Abstract:
An improved suspension package system in which one or more suspension frames are used to suspend an article within a shipping container, wherein the suspension frame includes a suspension mechanism formed by a plurality of generally concentric cuts forming a plurality of suspension channel members, each cut being interrupted by one or more nicks. The nicks conjoin adjacent channel members, and conjoin an innermost channel member to an optional article platform, and conjoin an outermost channel member to an optional perimeter portion. Sidewalls give the suspension frame a 3-D shape and provide suspension clearance. The article can be sandwiched between two opposing suspension frames. The suspension frame can be formed as a monolithic piece of corrugated containerboard. Forming the suspension of corrugated containerboard improves the recyclability of the product, and reduces its manufacturing cost by eliminating the need for purchasing and assembling a plastic suspension sheet. The frame can also be configured as a retention frame.

Description:
BACKGROUND OF THE INVENTION  
       [0001]    1. Technical Field of the Invention 
         [0002]    This invention relates generally to shipment packaging, and more specifically to packaging formed of corrugated containerboard, folding carton stock, paperboard, or the like, having an improved means of suspending or retaining articles packaged therein. 
         [0003]    2. Background Art 
         [0004]    U.S. Pat. No. 5,388,701 “Suspension Packaging” by Devin C. Ridgeway and assigned to Sealed Air Corp. teaches a suspension packaging system in which two suspension frames are disposed within a corrugated containerboard box. Each suspension frame includes a corrugated containerboard frame to which is affixed a resilient member formed of a sheet of plastic. The suspension frames are placed one atop the other, with their plastic sheets adjacent each other, and the packaged article is suspended between the plastic sheets. The resiliency of the plastic sheets provides the suspension characteristic of the packaging, and allows the packaged article to move or bounce within the package. The depth of the corrugated containerboard frames provides clearance so the article does not strike the enclosing corrugated containerboard box. This packaging system has been widely adopted. Unfortunately, it requires the use of plastic sheeting, which is less ecologically friendly than the corrugated containerboard. And unfortunately, the use of the plastic sheeting raises manufacturing costs not only in materials but also in assembly. 
         [0005]    U.S. Pat. Nos. 7,296,681 and 6,675,973, both entitled “Suspension Packaging Assembly” and both by McDonald et al., teach a packaging system in which a sheet of polyethylene film is stretched over an article to retain it against the corrugated cardboard suspension pieces. These suffer the same flaws as the Ridgeway invention. 
         [0006]    What is needed is an improved suspension packaging system having improved recyclability and lower manufacturing cost. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0007]      FIG. 1  shows one embodiment of the corrugated containerboard suspension frame of this invention, in a flat configuration as manufactured before folding into a 3-D configuration. 
           [0008]      FIG. 2  shows the folded, 3-D configuration of the suspension frame of  FIG. 1 . 
           [0009]      FIG. 3  shows the suspension frame in cross-section view, illustrating the movement of the suspension features. 
           [0010]      FIG. 4  shows the assembly of the suspension package system, including a corrugated containerboard box and two opposed suspension frames, in an exploded view. 
           [0011]      FIG. 5  shows the suspension package system in use suspending an article to be shipped, in cross-section view. 
           [0012]      FIG. 6  shows another embodiment of a suspension frame. 
           [0013]      FIG. 7  shows yet another embodiment of a suspension frame. 
           [0014]      FIG. 8  shows another embodiment of a suspension package system, employing suspension frames on multiple sides of an article to be shipped. 
           [0015]      FIG. 9  shows an embodiment of a retention frame, in a flat configuration as manufactured before folding into a 3-D configuration. 
       
    
    
     DETAILED DESCRIPTION  
       [0016]    The invention will be understood more fully from the detailed description given below and from the accompanying drawings of embodiments of the invention which, however, should not be taken to limit the invention to the specific embodiments described, but are for explanation and understanding only. 
         [0017]      FIG. 1  with detail view IA illustrates one embodiment of a suspension frame  10  which may be used in practicing the principles of this invention. The suspension frame may advantageously be formed from a single sheet of corrugated containerboard, with its features being formed by die cutting. The suspension frame includes an article platform portion  12  which may in some embodiments be located generally in a center of the suspension frame. The suspension frame also includes a perimeter portion  14  which will define a mating face of the suspension frame, and sidewall portions  16  which will be folded during the assembly process to give the suspension frame a 3-D shape providing depth for suspension clearance. 
         [0018]    The article platform is coupled to the perimeter portion by a suspension portion  18  having a plurality of cuts  20  which extend through the corrugated containerboard and define between them a plurality of suspension channels  22 . In one embodiment, the cuts are arranged in a generally concentric, evenly-spaced manner. Any given cut is interrupted by a plurality of nicks  24 . Each nick conjoins two adjacent channels, maintaining structural integrity of the suspension frame. 
         [0019]    In some applications, or with some manufacturing equipment, it may be desirable to form the cuts as simple slices, in which no material is removed. In other applications, or with other manufacturing equipment, it may be desirable to form the cuts by removing material from the suspension frame. 
         [0020]    The relative geometries of the number and width (if any) of the cuts, the number and length of the nicks, the width of the channels, the thickness and stiffness of the suspension frame material, and so forth, should all be determined according to the dictates of the application at hand, taking into account the size, mass, shape, and fragileness of the article to be shipped. 
         [0021]    In the embodiment shown, the nicks are arranged in a regular pattern in which each cut is interrupted by six nicks, and every second cut is angularly offset from its neighbors by half, such that there are twelve “spokes” of nicks. The outermost cut has two pairs of nicks  26  which conjoin the outermost channel to the perimeter portion of the frame at respective, opposing sides of the suspension frame, and two individual nicks  28  which conjoin the outermost channel to the perimeter portion of the frame at the other opposite sides. 
         [0022]    Other nick patterns are certainly conceivable and useable within the teachings of this invention. 
         [0023]    Optionally, the perimeter portion of the suspension frame may include one or more voids  30  which provide containment and/or display of the articles enclosed. 
         [0024]      FIG. 2  illustrates the suspension frame  10  after folding during assembly. In this embodiment, the sidewall portions  16  have been folded and their tabs engaged with the slots  32  at the outer edges of the perimeter portion  14 , to lock the suspension frame into shape. A variety of other mechanisms could be used to accomplish this. The platform portion  12  is raised by the height of the folded sidewall portions, to provide suspension clearance as will be shown below. 
         [0025]      FIG. 3  illustrates the suspension frame  10  in cross-section view, more particularly illustrating the suspension characteristics. The platform portion  12  is offset (downward in this view) from the perimeter portion  14 , such as if there were an article pressing against it. The sidewall portions  16  should be sized appropriately, to provide adequate suspension movement clearance such that the article does not “bottom”. 
         [0026]      FIG. 4  illustrates the assembly of the overall suspension packaging system  40 , in an exploded view. The packaging system includes e.g. a corrugated containerboard box  42 , a lower suspension frame  10 L and an upper suspension frame  10 U. The box&#39;s inner dimensions may advantageously match the suspension frames&#39; outer dimensions, such that the suspension frames are held securely in place when disposed within the box. The upper suspension frame is upside-down with respect to the lower suspension frame, such that their perimeter portions and, more importantly, their article platform portions, are directly adjacent each other. 
         [0027]      FIG. 5  illustrates the suspension packaging system  40  in use. An article  44  is trapped between the opposing faces of the platform portions (and perhaps part of the suspension portions) of the lower and upper suspension frames  10 L and  10 U, and the suspension frames are enclosed within the corrugated containerboard box  42  (which will, of course, be closed before shipment). The suspension of the lower suspension frame is distended downward, and the suspension of the upper suspension frame is distended upward, entrapping the article for shipment. Optionally but advantageously, the sidewall portions of the suspension frames provide additional clearance, such that when the box is dropped or jostled, the article does not strike the inner surfaces of the box (or does so with reduced force, at least). 
         [0028]      FIG. 6  illustrates an alternative embodiment of a suspension frame  50  which may be used in practicing this invention. Whereas in the previous figures the suspension cuts were illustrated as being a series of concentric, nick-interrupted circles, in this embodiment the cuts take a more rectangular shape. 
         [0029]    The suspension frame includes an article platform portion  52 , a perimeter portion  54 , and sidewall portions  56 . It further includes a plurality of generally concentric cuts  58  interrupted by nicks  60 . In one embodiment, the cuts could have a strict rectangular shape. However, in the embodiment shown, the cuts have a “rounded rectangle” shape such that the portion  62  of the channels at the corners provides a rounded, smooth transition. Avoiding abrupt, sharp angles in the cuts may improve the strength and durability of the channels, by preventing tearing. 
         [0030]      FIG. 7  illustrates yet another embodiment of a suspension frame  70 , in which the article platform portion  72  is interrupted by a central void  74 . This void may, in some applications, be advantageous for engaging with the shape of a particular piece of the article to be shipped (not shown), preventing lateral movement, twisting, and the like. 
         [0031]      FIG. 8  illustrates a packaging system  80  according to yet another embodiment of this invention. Within a box  80 , an article to be shipped (not shown) is surrounded by multiple suspension frames. For example, a first suspension frame  84  resides beneath the article, and has a heavy suspension with extra clearance, to support the weight of the article. Four suspension frames  86 ,  88 ,  90 ,  92  are disposed at four sides of the article, and a suspension frame  94  is disposed above the article. It should be noted that, not only can the suspension frames be of different construction, strength, clearance, and so forth, they may have their platform portions arranged in a variety of locations, not necessarily symmetric with each other, as dictated by the shape and characteristics of the article to be shipped. 
         [0032]      FIG. 9  illustrates a retention frame  100  according to still another embodiment of this invention. The frame includes an article platform portion  112  which is connected to a perimeter portion  114  by a suspension portion  118 . The article platform portion may optionally include a hole  120  sized and shaped to engage or mate with a portion of, or a perimeter of, the article to be packaged (not shown). The frame includes a plurality of portions, tabs, panels, etc. which can be folded to create the 3-D configuration of the frame, as is known in the art. 
         [0033]    The article platform portion, perimeter portion, and suspension portion are parts of (and, ideally but optionally, are of monolithic construction comprising) a first panel  122 . When the suspension package is assembled by folding into its 3-D configuration, the article is sandwiched between the first panel and an adjacent second panel  124 . The first and second panels are folded to be substantially parallel. A third panel  126  is folded at right angles to the second panel, and defines the height of the suspension package. A fourth panel  128  is folded parallel with the first and second panels. A fifth panel  130  is folded parallel with the third panel. At some point in the folding process, sixth and seventh panels  132  are folded at right angles to the second panel. The third, fifth, sixth, and seventh panels form the four “sides” of the package, while the second panel forms the “bottom” and the fourth panel forms the “top”. Eighth and ninth panels  134  are folded so as to be substantially flush with their respective counterparts of the sixth and seventh panels, and serve to keep the first panel in position so the suspension retains the article against the second panel. 
         [0034]    The assembled retention frame may optionally be included within a shipping box (not shown). And, optionally, the box may be equipped with a means for suspending the suspension package such that the second panel is not in direct contact with an exterior panel of the box, whereby the packaged article is provided with clearance to reduce the chance of damage if the box is penetrated or crushed. 
       CONCLUSION  
       [0035]    When one component is said to be “adjacent” another component, it should not be interpreted to mean that there is absolutely nothing between the two components, only that they are in the order indicated. 
         [0036]    The various features illustrated in the figures may be combined in many ways, and should not be interpreted as though limited to the specific embodiments in which they were explained and shown. 
         [0037]    Those skilled in the art, having the benefit of this disclosure, will appreciate that many other variations from the foregoing description and drawings may be made within the scope of the present invention. Indeed, the invention is not limited to the details described above. Rather, it is the following claims including any amendments thereto that define the scope of the invention. 
         [0038]    In some applications, it may be desirable to manufacture the suspension frame of this invention from corrugated containerboard, while in other applications, it may be desirable to use a different material such as corrugated plastic, or metal sheeting, or what have you. In the preferred embodiment, the suspension flame is manufactured of corrugated containerboard, but the invention is not limited to that particular material. 
         [0039]    For convenience only, the suspension frame and packaging system have been illustrated in square or rectangular shaped embodiments. Although those are certainly the most common packaging shapes in use, due to their manufacturability and effective packing density when multiple packages are stacked next to each other, the invention is not limited to those shapes. Other shapes of suspension frames may utilize the principles of this invention, such as round, oval, triangular, hexagonal, and so forth, as determined by the dictates of the application at hand. 
         [0040]    In some applications, it may be desirable to use different suspension frames together in the same package. For example, a heavy article may dictate a heavy, stiff lower suspension, but a lighter, less stiff upper suspension. 
         [0041]    Although, for convenience, the various suspension frames have been illustrated as including both a perimeter portion and a sidewall portion, in some applications either of those may be omitted. For example, if the suspension portion extends all the way to the edge of the frame and is conjoined directly with the sidewall portion, then technically there is no perimeter portion. Or, if the suspension clearance is to be provided by independent legs, or standoffs within the box, or by the suspension frame being stapled or glued to the box at a position somewhat removed from the end of the box, there may not necessarily be a sidewall portion in the sense suggested above. The salient feature of this invention is the suspension portion. And furthermore, even the article platform portion may be omitted, such as if the suspension cuts extend all the way to the center or at least to a central void.