 . 
     FIGS. 6 and 7  show a second modular configuration of the cushion units  2  useful in packaging a computer housing  82  in an unfolded rectangular configuration. The packaging procedure is as follows: Firstly, the base members  3  are positioned respectively at four corners of the bottom of a box  84 . After the computer housing  82  is placed in the box  84 , the second projections  45  of the modular components  4  are assembled in the respective receiving corner portions  34  of the base members  3  so that eight corner parts  821  and four lateral edges  822  each interconnecting two adjacent top and bottom corner parts  821  are covered by the respective cushion units  2 . Especially, as the first projections  44  of the modular components  4  provide prolonged length to cover edges of the computer housing  82 , the protecting and cushioning effects are enhanced. In addition, the interlocking of the base members  3  with the respective modular components  4  provides a support to reinforce the structure of the box  84 . On the other hand, inner side faces of the base members  3  and the modular components  4  which are in contact with the computer housing  82  are provided with a plurality of recessed and raised patterns  35 ,  46  that are matchable with the surfaces of the computer housing  82 . For example, the recessed and raised patterns  35 ,  46  matchable with the surfaces of the computer housing  82  at positions corresponding to leg pads  823  can avoid interference between contact surfaces so that the base members  3  and the modular components  4  can abut tightly against the surface of the computer housing  82 . 
   Referring to  FIG. 8 , there is shown the second preferred embodiment of a packaging cushion device  6  according to the present invention. The second preferred embodiment is substantially similar to the first preferred embodiment. The difference therebetween is that the base member  5  in the second preferred embodiment may be considered as one having two interconnected base members  3  of the first preferred embodiment (see  FIG. 2 ). In particular, the base member  5  includes the base wall  51 , the first sidewall  52 , the second sidewall  53 , a third sidewall  54 , and first and second receiving corner portions  55  defined by the first, second and third sidewalls  52 ,  53 ,  54 . The second sidewall  53  is longer than the first and third sidewalls  52 ,  54 . The base wall  51  has first and second edges  56 ,  57  forming a corner therebetween, and a third edge  58  forming another corner with the second edge  57  opposite to the first edge  56 . The first and second sidewalls  52 ,  53  are connected respectively to the first and second edges  56 ,  57  and are spaced apart from the corner thereof so that the first receiving corner portion  55  is defined therebetween. The third sidewall  54  is connected to the third edge  58  and opposite to the first sidewall  52 . The third and second sidewalls  54 ,  53  are spaced from the aforesaid another corner so that the second receiving corner portion  55  is defined therebetween. Thus, the first and second receiving corner portions  55  are formed at two longitudinally opposed ends of the second side wall  53  to receive respectively the first projections  44  or the second projections  45  of two modular components  4 . 
   Therefore, the packaging cushion device  6  according to the present invention includes two sets of one-to-two assemblage cushion units  7  each has one base member  5  and two modular components  4 . Since the method of assembly in the second preferred embodiment is similar to that in the first preferred embodiment, it is not detailed herein. 
   In sum, due to the changeable modular configuration of the base members and the modular components of the cushion units, the packaging cushion device according to the present invention can satisfy the packaging requirements of the foldable computer housing in either folded or unfolded configuration. In addition, the present invention reduces consumption of packaging materials, facilitates configurational changes, effectively reduces shocks caused to the computer housing during transport, and provides better protecting and shock-absorbing effects. 
   While the present invention has been described in connection with what are considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiment but is intended to cover various arrangement included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.