Abstract:
An integral, generally rectangular corrugated fibreboard blank folds to form an insert having three air cells for cradling and protecting a product. Two of the air cells stand vertically with the third air cell suspended between them. A product rests on the third air cell and is received and captured between the vertical air cells. The insert, with the product in place, fits into a box where tabs projecting from the insert cooperates with the box to form two more air cells at the opposite ends of the insert.

Description:
CROSS-REFERENCE 
   This application is a Continuation-in-Part of Ser. No. 09/921,091, entitled “Cartridge Insert Which Fits Into A Box” and filed Aug. 2, 2001, which issued as U.S. Pat. No. 6,685,025 on Feb. 3, 2004. 
   BACKGROUND OF THE INVENTION 
   This invention relates to corrugated fibreboard inserts which fit into a carton to receive and protect an elongated or generally rectangular product and more particularly—but not exclusively—to inserts which can accommodate toner or similar cartridges having any of a number of different configurations. 
   In general, the invention is directed to packaging elongated or generally rectangular products. A moment&#39;s thought will readily bring to mind many such products such as a VCR cartridge, a glass ornament, a work of art, a portable radio, or the like. For convenience of description, all of these and other objects will hereinafter be included in the term “toner cartridge” for a computer printer. 
   Some fields of a product have parts which are very similar and yet are also different in detail. This means that the manufacturer of that product has often been required to inventory a different packaging system for each product in the field. This need not only increases costs for warehousing, handling, and the like, but also creates inefficiencies because the correct box may not always be available or may be in the wrong place at the wrong time. 
   A toner cartridge is an example of such a product. There are many manufacturers of printers which use toners in cartridges of its own design. Each manufacturer may also have a variety of toner cartridges which have evolved with improvements over the years. The same toner manufacturer may supply toner for most, if not all of these cartridges, for printers of different manufacturers. Therefore, that toner manufacturer will want to minimize the types and styles of packaging materials which it must keep in inventory, despite the fact that each printer manufacturer has its own design. The problem is further complicated since a toner cartridge does not have the smooth configuration of a rectangular box, such as a VCR cartridge. 
   Another consideration is the type of packaging material insofar as its bulk, ease of use, disposition and the like. For example, one type of packaging material is either molded pulp or polystyrene foam that is molded in a shape which receives and cradles a toner cartridge. Also, this requires mold tooling. It is particularly inefficient since the molded shape may not receive essentially the same cartridge if this surface contour is changed without altering the overall outer dimensions. This type of molded packaging is bulky and is costly to store and transport since it amounts to storing and shipping air. Further, it creates bulky trash for the customer to discard. In the case of polystyrene, the material is not recyclable or environment friendly. 
   A desirable form of packaging is a corrugated fibreboard insert because it is inexpensive, and can be stored flat to take up a minimum amount of room. It is recyclable and environmentally friendly. Such an insert should be simple, easy to fold, and to interlock into place with a minimum amount of effort. Also, it should be easy for the customer to unfold and to discard it after it has done its job. Further, it should be versatile and equally easy to form and use any blank for any of many types of cartridge that may be fitted therein. 
   When the corrugated fibreboard blank is designed, it should use as small an amount of fibreboard as possible considering the need to physically protect the product. It should have reliable interlocking parts or other means to keep it in an assembled condition. 
   OBJECTS AND SUMMARY OF THE INVENTION 
   A primary object of the invention is to provide a multi-purpose environmental friendly, insert which may receive and protect any one of a plurality of toner or other cartridges—or similar products—with equal protection and ease of use. 
   Briefly, and in accordance with the foregoing, the present invention discloses a corrugated fibreboard blank for receiving and protecting products, such as a toner cartridge, which is designed to securely receive the products in an upright position. The product may be either wrapped or unwrapped. Different types and sizes of product may be received and protected by the way that the blank is folded before or during an insertion of the product. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, wherein like reference numerals identify like elements in which: 
       FIG. 1  is a perspective view of a corrugated fibreboard blank which is used for the formation of the insert of a first embodiment of the invention; 
       FIG. 2  is a perspective view of a toner cartridge; 
       FIGS. 3A–3F  are stop motion illustrating how the corrugated fibreboard blank of  FIG. 1  is folded to form the insert of the first embodiment of the invention; 
       FIG. 4  is a cross section of an air cell at a bottom of the insert of the first embodiment of the invention; 
       FIG. 5  is a cross section of an air cell at an end of the insert of the first embodiment of the invention; 
       FIG. 6  is a perspective view showing an end air cell of the insert of the first embodiment of the invention; 
       FIG. 7  is a perspective drawing of a complete insert of the first embodiment of the invention with a plastic wrapped cartridge in place in the insert; 
       FIG. 8  is a cross section of the insert of the first embodiment of the invention inside a box; 
       FIG. 9A  is a perspective view of a corrugated fibreboard blank which is used for the formation of the insert of a second embodiment of the invention; 
       FIGS. 9B–9F  are stop motion illustrating how the corrugated fibreboard blank of  FIG. 9A  is folded to form the insert of the second embodiment of the invention; 
       FIG. 10A  is a perspective view of a corrugated fibreboard blank which is used for the formation of the insert of a third embodiment of the invention; and 
       FIGS. 10B–10F  are stop motion illustrating how the corrugated fibreboard blank of  FIG. 10A  is folded to form the insert of the third embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   While the invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, specific embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated and described herein. 
   A first embodiment of the invention is illustrated in  FIGS. 1–8 . A second embodiment of the invention is illustrated in  FIGS. 9A–9F . A third embodiment of the invention is illustrated in  FIGS. 10A–10E . Like elements are denoted with like reference numerals with the first embodiment being in the tens and one hundreds, the second embodiment being in the two and three hundreds, and the third embodiment being in the four and five hundreds. 
   Attention is invited to the first embodiment of the invention which is directed to a corrugated fibreboard blank  20  ( FIG. 1 ) which may be folded to form an insert for receiving and protecting a product. Dot-dashed lines show where the blank  20  folds. Solid lines show where the blank  20  is cut. Hash marks, such as shown at  21 , identify lines which are partially or almost cut through, as by knicked knives, so that they will initially fold as a unit, but will break apart when the blank  20  reaches a final fold. These partially cut lines  21  divide the blank  20  into three parts which will become a central air cell having a cradle air cell on each end. 
   A generally rectangular and integrally formed blank  20  is divided longitudinally into a bottom panel  22  flanked by side panels  24 ,  25  joined to outer panels  26 ,  27 . The bottom panel  22  has a rectangular central bottom panel  28  with opposite sides at fold lines  30 ,  32  and ends  34 ,  36 . The side panels  24 ,  25  have splayed panels  38 ,  40  joined to central bottom panel  28 . 
   The side panels  24 ,  25  are joined to outer panels  26 ,  27  which have bottom air cell panels  42 ,  44  joined to splayed panels  38 ,  40 . The splayed panels  38 ,  40  and bottom air cell panels  42 ,  44  will fold to form an air cell below central bottom panel  28 . 
   A central cradle panel  54 ,  56  is formed at each end of the central bottom panel  28 . The side panels  24 ,  25  and the outer panels  26 ,  27  have intermediate and outer cradle panels  62 ,  64  and  66 ,  68 , respectively, which fold to form an air cell behind the central cradle panels  54 ,  56 . Similar cradle panels (identified by the suffix (a)) are formed on the opposite ends of outer panels  26 ,  27 . Therefore, air cells are formed on each end and at the bottom of the insert formed by blank  20 . Product anchoring tabs  70 ,  72 ,  74 ,  76 ,  78 ,  80  are formed on the central cradle panels  54 ,  56 . 
   The intermediate cradle panels  62 ,  66  and the outer cradle panels  64 ,  68  will fold to form an air cell behind the central cradle panels  54 ,  56 . In greater detail, outer cradle panels  64 ,  68  fold and are positioned parallel to, behind, and spaced from central cradle panel  56 . Outer cradle panels  64  and  68  are in face to face contact at which time, they are locked together when tab  82  is pushed through hole  84  and when somewhat keystone shaped tabs  85 ,  87  are bent into the air cell. The tab  82  has a somewhat mushroom shape to provide a handle for two fingers after it is pushed into hole  84 . 
   The splayed panels  38 ,  40  and their bottom air cell panels  42 ,  44  are separated from intermediate cradle panels  62 ,  66  and from their outer cradle panels  64 ,  68  by lines  90  which are partially cut by knicked knives, as indicated by twin hash marks such as those shown at  21 . That is to say, the corrugated fibreboard is almost, but not quite, cut through. 
   Three product anchor flaps  70 ,  72 ,  74  and  76 ,  78 ,  80  are formed in the central cradle panels  54 ,  56  on opposite ends  58 ,  60  of the bottom panel  22 . Preferably, these anchor flaps  70 ,  72 ,  74 ,  76 ,  78 ,  80  have irregular shape in order to accommodate different end profiles of the product packaged in the cartridge insert. In greater detail, these flaps  70 ,  72 ,  74 ,  76 ,  78 ,  80  push out to receive and hold lower corners of the product. The opposite ends of the outer panel  26  have locking tabs  82 ,  82   a  which fit into holes  84 ,  84   a , respectively, of the outer panel  27  in order to lock the formed air cell in place. By a selection of these irregular shapes, it is possible to design one insert to receive, for instance, three different cartridges. 
     FIG. 2  shows a product  100  (here shown by way of example as a toner cartridge). However, any product having a similar corner configuration may be cradled by the inventive cartridge insert. This is different from packing the product in a molded pulp or foam cradle which depends upon a cavity having the surface configuration of the product. The important feature in showing  FIG. 2  is that the product  100  has complex outside contours which can be protected without reference to these contours. The outside dimensions of the product  100 , not the surface configuration, determines the characteristics which enable a use of the inventive insert. 
   The use of blank  20  ( FIG. 3A ) begins with  FIG. 3B  which is a first step where side panel  25  is folded to stand perpendicular to bottom panel  22 . Then, outer panel  27  is folded to be parallel to bottom panel  22  and perpendicular to side panel  25 . 
   In  FIG. 3C , the side panel  24  (not seen in  FIG. 3C ) is folded to stand perpendicular to bottom panel  22 . Outer panel  26  is folded to be perpendicular to side panel  24 , parallel to and in face-to-face contact with outer panel  27  (see also  FIG. 3B ). Locking tab  86  is pushed into locking hole  88  to secure the blank  20  in the folded configuration of  FIG. 3C . The resulting structure is a generally tubular shaped structure. 
   It should be noted that the spacer tabs  94  are upstanding and have not folded over with the folding of the center panels  26 ,  27 . It should also be noted that the lines  90  which were cut partially through by a knicked knife have held together so that the panels  22 – 27  folded as a unit and did not break apart through the folding of  FIGS. 3B and 3C . 
   In  FIG. 3D , the blank folded in  FIG. 3C  is flipped over so that bottom panel  22  is on top and outer panel  26  is on the bottom. Then ( FIG. 3E ), the end  60  is folded up. The lines  90  partially cut by knicked knives were strong enough to remain intact during the folding and flipping of  FIGS. 3B–3D , but are not strong enough to resist the folding of the air cell at end  60 . 
   In  FIG. 3F , the folding is complete when the air cell at end  58  is folded and standing approximately perpendicular to center bottom panel  28  and parallel to the air cell at end  60 . As can be seen in  FIG. 3F , the insert is a generally U-shaped structure when in its final form. The product anchor tabs  70 – 80  are pushed in, and ready to receive the product.  FIG. 4  is a cross-section of the air cell beneath the center bottom panel  28  which shows the locking tab  86  pressed through locking hole  88  in order to lock panels  42 ,  44  in an assembled position. 
     FIG. 5  is a cross section of the air cell formed between central cradle cell  56  and outer cradle panel  68  which shows locking tab  82  pressed through locking hole  84  to lock panels  64 ,  68  together. 
   An air cell ( FIG. 6 ) is formed on each end of the insert formed by folded blank  20 . The bottom edges of panels  68 ,  64  and  68   a ,  64   a  are locked together by pushing somewhat keystone shaped panels  85 ,  87  and  85   a ,  87   a  inwardly ( FIG. 6 ). 
   After the air cells are formed on each of the opposite ends and the bottom of the insert, the product  100  ( FIG. 7 ) is placed on the bottom panel  28  and between the product anchor flaps  70 ,  72 ,  74  and  76 ,  78 ,  80 . As the end air cells are brought together, the lower corners of the product  100  are captured as they force the anchor flaps  70 – 74  and  76 – 80  outwardly. 
   For toner cartridges, enclosure within a plastic bag is required by the cartridge manufacturers to avoid problems relating to the possibility of spilling ink. A plastic bag is not necessary for packaging a different type of product, which has no spillage possible. 
   Preferably, the toner cartridge is placed inside a plastic bag  130  ( FIG. 7 ) when the packaging is complete. The assembled insert and product  100  is now ready to be slid or placed in an outer box or carton. 
   It should be apparent from a study of  FIG. 8  that cartridges having different configurations may be accommodated since there is nothing dedicating the cartridge to specific surface shapes. Therefore, one insert may serve a family of different cartridges. In an acceptable size, the insert will be held in place by the carton or box in which the insert is used. 
     FIG. 8  shows a completely folded insert  20  inside an outer box or carton  134 . Edges where flutes of the corrugated fibreboard may be seen are indicated, as at  136 , for example. As the panels  64 ,  68  fold to be perpendicular to panels  62 ,  66 , a spacer tab  94  projects outwardly as shown on panels  62 ,  62   a  ( FIG. 3C ), for example, on each side and each end of the air cell. When the insert is placed inside a box  116  or carton  134 , these spacer tabs  94  rest against the inside end surfaces of the box  134 , thereby forming another air cell  138  to protect the product. The splayed panel  40  of the bottom air cell is in the nature of a bridge suspended between the vertical cradle air cells identified by their side panels  66   a ,  66 . 
   As shown in  FIGS. 6 ,  7  and  8 , the insert  20  is positioned to receive and cradle a product of a medium length. This particular insert fits three different cartridges of similar length, but different profiles. If the cartridge is longer or shorter, it requires a longer or shorter insert. Normally, cartridges come grouped in similar lengths. 
   The product anchoring tabs  70 – 80  ( FIG. 1 ) provide enough relief at the bottom of the product  100  to accept a product of any suitable length which the insert can accommodate. 
   Attention is invited to the second embodiment of the invention which is directed to a corrugated fibreboard blank  220  ( FIG. 9A ) which may be folded to form an insert  310  for receiving and protecting a product  100 . Dot-dashed lines show where the blank  220  folds. Solid lines show where the blank  220  is cut. Hash marks, such as shown at  221 , identify lines which are partially or almost cut through, as by knicked knives, so that they will initially fold as a unit, but will break apart when the blank  220  reaches a final fold. These partially cut lines  221  divide the blank  220  into three parts which will become a central air cell having a cradle air cell on each end. 
   A generally rectangular and integrally formed blank  220  is divided longitudinally into a bottom panel  222  flanked by side panels  224 ,  225  joined to outer panels  226 ,  227 . The bottom panel  222  has a rectangular central bottom panel  228  with opposite sides at fold lines  230 ,  232  and ends  234 ,  236 . The side panels  224 ,  225  have splayed panels  238 ,  240  joined to the central bottom panel  228 . 
   The central bottom panel  228  has a panel  292  provided therein which is defined by solid lines  294   a ,  294   b ,  294   c , which as defined above is where the blank  220  is cut, and by a dot-dashed line  296 , which as defined above is where the blank  220  is folded. The solid line  294   a  is provided along a portion of the fold line  230  and solid line  294   c  is provided along a portion of the fold line  232 . The solid line  294   b  extends from one end of the solid line  294   a  to one end of the solid line  294   c . The dot-dashed line  296  extends from an opposite end of the solid line  294   a  to an opposite end of the solid line  294   c . The solid line  294   b  further defines a tab portion  298  of the panel  292 . The purpose of the panel  292  and of the tab portion  298  of the panel  292  will be discussed further herein in connection with the formation of the insert  310  of the second embodiment from the blank  220 . 
   The side panels  224 ,  225  are joined to the outer panels  226 ,  227  which have bottom air cell panels  242 ,  244  joined to the splayed panels  238 ,  240 . The splayed panels  238 ,  240  and the bottom air cell panels  242 ,  244  will fold to form an air cell below the central bottom panel  228 . The bottom air cell panel  242  has a hole  243  provided therethrough. The hole  243  is sized and positioned such that upon formation of the insert  310  of the second embodiment, the hole  243  can receive and lock the tab portion  298  of the panel  292  therein in order to hold the panel  292  in place, as will be discussed further herein. 
   A central cradle panel  254 ,  256  is formed at each end of the central bottom panel  228 . The side panels  224 ,  225  and the outer panel  226 ,  227  have intermediate and outer cradle panels  262 ,  264  and  266 ,  268 , respectively, which fold to form an air cell behind the central cradle panels  254 ,  256 . Similar cradle panels (identified by the suffix (a)) are formed on the opposite ends of the outer panels  226 ,  227 . Therefore, air cells are formed on each end and at the bottom of the insert formed by blank  220 . Product anchoring tabs or flaps  270 ,  272 ,  274 ,  276 ,  278 ,  280  are formed on the central cradle panels  254 ,  256 . 
   The intermediate cradle panels  262 ,  266  and the outer cradle panels  264 ,  268  will fold to form an air cell behind the central cradle panels  254 ,  256 . In greater detail, the outer cradle panels  264 ,  268  fold and are positioned parallel to, behind, and spaced from the central cradle panel  256 . The outer cradle panels  264 ,  268  are in face to face contact at which time, they are locked together when tab  282  is pushed through hole  284  and when somewhat keystone shaped tabs  285 ,  287  are bent into the air cell. The tab  282  has a somewhat mushroom shape to provide a handle for two fingers after it is pushed into hole  284 . 
   The splayed panels  238 ,  240  and their bottom air cell panels  242 ,  244  are separated from the intermediate cradle panels  262 ,  266  and from their outer cradle panels  264 ,  268  by lines  290  which are partially cut by knicked knives, as indicated by twin hash marks such as those shown at  221 . That is to say, the corrugated fibreboard is almost, but not quite, cut through. 
   Three product anchor flaps or tabs  270 ,  272 ,  274  and  276 ,  278 ,  280  are formed in the central cradle panels  254 ,  256  on opposite ends  258 ,  260  of the bottom panel  222 . Preferably, these anchor flaps  270 ,  272 ,  274 ,  276 ,  278 ,  280  have an irregular shape in order to accommodate different end profiles of the product packaged in the cartridge insert. In greater detail, these flaps  270 ,  272 ,  274 ,  276 ,  278 ,  280  push out to receive and hold lower corners of the product  100 . The opposite ends of the outer panel  226  have locking tabs  282 ,  282   a  which fit into holes  284 ,  284   a , respectively, of the outer panel  227  in order to lock the formed air cell in place. By a selection of these irregular shapes, it is possible to design one insert to receive, for instance, three different cartridges. 
   The use of the blank  220  ( FIG. 9A ) begins with  FIG. 9B  which is a first step where the side panel  225  is folded to stand perpendicular to the bottom panel  222 . Then, the outer panel  227  is folded to be parallel to the bottom panel  222  and perpendicular to the side panel  225 . 
   In  FIG. 9C , the side panel  224  (not seen in  FIG. 9C ) is folded to stand perpendicular to the bottom panel  222 . The outer panel  226  is folded to be perpendicular to the side panel  224 , parallel to and in face-to-face contact with the outer panel  227  (see also  FIG. 9B ). The locking tab  286  is pushed into the locking hole  288  to secure the blank  220  in the folded configuration of  FIG. 9C . The resulting structure is a generally tubular shaped structure. 
   It should be noted that the spacer tabs  294  are upstanding and have not folded over with the folding of the center panels  226 ,  227 . It should also be noted that the lines  290  which were cut partially through by a knicked knife have held together so that the panels  222 – 227  folded as a unit and did not break apart through the folding of  FIGS. 9B and 9C . 
   In  FIG. 9D , the blank folded in  FIG. 9C  is flipped over so that the bottom panel  222  is on top and the outer panel  226  is on the bottom. The panel  292  is also pushed down toward the bottom air cell panel  242  until the tab portion  298  of the panel  292  is inserted into and locked within the hole  243  of the bottom air cell panel  242 . The purpose of the panel  292  being locked within the hole  243  is to stabilize the bottom air cell to ensure that the bottom air cell of the insert  310  maintains its shape, preventing the insert  310  from swaying from side to side. If the panel  292  is not locked into the hole  243 , the bottom air cell panel  242  and the bottom air cell, which is provided between the bottom air cell panel  242  and the bottom panel  228 , has a tendency to collapse. 
   Then ( FIG. 9E ), the end  260  is folded up. The lines  290  partially cut by knicked knives were strong enough to remain intact during the folding and flipping of  FIGS. 9B–9D , but are not strong enough to resist the folding of the air cell at end  260 . 
   In  FIG. 9F , the folding is complete when the air cell at end  258  is folded and standing approximately perpendicular to the center bottom panel  228  and parallel to the air cell at end  260 . As can be seen in  FIG. 9F , the insert  310  is a generally U-shaped structure when in its final form. The product anchoring tabs  270 – 280  are pushed in, and ready to receive the product  100 . The locking tab  286  is pressed through the locking hole  288  in the same manner as the locking tab  86  is pressed through the locking hole  88  of the first embodiment of the insert, as illustrated in  FIG. 4 . The locking tab  286  being pressed through the locking hole  288  thus lock the panels  242 ,  244  in an assembled position. 
   Locking tab  282  is pressed through locking hole  284  to lock panels  264 ,  268  together in the same manner in which locking tab  82  is pressed through locking hole  84  to lock panels  64 ,  68  together in the first embodiment of the insert, as illustrated in  FIG. 5 . 
   An air cell is formed on each end  258 ,  260  of the insert  310  formed by folded blank  220 . The bottom edges of panels  268 ,  264  and  268   a ,  264   a  are locked together by pushing somewhat keystone shaped panels  285 ,  287  and  285   a ,  287   a  inwardly. This is done in identical fashion as in the first embodiment of the insert as illustrated in  FIG. 6 . 
   After the air cells are formed on each of the opposite ends and the bottom of the insert  310 , the product  100  is placed on the bottom panel  228  and between the product anchor flaps  270 ,  272 ,  274  and  276 ,  278 ,  280 . As the end air cells are brought together, the lower corners of the product  100  are captured as they force the anchor flaps  270 – 274  and  276 – 280  outwardly. While this is not illustrated in the drawings, it is identical to that as shown in  FIG. 7  with regard to the first embodiment of the insert. 
   Preferably, the toner cartridge is placed inside a plastic bag  130  when the packaging is complete. The assembled insert  310  and product  100  is now ready to be slid or placed in an outer box or carton in the same manner described in connection with the insert of the first embodiment of the invention, and as illustrated in  FIG. 8 , and therefore this discussion with not be repeated and reillustrated for brevity purposes. 
   Attention is invited to the third embodiment of the invention which is directed to a corrugated fibreboard blank  420  ( FIG. 10A ) which may be folded and adhered together to form an insert  510  for receiving and protecting a product  100 . Dot-dashed lines show where the blank  420  folds. Solid lines show where the blank  420  is cut. Hash marks, such as shown at  421 , identify lines which are partially or almost cut through, as by knicked knives, so that they will initially fold as a unit, but will break apart when the blank  420  reaches a final fold. These partially cut lines  421  divide the blank  420  into three parts which will become a central air cell having a cradle air cell on each end. 
   A generally rectangular and integrally formed blank  420  is divided longitudinally into a bottom panel  422  flanked by side panels  424 ,  425  joined to outer panels  426 ,  427 . The bottom panel  422  has a rectangular central bottom panel  428  with opposite sides at fold lines  430 ,  432  and ends  434 ,  436 . The side panels  424 ,  425  have splayed panels  438 ,  440  joined to the central bottom panel  428 . 
   The central bottom panel  428  has a panel  492  provided therein which is defined by solid lines  494   a ,  494   b ,  494   c , which as defined above is where the blank  420  is cut, and by a dot-dashed line  496 , which as defined above is where the blank  420  is folded. The solid line  494   a  is provided along a portion of the fold line  430  and solid line  494   c  is provided along a portion of the fold line  432 . The solid line  494   b  extends from one end of the solid line  494   a  to one end of the solid line  494   c . The dot-dashed line  496  extends from an opposite end of the solid line  494   a  to an opposite end of the solid line  494   c . The solid line  494   b  further defines a tab portion  498  of the panel  492 . The purpose of the panel  492  and of the tab portion  498  of the panel  492  will be discussed further herein in connection with the formation of the insert  510  of the third embodiment from the blank  420 . 
   The side panels  424 ,  425  are joined to the outer panels  426 ,  427  which have bottom air cell panels  442 ,  444  joined to the splayed panels  438 ,  440 . The splayed panels  438 ,  440  and the bottom air cell panels  442 ,  444  will fold to form an air cell below the central bottom panel  428 . The bottom air cell panel  442  has a hole  443  provided therethrough. The bottom air cell panel  440  has a notch  441  provided therethrough. The hole  443  and the notch  441  are sized and positioned such that upon formation of the insert  510  of the third embodiment, the hole  443  and the notch  441  can receive and lock the tab portion  498  of the panel  492  therein in order to hold the panel  492  in place, as will be discussed further herein. 
   A central cradle panel  454 ,  456  is formed at each end of the central bottom panel  428 . The side panels  424 ,  425  and the outer panel  426 ,  427  have intermediate and outer cradle panels  462 ,  464  and  466 ,  468 , respectively, which fold to form an air cell behind the central cradle panels  454 ,  456 . Similar cradle panels (identified by the suffix (a)) are formed on the opposite ends of the outer panels  426 ,  427 . Therefore, air cells are formed on each end and at the bottom of the insert formed by blank  420 . Product anchoring tabs or flaps  470 ,  472 ,  474 ,  476 ,  478 ,  480  are formed on the central cradle panels  454 ,  456 . 
   A fold line  433  is provided on the bottom panel  422  equidistantly from the fold lines  430  and  432 . The fold line  433  extends through the central cradle panel  454 , through the product anchoring tab  470 , through the bottom panel  428 , through the panel  492 , through the product anchoring tab  476 , and through the central cradle panel  456 . 
   A fold line  435  is provided at the middle of the outer panel  427 . The fold line  435  extends through the outer cradle panel  464   a , the bottom air cell panel  442 , and the outer cradle panel  464 . 
   The outer panel  426  has a adhesive  483 , such as a glue strip, provided thereon which extends over the middle of the outer panel  426 . The adhesive  483  extends over the outer cradle panel  468   a , through the bottom air cell panel  444 , and through the outer cradle panel  468 . 
   The intermediate cradle panels  462 ,  466  and the outer cradle panels  464 ,  468  will fold to form an air cell behind the central cradle panels  454 ,  456 . In greater detail, the outer cradle panels  464 ,  468  fold and are positioned parallel to, behind, and spaced from the central cradle panel  456 . The outer cradle panels  464 ,  468  are in face to face contact. Prior thereto, they are locked together when the blank  420  is folded along the fold lines  433 ,  435  such that the adhesive  483  secures the outer panel  426  to the outer panel  427 . 
   The splayed panels  438 ,  440  and their bottom air cell panels  442 ,  444  are separated from the intermediate cradle panels  462 ,  466  and from their outer cradle panels  464 ,  468  by lines  490  which are partially cut by knicked knives, as indicated by twin hash marks such as those shown at  421 . That is to say, the corrugated fibreboard is almost, but not quite, cut through. 
   Three product anchor flaps or tabs  470 ,  472 ,  474  and  476 ,  478 ,  480  are formed in the central cradle panels  454 ,  456  on opposite ends  458 ,  460  of the bottom panel  422 . Preferably, these anchor flaps  470 ,  472 ,  474 ,  476 ,  478 ,  480  have an irregular shape in order to accommodate different end profiles of the product packaged in the cartridge insert. In greater detail, these flaps  470 ,  472 ,  474 ,  476 ,  478 ,  480  push out to receive and hold lower corners of the product  100 . By a selection of these irregular shapes, it is possible to design one insert to receive, for instance, three different cartridges. 
   The use of the blank  420  ( FIG. 10A ) begins with folding the blank  420 , as illustrated in  FIG. 10B , along the fold line  435  such that the outer panel  427  is folded into two parts  427   a ,  427   b  with part  427   a  being folded over on top of part  427   b . The blank  420  is then folded along the fold line  433  such that the outer panel  426  having the adhesive  483  thereon comes into contact with the part  427   a  of the outer panel  427 , and such that the notch  441  is in communication with the hole  443 . The adhesive  483  thus secures the outer panel  426  to the part  427   a  of the outer panel  427   a . The blank  420  is thus formed into the flat configuration illustrated in  FIG. 10C . 
   In  FIG. 10D , the blank  420  is pushed downwardly along the fold line  433  such that the tubular insert  510  is formed by the blank  420  being folded along the fold lines  430 ,  432 , and the fold lines separating the outer panels  426 ,  427  from the side panels  424 ,  425 , respectively. Thus, the side panel  424  (not seen in  FIG. 10D ) is folded to stand perpendicular to the bottom panel  422 . The outer panel  426  is folded to be perpendicular to the side panel  424 , parallel to and in face-to-face contact with the outer panel  427 . The blank  420  is secured in the folded configuration of  FIG. 10D  because of the adhesive  483  of the outer panel  426  being secured to the part  427   a  of the outer panel  427 . The resulting structure is a generally tubular shaped structure. 
   It should be noted that the spacer tabs  494  are upstanding and have not folded over with the folding of the center panels  426 ,  427 . It should also be noted that the lines  490  which were cut partially through by a knicked knife have held together so that the panels  422 – 427  folded as a unit and did not break apart through the folding of  FIGS. 10C and 10D . 
   In  FIG. 10E , the panel  492  is pushed down toward the bottom air cell panel  442  until the tab portion  498  of the panel  492  is inserted into and locked within the hole  443  of the bottom air cell panel  442  and the notch  441  of the bottom air cell panel  444 . The purpose of the panel  492  being locked within the hole  443  and the notch  441  is to ensure that the bottom air cell of the insert  510  maintains its shape, preventing the insert  510  from swaying from side to side. If the panel  492  is not locked into the hole  443  and the notch  441 , the bottom air cell panel  442  and the bottom air cell, which is provided between the bottom air cell panel  442  and the bottom panel  428 , has a tendency to collapse. 
   As illustrated in  FIG. 10E , the ends  458 ,  460  are also folded up. The lines  490  partially cut by knicked knives were strong enough to remain intact during the folding and flipping of  FIGS. 10C–10D , but are not strong enough to resist the folding of the air cell at ends  458 ,  460 . 
   In  FIG. 10F , the folding is complete when the air cell at end  458  is folded and standing approximately perpendicular to center bottom panel  428  and parallel to the air cell at end  460 . As can be seen in  FIG. 10F , the insert  510  is a generally U-shaped structure when in its final form. The product anchoring tabs  470 – 480  are pushed in, and ready to receive the product  100 . An air cell is formed on each end of the insert  510  formed by the folded blank  420 . 
   After the air cells are formed on each of the opposite ends  458 ,  460  and the bottom of the insert  510 , the product  100  is placed on the bottom panel  428  and between the product anchor flaps  470 ,  472 ,  474  and  476 ,  478 ,  480 . As the end air cells are brought together, the lower corners of the product  100  are captured as they force the anchor flaps  470 – 474  and  476 – 480  outwardly. While this is not illustrated in the drawings, it is identical to that as shown in  FIG. 7  with regard to the first embodiment of the insert. 
   Preferably, the toner cartridge is placed inside a plastic bag  130  when the packaging is complete. The assembled insert  510  and product  100  is now ready to be slid or placed in an outer box or carton in the same manner described in connection with the insert of the first embodiment of the invention, and as illustrated in  FIG. 8 , and therefore this discussion with not be repeated and reillustrated for brevity purposes. 
   It should be noted that the blank  420  which forms the insert  510  of the third embodiment of the invention, could be formed without the panel  492  in the bottom panel  428 , similar to the insert of the first embodiment of the invention. 
   It should further be noted that the blank  420  has the advantage of being shipped to a customer in an already partially formed insert. The blank  420  can be prepared by the manufacturer of the blank  420  to the configuration of the blank  420  as illustrated in  FIG. 10C . Thus, the blank  420  can still be shipped flat to the customer and the customer does not need to do as many assembly steps prior to securing the product  100  into the insert  510  of the third embodiment. The gluing of the blank  20  also saves the manufacturer from extra costs involved in manually securing the anchoring tabs or flaps in the anchoring holes. In other words, once the customer receives the blank  420 , the customer need only perform the steps illustrated in  FIGS. 10D–10F . 
   All of the blanks  20 ,  220 ,  420  have a number of features and advantages. For instance, the blanks  20 ,  220 ,  420  allow for fast and easy assembly and handling, they provide for space-saving as they ship and store flat, they are inexpensive as they are formed of corrugated fibreboard, they are versatile as each insert formed from the blanks  20 ,  220 ,  420  can secure up to five different cartridges, they are environmentally friendly as they are formed of recyclable material, and they replace molded insert products, which are typically in foam and plastic. 
   While preferred embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims.