Abstract:
A packaging assembly can include a container comprising a top, a bottom and a plurality of sidewalls, a first frame and a second frame. The first frame can include a first support panel including a first surface configured to face an article and a second surface opposite to the first surface, and a first leg portion pivotably connected to the first support panel and located between the first support panel and the bottom. The first leg portion can cause a resilient force to bias the first support panel away from the bottom when the first leg portion is located at a third rotational position between the first rotational position and the second rotational position. The second frame can include a second support panel. The second frame can nest with the first frame within the container so as to retain an article between the first and second support panels.

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 61/077,765, titled SUSPENSION PACKAGING ASSEMBLY, filed Jul. 2, 2008, the entire contents of which is hereby expressly incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTIONS 
     1. Field of the Inventions 
     The present inventions are directed to packaging systems, for example, suspension packaging systems that includes a plurality of foldable members. 
     2. Description of the Related Art 
     Protective packaging devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact with the inner walls of the box that might be caused by shocks imparted to the box during loading, transit, and unloading. 
     In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is suspended within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box. 
     U.S. Pat. No. 6,675,973 discloses a number of inventions directed to suspension packaging assemblies which incorporate frame members and one or more retention members. For example, at least one of the embodiments of the U.S. Pat. No. 6,675,973 patent includes the use of a foldable member of a substantially rigid board, for example, a cardboard. The foldable member includes foldable portions configured to form a frame member. Additionally, a retention member formed of a resilient material is used. Some of the retention members include pockets at opposite ends thereof. 
     SUMMARY OF THE INVENTIONS 
     One aspect of at least one of the inventions disclosed herein includes the realization of suspension packaging assemblies can be constructed in a manner so as to provide sufficient cushioning without any plastic or plastic-like materials yet provide sufficient cushioning for delicate items and provide convenient and easy un-packing and/or re-packaging. Additionally, another aspect includes the realization that such suspension packaging assemblies can also be constructed such that additional resilient plastic materials can optionally be used with the packing structure to provide additional cushioning if desired, thereby providing two modes of use. Such packaging systems can be particularly advantageous, for example, to a rental business of electronic devices or a business providing repair services requiring shipping of delicate components back and forth between the owner and service provider 
     In accordance with an embodiment, a packaging assembly for packaging an article and maintaining the article therein, the assembly can comprise: a container comprising a top, a bottom and a plurality of sidewalls; a first frame contained within the container, the first frame comprising a first support panel comprising a first surface configured to face an article and a second surface opposite to the first surface, and a first leg portion pivotably connected to the first support panel and located between the first support panel and the bottom, wherein the first leg portion is rotatable relative to the first support panel between a first rotational position and a second rotational position so as to allow movement of the first support panel relative to the bottom, wherein the first leg portion is configured to cause a resilient force to bias the first support panel away from the bottom when the first leg portion is located at a third rotational position between the first rotational position and the second rotational position; and a second frame comprising a second support panel, the second frame being configured to nest with the first frame within the container so as to retain an article between the first and second support panels. 
     In the foregoing embodiment, the first frame can further comprise a first anchor panel extending between the top and bottom of the container; and a first connecting portion interconnecting the first support panel and the first anchor panel and comprising at least one fold line configured to allow movement of the first support panel relative to the bottom of the container. The first connecting portion can comprise at least two panels pivotably connected to each other along the at least one fold line. 
     Still in the foregoing embodiment, the first connecting portion can comprise a first side panel pivotally connected to the first support panel, and a ridge panel pivotably connected to each of the first anchor panel and the first side panel, wherein the first anchor panel and the first side panel are substantially parallel to each other. The first frame further can comprise: a second anchor panel extending between the top and the bottom of the container; and a second connecting portion interconnecting the first support panel and the second anchor panel and comprising at least one fold line configured to allow movement of the first support panel relative to the bottom of the container. The first frame can further comprise a second connecting portion interconnecting the first support panel and one of the plurality of sidewalls of the container and comprising at least one fold line configured to allow movement of the first support panel relative to the bottom of the container. 
     Yet in the foregoing embodiment, the first leg portion can comprise a distal end contacting the bottom and configured to slide with respect to the bottom when the first leg portion moves between the first and second rotational positions. The first frame can further comprise a second leg portion pivotably connected to the first support panel such that the first support panel is interposed between the first and second leg portions. 
     Further in the foregoing embodiment, the second support panel of the second frame can comprise at least one foldable flap configured to resiliently support an article retained between the first and second frames. The second frame can be sized such that the second frame substantially fits into a space defined by the container and first frame. The assembly can further comprise a retention member which comprises a resilient body and an end portion configured to engage with the at least one folded portion such that the resilient body disposed over the second support panel, wherein the resilient body is configured to resiliently support an article retained between the first and second frames. The assembly may have no resilient retention sheet member configured to engage with one of the first and second frames. The assembly can be configured to provide substantial cushioning without a resilient retention sheet member configured to engage with one of the first and second frames. 
     The second frame can comprise a third leg portion pivotably connected to the second support panel and located between the second support panel and the top, wherein the third leg portion is rotatable relative to the second support panel between a first rotational position and a second rotational position so as to allow movement of the second support panel relative to the top, wherein the third leg portion is configured to cause a resilient force to bias the second support panel away from the top when the third leg portion is located at a third rotational position between the first rotational position and the second rotational position. The container and the first frame can be pivotably connected to each other and are formed of a single cardboard. 
     In another embodiment, a packaging kit for packaging an article and maintaining the article can comprise: a container forming member comprising a plurality of foldable portions configured to form a container which comprises a top, a bottom and a plurality of sidewalls; a first frame forming member comprising a plurality of foldable portions configured to form a first frame to be contained within the container, wherein the first frame comprises a first support panel comprising a first surface configured to face an article and a second surface opposite to the first surface, and a first leg portion pivotably connected to the first support panel and configured to be located between the first support panel and the bottom, wherein the first leg portion is rotatable relative to the first support panel between a first rotational position and a second rotational position so as to allow movement of the first support panel relative to the bottom, wherein the first leg portion is configured to cause a resilient force to bias the first support panel away from the bottom when the first leg portion is located at a third rotational position between the first rotational position and the second rotational position; and a second frame forming member comprising a plurality of foldable portions and configured to form a second frame which comprises a second support panel and at least one side panel connected to the second support panel, the second frame being configured to nest with the first frame within the container so as to retain an article between the first and second support panels. 
     In the foregoing embodiment, the first frame can further comprise: a first anchor panel extending between the top and bottom of the container when the first frame is contained in the container; and a first connecting portion interconnecting the first support panel and the first anchor panel and comprising at least one fold line configured to allow movement of the first support panel relative to the bottom of the container. The first connecting portion can comprise a first side panel pivotally connected to the first support panel and a ridge panel pivotably connected to each of the first anchor panel and the first side panel, wherein the first anchor panel and the first side panel are substantially parallel to each other. 
     Still in the foregoing embodiment, the first frame can further comprise: a second anchor panel extending between the top and the bottom of the container when the first frame is contained in the container; and a second connecting portion interconnecting the first support panel and the second anchor panel and comprising at least one fold line configured to allow movement of the first support panel relative to the bottom of the container. 
     Still in another embodiment, a packaging kit for packaging an article and maintaining the article can comprise: a first foldable member comprising a plurality of foldable portions, the first foldable member being configured to form a container which comprises a top, a bottom and a plurality of sidewalls, and further configured to form a first frame to be contained within the container and pivotably connected to the container, wherein the first frame comprises a first support panel comprising a first surface configured to face an article and a second surface opposite to the first surface, and a first leg portion pivotably connected to the first support panel and configured to be located between the first support panel and the bottom, wherein the first leg portion is rotatable relative to the first support panel between a first rotational position and a second rotational position so as to allow movement of the first support panel relative to the bottom, wherein the first leg portion is configured to cause a resilient force to bias the first support panel away from the bottom when the first leg portion is located at a third rotational position between the first rotational position and the second rotational position; and a second foldable member comprising a plurality of foldable portions and configured to form a second frame which comprises a second support panel and at least one side panel connected to the second support panel, the second frame being configured to nest with the first frame within the container so as to retain an article between the first and second support panels. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features of the inventions are described below with reference to the drawings of several embodiments of the present packaging assemblies and kits which are intended to illustrate, but not to limit, the inventions. The drawings contain the following figures: 
         FIG. 1  is an exploded, perspective view of a packaging assembly in accordance with one embodiment along with an article to be packaged; 
         FIG. 2  is a plan view of a first foldable member configured to form a container and a first suspension support shown in  FIG. 1 , illustrating an unfolded and unassembled state thereof, the first foldable member having folding lines and foldable portions; 
         FIG. 3  is a plan view of the first foldable member of  FIG. 2  in a first partially folded state; 
         FIG. 4  is a plan view of the first foldable member of  FIG. 2  in a second partially folded state; 
         FIG. 5  is a sectional view of the first foldable member taken along line  5 - 5  of  FIG. 4 ; 
         FIG. 6  is a sectional view of the first foldable member taken along line  6 - 6  of  FIG. 4 ; 
         FIG. 7  is a plan view of the first foldable member of  FIG. 2  in a third folded state; 
         FIG. 8  is a sectional view of the first foldable member taken along line  8 - 8  of  FIG. 7 ; 
         FIG. 9  is a plan view of a second foldable member configured to form a second suspension support shown in  FIG. 1 , illustrating an unfolded and unassembled state thereof; 
         FIG. 10  is a plan view of the second suspension support of  FIG. 9  in a folded state; 
         FIG. 11  is a plan view of the packaging assembly shown in  FIG. 1 , the first and second suspension supports being assembled and an article being located therebetween; 
         FIG. 12  is a cut-away side elevation view of the packaging assembly with a lid closed, an article being packaged between the first and second suspension supports; 
         FIG. 13  is a cut-away front elevation view of the packaging assembly with a lid closed, an article being packaged between the first and second suspension supports; 
         FIG. 14  is a plan view of a retention member having pockets in accordance with one embodiment; 
         FIG. 15  is a plan view of a sub-assembly of a foldable member and the retention member configured to form a second suspension support in accordance with an embodiment; 
         FIG. 16  is a cut-away front elevation view of a packaging assembly in accordance with one embodiment, the second suspension support being formed of the sub-assembly shown in  FIG. 15 ; 
         FIG. 17  is a perspective view of a packaging assembly in accordance with one embodiment, an article being located between first and second suspension supports; 
         FIG. 18  is a perspective view of the second suspension support shown in  FIG. 17 ; 
         FIG. 19  is a plan view of a foldable member configured to form the second suspension support shown in  FIG. 17 ; 
         FIG. 20  is a cut-away side elevation view of the packaging assembly shown in  FIG. 17  with a lid closed, an article being located between the first and second suspension supports; 
         FIG. 21  is a perspective view of a sub-assembly of a packaging assembly in accordance with one embodiment, illustrating that a first suspension support is being folded and inserted into a container; 
         FIG. 22  is a plan view of a foldable member configured to form the container member of the sub-assembly shown in  FIG. 20 ; 
         FIG. 23  is a plan view of a foldable member configured to form the first suspension support of the sub-assembly shown in  FIG. 20 , showing the unfolded state thereof; 
         FIG. 24  is a cut-away side elevation view of the packaging assembly including the container and the suspension supports shown in  FIG. 21  with a lid closed, an article being located between first and second suspension supports. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     An improved packaging system is disclosed herein. The packaging system includes an improved structure which provides new alternatives to known suspension packaging systems. 
     In the following detailed description, terms of orientation such as “top,” “bottom,” “front,” “upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,” “midpoint,” and “end” may be used here to simplify the description in the context of the illustrated embodiments. Because other orientations are possible, however, the present inventions should not be limited to the illustrated orientations. Additionally, the term “suspension” is not intended to require that anything, such as an article to be packaged, is suspended above anything. Rather, the terms “suspended” as used herein, is only intended to reflect that such an article is held in a position spaced from another member, such as at least some of the walls of a container or box. Those skilled in the art will appreciate that other orientations of various components described herein are possible. 
     With reference to  FIG. 1 , a packaging assembly  100  is constructed in accordance with one embodiment. The packaging assembly  100  includes a container  102 , a first suspension support  104  and a second suspension support  106 . The container  102  has a cavity or a recess. The suspension supports  104 ,  106  can nest with each other within the container  102 , and support an article  108  to be packaged in a position spaced from at least some of the walls of the container portion  102 . In  FIG. 1 , the first suspension support  104  is contained within the cavity of the container  102 . The article  108  is shown to be positioned over the first suspension support  104 , and the second suspension support  106  is inserted in the container to nest with the first suspension support  104 . 
     Referring to  FIG. 2 , a first foldable packaging member  110  is illustrated therein in an unfolded state and is constructed in accordance with one embodiment. The foldable member  110  includes a plurality of foldable portions configured to form the container  102  and a first suspension support  104 . 
     A further advantage is provided where, as illustrated in  FIGS. 1 and 2 , the container portion  102  is connected to the first support portion  104 . As such, when manipulated into a folded state, the support portion  104  can be conveniently folded into the cavity of the container portion  102 . Additionally, in this embodiment, both the container portion  102  and the suspension portion  104  can be formed from a single piece of material. 
     In one embodiment, the member  110  can be constructed from various materials, including but without limitation, paper, cardboard, corrugated cardboard, plastic, and other appropriate materials. The chosen material for constructing the member  110  can be any substantially rigid but foldable material. It will be appreciated that, although denominated as rigid or substantially rigid, the chosen material would preferably have an amount of flexibility in the cases of extreme physical impact. In some embodiments, the material used to form the member  110  is a single wall corrugated C-flute cardboard. 
     Referring to  FIGS. 1 and 2 , in one embodiment, the member  110  includes two portions foldably connected to each other and configured to form the container  102  and the first suspension support  104 , respectively. The container  102  includes a bottom panel  120 . The size of the panel  120  can be chosen by one of ordinary skilled in the art to provide the desired amount of surface area of the bottom of the container  102  formed by the member  110 . In an example but non-limiting embodiment, where the member  110  is intended to package a handheld communication device, modem or a hard drive, the panel  120  can be about 10 inches square. However, this is merely an embodiment, and the panel member  120  can have other dimensions for use in packaging modems or hard drives, or any other article that is to be packaged. 
     Still referring to  FIGS. 1 and 2 , the container  102  can also include lateral walls  122 ,  124  and end walls  126 ,  128 . For brevity, the construction of the lateral wall portion  122  will be described. However, it is to be understood that the lateral wall portion  124  also can include the same features. The lateral wall  122  has a double wall structure when folded. For this end, the member  110  includes an inner panel  130  and an outer panel  132  configured to form a double wall structure  122 . Additionally, the lateral wall  122  can include at least one fold line  134  defined between the inner panel  130  and the outer panel  132 . In the illustrated embodiment, the lateral wall portion  122  includes two fold lines  134 . 
     The fold lines  134  can be formed as perforations in the member  110 , i.e., broken cut lines passing partially or completely through the material forming the member  110 . In the alternative, or in addition, the fold lines can be crushed portions of the material forming the member  110 . Of course, depending on the material used to construct the member  110 , the fold lines can be formed as mechanical hinges, thinned portions, adhesive tape, or any other appropriate mechanical connection which would allow various portions of the tray member to be folded or rotated with respect to each other. These concepts apply to all the fold lines described herein, although this description will not be repeated with respect to the other fold lines described below. For brevity, the construction of the fold lines  134  has been described above. However, it is to be understood that the other fold lines in the member  110  or other members described in the description also can include the same features. 
     In the illustrated embodiment, when the lateral wall  122  is folded upwardly and inwardly towards the panel member  120 , the inner panel  130  forms an outer wall of the container  102  and the outer panel  132  forms an inner wall. The area between the fold lines  134 , identified generally by the reference numeral  138 , will form an upper edge of the lateral wall  122 . 
     The lateral wall  122  can also include means for securing the walls in place when folded. For example, in the illustrated embodiment, the outer panel  132  includes a projection  140  on its outermost edge  142 . When the lateral wall  122  is completely folded, the projection  140  will rest against the panel member  120  adjacent a fold line  144  defined at the boundary between the bottom portion  120  and the lateral wall  122 . The projection  140  is merely one type of configuration that can be provided for securing the lateral wall portion  122  in place. Further, in one embodiment, the panel member  120  can include an aperture for receiving the projection  140 . 
     Still referring to  FIGS. 1 and 2 , each of the end walls  126 ,  128  can include a single wall panel  150  connected to the main panel  120  along a fold line  152 . For brevity, the construction of the end wall  126  will be described. However, it is to be understood that the end wall portion  128  also can include the same features. The end wall  126  can also include corner flaps  154 ,  156 , connected to the wall panel  150  along fold lines  158 ,  160 . 
     The end wall  126  is configured such that the panel  150  can be folded towards the bottom portion  120  along the fold line  152 . Additionally, the corner flaps  154 ,  156  can be folded inwardly towards the panel  150 , at about a right angle, for example, such that when the panel  150  is folded into an orientation being approximately perpendicular to the bottom portion  120 , each of the corner flaps  154 ,  156  lie along or adjacent to the fold lines  144  between the bottom portion  120  and one of the lateral walls  122 ,  124 . With the corner flaps  154 ,  156  in this orientation, each of the lateral walls  122 ,  124  can be folded over the corner flaps  154 ,  156 . As such, for example, each of the corner flaps  154 ,  156  can be sandwiched between the inner panel  130  and the outer panel  132 . 
     In one embodiment, the container  102  can include a lid portion  166  connected to the end wall  126 . The lid  166  can include a top panel  170  connected to the wall panel  150  along the fold line  168 . The top panel  170  can be approximately the same size as the bottom panel  120 . 
     Additionally, the lid portion  166  can include a front panel  172  and corner flaps  174 ,  176 . The front panel  172  is connected to the top panel  170  along a fold line  178 . Additionally, the corner flaps  174 ,  176  are attached to the front panel  172  along fold lines  180 ,  182 . Each of the corner flaps  174 ,  176  are configured to be inserted into a space between the panels  130 ,  132  of one of the lateral walls  122 ,  124 . 
     In one embodiment, the lid  166  can include side flaps  184 ,  186  connected to the top panel  170  along fold lines  188 ,  190 . For brevity, the construction of the side flap  184  will be described. However, it is to be understood that the side flap  186  also can include the same features. 
     The side flap  184  can be folded inwardly towards the top panel  170 , at about a right angle, for example, such that when the panel  170  is folded into an orientation being approximately perpendicular to the end wall  126 , the side flap  184  lies along and adjacent the lateral wall portion  122 . In one embodiment, a width of the top panel  170  that is a distance between the fold lines  188 ,  190  is sized such that the side flaps  184 ,  186  are positioned inside and contact the inner walls of the lateral wall portions  122 ,  124 . Additionally, the side flap  184  is sized such that a distance between the fold line  188  or  190  and a distal end of the side flap  184  or  186  is generally same with or slightly smaller than the height of the lateral wall  122 ,  124 , but not limited thereto. 
     With continued reference to  FIGS. 1 and 2 , in one embodiment, the first suspension support  104  is connected to the end wall  128  along a fold line  192 . The first suspension support portion  104  can include a support panel  212  and at least one foldable leg portion pivotally connected to the first article support panel  212 . The panel  212  can include a first surface  208  and a second surface  210  opposing the first surface. (See  FIGS. 5 and 13 ) The first surface  208  faces an article  108 , when the article is packaged. 
     In some embodiments, the first suspension support portion  104  can include two foldable leg portions  214 ,  216  such that the support panel  212  is interposed between the leg portions  214 ,  216 . Each of the foldable leg portions  214 ,  216  is pivotably connected to the support panel  212  along a fold line  218 . Each of the leg portions  214 ,  216  can be folded towards the second surface  210  to form an angle with respect to the second surface  210  smaller than about 90° such that each of the leg portions  214 ,  216  provides a spring effect. (See  FIGS. 8 and 13 ). 
     In one embodiment, the first suspension support  104  can include side panels  222 ,  224 . Each of the side panels  222 ,  224  is pivotably connected to the support panel  212  along a fold line  226  such that the base panel  212  is interposed between the side panels  222 ,  224 . Each of the side panels  222 ,  224  can be folded towards the first surface  208  into a generally perpendicular orientation relative to the base panel  212 . 
     Referring to  FIG. 2 , in some embodiments, the first suspension support portion  104  can include corner panels  230 ,  232 ,  234 ,  236 . For brevity, the construction related to the corner panel  230  will be described. However, it is to be understood that the packaging assembly can include the same features for the corner panels  232 ,  234 ,  236 . The corner panel  230  is connected to both the leg portion  214  and the side panel  222  along fold lines  238 ,  240 , respectively. In one embodiment, the side panels  222  include a hole  242  located near the corner panel  230 . As shown in  FIG. 2 , a cut line  244  extends from a side edge  245  of the side panel  222  to the hole  242 . A further fold line  246  can be formed from a corner  248  of the base panel  212  to the hole  242 . 
     The corner panel  230  can be folded along the fold line  238  towards the side panel  222 , to form a first folded state of the corner panel  230  when the leg panel  214  is folded towards the second surface  210  of the base panel  212 . In this configuration, the corner panel  230  can form an angle smaller than about 90° with respect to the side panel  222 . In one embodiment, the corner panel  230  can be further folded along the fold line  240  to form a second folded state of the corner panel  230  when the side panel  222  is folded towards the first surface of the base panel  212 . Additionally, in this folded configuration, a delta-shaped portion  250  of the side panel  222  is configured to be folded along the fold lines  246  with respect to a main portion of the side panel  222 . This configuration can allow an edge of the corner panel  230  to be spaced from the side panel  222 , and provide a spring effect. 
     In one embodiment, the first suspension support  104  can include ridge portions  260 ,  262  that are pivotally connected to the side panels  222 ,  224  along fold lines  264 ,  266 , respectively. The ridge portion  222  is pivotally connected to the end wall  128  of the container  102  along the fold line  192 . Additionally, the first suspension support  104  can further include a foldable anchor panel  270  that is connected to the ridge  262  along a fold line  274 . 
     In some embodiments, the ridge portion  260  and the side panel  222  can be folded towards the end wall  128  such that the side  128  and the side panel  222  are generally parallel to each other. Similarly, the ridge portion  262  and the anchor panel  270  can be folded towards the side panel  224  such that the anchor  270  and the side panel  224  are generally parallel to each other. 
     With reference to  FIGS. 2 and 3 , when folding the container  102  so as to define a cavity, the corner panels  154 ,  156  can first be folded upwardly into a generally perpendicular orientation relative to the end walls  126 ,  128 . Then, the walls  126 ,  128 , along with the corner panels  154 ,  156  attached thereto and folded relative thereto, can be folded upwardly into a generally perpendicular orientation relative to the panel  120 . The panels  130 ,  132  of the lateral wall portions  122 ,  124  can then be folded so as to enclose the corner panels  154 ,  156  therein. As shown in  FIG. 3 , the lateral wall sections  122 ,  124 , now form walls of a cavity  280 . Similarly, the end walls  126 ,  128  form walls of the cavity  280 , with the bottom portion  120  forming the bottom thereof. After the formation of the cavity  280  as such, the folded structure of the first suspension support  104  can be inserted in the cavity  280 . 
       FIG. 3  illustrates the ridge portion  262  folded with respect to the end wall  124  into an orientation being approximately perpendicular to the end wall  124  such that the support panel  212  is approximately parallel to the panel  120  of the container  102 . However, in another embodiment, the ridge portion  262  is not folded during the formation of the folded structure of the first suspension support  104 , which will be described further. 
     Referring to  FIGS. 3 to 6 , in one embodiment, the foldable leg portions  214 ,  216  can be folded until leaving a clearance between the foldable portions  214 ,  216  and the panel  212  with an angle α smaller than about 90°. This can provide cushioning for an article  108  when an article  108  is packaged. When folding the leg panels  214 ,  216 , the corner panels  230 ,  232 ,  234 ,  236  can be folded with respect to the side panels  222 ,  224 , too. 
     Subsequently, the side panels  222 ,  224  can be folded towards the first surface of the support panel  212  to be approximately perpendicular to the support panel. When folding the side panels  222 ,  224 , the corner panels  230 ,  232 ,  234 ,  236  can be folded with respect to the leg panels  214 ,  216 . Further, the portion  250  can be folded along the fold line  246  and provides a clearance between each of the corner panels  230 ,  232  and the side panel  222  and between each of the corner panels  234 ,  236  and the side panel  224 . 
     Additionally, the side panel  222  can be folded with respect to the ridge portion  260  into an orientation being approximately perpendicular orientation to the ridge portion  260 . Similarly, the side panel  224  can be folded with respect to the ridge portion  262  into an orientation being approximately perpendicular orientation to the ridge portion  262 . The anchor panel  270  can be folded towards the side panel  224  with respect to the ridge portion  262  into an orientation being approximately perpendicular orientation to the ridge portion  262 . In this folded configuration, the side panel  224  is approximately parallel to the anchor panel  270 . 
     With reference to  FIGS. 6 and 7 , once the folded formation of the first suspension support  104  is completed, the ridge portion  262  can be folded with respect to the end wall  128  of the container such that the first suspension support  104  is contained in the container  102 . As shown in  FIG. 8 , the legs  214 ,  216  are positioned between the support panel  212  and the bottom panel  120  of the container. In one embodiment, edges of the leg portions  214 ,  216  contact the bottom of the container  102  so that the legs  214  resiliently support the support panel  212  and an article  108  that will be disposed over the support panel  212  and suspended within the container. As shown in  FIG. 12 , in some embodiments, at least a portion of each of the corner panels  130 ,  132  can be interposed between one of the side panel  222  and the end wall  128 . Edges of the corner panels  130 ,  132  contact the end wall  128 . Similarly, in some embodiments, at least a portion of each of the corner panels  134 ,  136  can be interposed between one of the side panel  222  and the end wall  126 . In the illustrated embodiment, edges of the corner panels  130 ,  132  contact the anchor panel  270 . 
     Referring to  FIGS. 1 ,  9  and  10 , in one embodiment, the second suspension support  106  can be formed by folding a second foldable member  112 . As shown in  FIG. 10 , the member  112  can include a plurality of foldable portions configured to form walls of the second suspension support  106 . In one embodiment, similarly to the member  110 , the member  112  can be constructed from various materials, including but without limitation, paper, cardboard, corrugated cardboard, plastic, and other appropriate materials. The chosen material for constructing the member  112  can be any substantially rigid but foldable material. It will be appreciated that, although denominated as rigid or substantially rigid, the chosen material would preferably have an amount of flexibility in the cases of extreme physical impact. In some embodiments, the material used to form the member  112  is a single wall corrugated C-flute cardboard. 
     The second suspension support  106  can include a support panel  302 . In one embodiment the size of the support panel  302  can be chosen by one of ordinary skilled in the art to allow the second suspension support  106  to nest with the first suspension support  104  shown in  FIG. 7 . In one embodiment, the size of the support panel  302  can be determined to allow the second suspension support  106  to fit within a space formed between the side panels  222 ,  224  and further between the side flaps  184 ,  186 . (See  FIGS. 11-13 .) 
     Still referring to  FIGS. 1 ,  9  and  10 , the second suspension support  106  can also include lateral walls  322 ,  324  and end walls  326 ,  328 . For brevity, the construction of the lateral wall portion  322  will be described. However, it is to be understood that the lateral wall portion  324  also can include the same features. The lateral wall  322  has a double wall structure when folded. For this end, the member  112  can include an inner panel  330  and an outer panel  332  configured to form a double wall structure  322 . Additionally, the lateral wall  322  can include at least one fold line  334  defined between the outer panel  330  and the outer panel  332 . 
     In the illustrated embodiment, when the lateral wall  222  is folded upwardly and inwardly towards the support panel  302 , the inner panel  330  forms an outer wall of the second support  106  and the outer panel  332  forms an inner wall. The lateral wall  322  can also include means for securing the walls in place when folded. For example, in the illustrated embodiment, the outer panel  332  can include a projection  340  on its outermost edge  342 . When the lateral wall  322  is completely folded, the projection  340  will rest against the support panel  302  adjacent a fold line  344  defined at the boundary between the support panel  302  and the lateral wall  322 . Further, in the illustrated embodiment, the support member  302  can include an aperture  346  for receiving the projection  340 . 
     Still referring to  FIGS. 1 ,  9  and  10 , each of the end walls  326 ,  328  can include a single wall panel  350  connected to the main panel  302  along a fold line  352 . For brevity, the construction of the end wall  326  will be described. However, it is to be understood that the end wall portion  328  also can include the same features. The end wall  326  can also include corner flaps  354 ,  356 , connected to the wall panel  350  along fold lines  358 ,  360 . 
     The end wall  326  is configured such that the panel  350  can be folded towards the support panel  302  along the fold line  352 . Additionally, the corner flaps  354 ,  356  can be folded inwardly towards the panel  350 , at about a right angle, for example, such that when the panel  350  is folded into an orientation being approximately perpendicular to the support panel  302 , each of the corner flaps  354 ,  356  lie along or adjacent to the fold lines  344  between the support panel  302  and one of the lateral walls  322 ,  324 . With the corner flaps  354 ,  356  in this orientation, each of the lateral walls  322 ,  324  can be folded over the corner flaps  354 ,  356 . As such, for example, each of the corner flaps  354 ,  356  can be sandwiched between the inner panel  330  and the outer panel  332 . 
     With reference to  FIGS. 9 and 10 , in one embodiment, the support panel  302  can include at least one foldable flap  364 . In particular, the support panel  302  can include four pivotable flaps  364  in the illustrated embodiment. To construct the pivotable flaps  364 , the support panel  302  can include a rectangular hole  362  at the center portion thereof and cut lines  365 . Each of the cut lines  365  extends from a corner of the hole  362  in an approximately diagonal direction. Each of the foldable flaps  364  is formed between two neighboring cut lines  365  and is foldable along a fold line  368 . In one embodiment, each of the foldable flaps  364  can be resiliently folded and be restored to the unfolded state. This configuration of the pivotable flaps  364  provides resilient support to an article to be packaged. 
     Now referring to FIGS.  1  and  11 - 13 , in one embodiment, when packaging an article  108 , the article  108  can be placed over the support panel  212  of the first suspension support  104 , and subsequently, the second suspension support  106  can be inserted into the container  102  and placed over the article  108 . As can be seen in  FIG. 12 , the pivotable flaps  364  can be folded to provide resilient support for the article  108 . Additionally, the lid  166  can be closed to cover the suspension supports  104 ,  106  and the article  108 .  FIGS. 12 and 13  illustrate sectional views of the packaging assembly with the lid  166  closed. 
     Referring to  FIG. 13 , in one embodiment, when an impact may be applied to the packaging assembly  100  to urge the article  108  to move in a downward direction, the leg portions  214 ,  216  can be further folded to decrease the angle α. The movement causes the generation of resilient force to support the article  108 , and provides cushioning to absorb of such impact. When the article  108  moves down along with the support panel  212 , the side panels  222 ,  224  move down so that the ridge portions  260 ,  262  are further folded with respect to the end wall  128  and/or the anchor panel  274 . The movement further provides cushioning to absorb of such impact. 
     As can be seen in  FIGS. 12 and 13 , in one embodiment, when an impact is applied to the packaging assembly  100  to urge the article  108  to move in an upward direction, at least one of the pivotable flaps  364  can be further folded. The movement of the flaps  364  causes the generation of resilient force to support the article  108 , and provides cushioning to absorb of such impact. 
     In one embodiment, when an impact is applied to the packaging assembly  100  to urge the article  108  to move in a horizontal direction, at least one of the pivotable flaps  364  can be further folded. The movement of the flaps  364  causes the generation of resilient force to support the article  108 , and provides cushioning to absorb of such impact. Further, as shown in  FIG. 13 , at least one of the corner panels  230 ,  232 ,  234 ,  236  can be further folded to decrease the clearance between the at least one of the corner panels and one of the side panels  222 ,  224 . The movement causes the generation of resilient force to support the article  108 , and provides cushioning to absorb of such impact. 
     With reference to  FIGS. 1 ,  2  and  7 , in one embodiment, the first support panel  212  can include at least one support tab  282 . In the illustrated embodiment, each of four support tabs  282  can be formed with a cut line  284  and a fold line  286 . Each tab  282  can be folded to an upright position to provide additional support to the article  108  in a horizontal direction. 
     In some embodiments illustrated in, for example,  FIGS. 1 and 13 , the assembly can have no resilient retention sheet member formed of, for example, a pliable plastic film, and configured to engage with one of the first and second frames and formed of a pliable plastic film. The assembly can be configured to provide sufficient cushioning without such resilient retention sheet member. 
     The amount of such cushioning can vary according to the articles maintained in the packaging assembly. In one embodiment, the sufficient cushioning of the packaging assembly that does not use such resilient retention sheet member can be accomplished by determining design parameters of the first frame and second frame. The design parameters can be, for example, size of the leg portions  214 ,  216 , the angle α of the leg portions  214 ,  216 , thickness and characteristics of the board material for forming the first and second frames, size of flaps  364  and the like. These design parameters for sufficient cushioning can be determined by one of ordinary skill in the art through modification of the above-noted design parameters or other design parameters and drop or impact tests. The drop or impact tests can be designed to apply impacts to the packaging assembly maintaining an article in various directions. The magnitude of the impacts can be, for example, 2-5 G (gravities) or more and is determined based on the durability of the article to be packaged in the assembly. 
       FIGS. 14-16  illustrate another embodiment, in which a second suspension support  406  can include a foldable member  412  and optionally a resilient member. It can be understood that a packaging assembly can be maintain an article therein with sufficient cushioning without using an optional resilient member. However, as shown in  FIGS. 14-16 , a resilient member can be used for providing further cushioning. The assembly  406  of the foldable member  412  and the resilient member can replace the second suspension support  106  used in the embodiments discussed in the above. It can be appreciated by one of the ordinary skilled in the art that a container  402  and a first suspension support  404  having structures same with those of the container  102  and the first suspension support  104  in the foregoing embodiments can be also used in the embodiment. 
     Referring to  FIG. 14 , the resilient member in the illustrated embodiment is identified as a retention member  470 . The retention member  470  preferably is formed of a resilient body  472 . The resilient body  472  also can include pockets  474 ,  476  at opposite ends thereof. In the illustrated embodiment, the retention member  470  is formed of a single piece of resilient material, and is sized to engage with the foldable member  412  having lateral walls  422 ,  424 . The configuration of the foldable member  412  is same with that of the foldable member  112  discussed above. The retention member  470  can be made of a polyethylene film. However, virtually any polymer, elastomer, or plastic film can be used to form the retention member  470 . The density of the film can be varied to provide the desired retention characteristics such as overall strength, resiliency, and vibrational response. Preferably, the density of the retention member  470  is determined such that the retention member  470  is substantially resilient when used to package a desired article. 
     Referring to  FIGS. 14 and 15 , in one embodiment, the lateral walls  422 ,  424  are received in the pockets  474 ,  476  in an unfolded state of the foldable member  412 . Subsequently, the foldable portions of the foldable member  412  are folded in the same manner with that of the foldable member  112  of the embodiment discussed above. When folding the foldable portions of the foldable member  412 , the retention member  470  is folded such that the body  472  is placed over an article support panel  402 . As shown in  FIG. 16 , the second suspension support  406  is retained in a container and assembled with a first suspension support  404  to package an article between the first and second suspension supports  404  and  406 . When packaged, the body  472  provides additional resilient support in addition to the resilient support of foldable flaps  466 . 
     In some embodiments, a second suspension support can include structures similar to the structures that the first suspension support  104  include as discussed above. For example, a second suspension support can include a base panel and leg panels configured to provide spring effect for resiliently supporting the base panel when folded.  FIGS. 17-20  illustrate one embodiment, in which a second suspension support  506  includes a foldable member  508  having a plurality of foldable portions to form a base panel and foldable leg panels. This suspension support can replace the second suspension support  106 ,  506  used in the foregoing embodiments. 
     Referring to  FIGS. 18 and 19 , the second suspension support  506  is formed from a foldable member  508  by folding foldable portions. In one embodiment, the member  508  can be constructed from various materials, including but without limitation, paper, cardboard, corrugated cardboard, plastic, and other appropriate materials. The chosen material for constructing the member  508  can be any substantially rigid but foldable material. It will be appreciated that, although denominated as rigid or substantially rigid, the chosen material would preferably have an amount of flexibility in the cases of extreme physical impact. In some embodiments, the material used to form the member  508  is a single wall corrugated C-flute cardboard. 
     With continued reference to  FIGS. 18 and 19 , in one embodiment, the second first suspension support  506  can include a support panel  512  and at least one foldable leg portion pivotally connected to the first article support panel  512 . The panel  512  includes a first surface  508  and a second surface  510  opposing the first on which an article to be packaged is disposed. In one embodiment, the first surface  508  faces an article  508  when the article is packaged. 
     In some embodiments, the second suspension support portion  506  can include two foldable leg portions  514 ,  516  such that the support base panel  512  is interposed between the leg portions  514 ,  516 . Each of the foldable leg portions  514 ,  516  is pivotably connected to the support panel  512  along a fold line  518 . Each of the leg portions  514 ,  516  can be folded towards the second surface  510  to form an angle with respect to the second surface  510  smaller than about 90° such that each of the leg portions  514 ,  516  provides a spring effect. 
     In one embodiment, the second suspension support  506  can include side panels  522 ,  524 . Each of the side panels  522 ,  524  is pivotably connected to the support base panel  512  along a fold line  526  such that the base panel  512  is interposed between the side panels  522 ,  524 . Each of the side panels  522 ,  524  can be folded towards the first surface  508  into a generally perpendicular orientation relative to the base panel  512 . 
     Referring to  FIG. 19 , in some embodiments, the second suspension support  506  includes corner panels  530 ,  532 ,  534 ,  536 . For brevity, the construction related to the corner panel  530  will be described. However, it is to be understood that the packaging assembly includes same features for the corner panels  532 ,  534 ,  536 . The corner panel  530  is connected to both the leg portion  514  and the side panel  522  along fold lines  538 ,  540 , respectively. In one embodiment, the side panels  522  include a hole  542  located near the corner panel  530 . As shown in  FIG. 19 , a cut line  544  extends from a side edge  545  of the side panel  522  to the hole  542 . A further fold line  546  can be formed from a corner  548  of the base panel  512  to the hole  542 . 
     The corner panel  530  can be folded along the fold line  538  towards the side panel  522 , to form a first folded state of the corner panel  530  when the leg panel  514  is folded towards the second surface  510  of the base panel  512 . In this configuration, the corner panel  530  can form an angle smaller than about 90° with respect to the side panel  522 . In one embodiment, the corner panel  530  can be further folded along the fold line  540  to form a second folded state of the corner panel  530  when the side panel  522  is folded towards the first surface of the base panel  512 . Additionally, in this folded configuration, a delta-shaped portion  550  of the side panel  522  is configured to be folded along the fold lines  546  with respect to a main portion of the side panel  522 . This configuration can allow an edge of the corner panel  530  to be spaced from the side panel  522 , and provide a spring effect. 
     In one embodiment, the foldable leg portions  514 ,  516  can be folded until leaving a clearance between the foldable portions  514 ,  516  and the panel  512  with an angle smaller than about 90°. This can provide cushioning for an article  508  when the article  508  is packaged. When folding the leg panels  514 ,  516 , the corner panels  530 ,  532 ,  534 ,  536  can be folded with respect to the side panels  522 ,  524 , too. 
     Subsequently, the side panels  522 ,  524  can be folded towards the first surface of the support panel  512  to be approximately perpendicular to the support panel. When folding the side panels  522 ,  524 , the corner panels  530 ,  532 ,  534 ,  536  can be folded with respect to the leg panels  514 ,  516 . Further, the portion  550  can be folded along the fold line  524  and provides a clearance between each of the corner panels  530 ,  532  and the side panel  522  and between each of the corner panels  534 ,  536  and the side panel  524 . 
     As shown in  FIG. 20 , in one embodiment, an article  508  is retained between the first and second suspension supports  504 ,  506 . When assembled, the legs  514 ,  516  can be positioned between the support panel  512  and the lid  520  of the container  502 . In some embodiments, edges of the leg portions  514 ,  516  contact the top of the container  502  so that the legs  514  resiliently urge the support panel  512  to support an article that will be disposed between the support panel  511  of the first suspension support  502  and the support panel  512  of the second suspension support  502 . In some embodiments, at least a portion of each of the corner panels  530 ,  532  can be interposed between one of the side panel  522  and the lateral wall  552 . Edges of the corner panels  530 ,  532  contact the lateral wall  554 . Similarly, in some embodiments, at least a portion of each of the corner panels  534 ,  536  can be interposed between one of the side panel  522  and the lateral wall  556 . In the illustrated embodiment, edges of the corner panels  530 ,  532  contact the lateral wall  556 . 
     Referring to  FIG. 20 , in one embodiment, when an impact may be applied to the packaging assembly  500  to urge the article  508  to move in an upward direction, the leg portions  514 ,  516  can be further folded to decrease the angle β. The movement causes the generation of resilient force to support the article  508 , and provides cushioning to absorb of such impact. In one embodiment, when an impact is applied to the packaging assembly  500  to urge the article  508  to move in a horizontal direction, at least one of the corner panels  530 ,  532 ,  534 ,  536  can be further folded to decrease the clearance between the at least one of the corner panels and one of the lateral walls  552 ,  554 . The movement causes the generation of resilient force to support the article  508 , and provides cushioning to absorb of such impact. 
     With reference to  FIGS. 21-24 , a modification of the embodiment shown in  FIGS. 1-13  will be described. As shown in  FIGS. 21-24 , a foldable member  610  can include foldable portions configured to form a container  102   a . A foldable member  611  includes foldable portions configured to form a first suspension support  104   a . The container  102   a  receives the first suspension support  104   a  to form a subassembly  601 . As shown in  FIGS. 21-24 , the container  102   a  is constructed substantially identical to the container  102  shown in  FIGS. 1-7  and  10 - 13  except that the container  102  is foldable connected to the first suspension support  104  as shown in  FIGS. 1-7  and  10 - 13  while the container  102   a  is not integrated with the first suspension support  104   a  as shown in  FIGS. 21-22 . Thus, the reference numerals used to designate the various components,for example, components  120   a ,  122   a , 124   a ,  130   a ,  132   a ,  150   a ,  154   a ,  156   a ,  158   a ,  160   a ,  166   a ,  170   a ,  172   a ,  174   a ,  176   a ,  184   a , and  186   a , of the container  102   a  are identical to those used for identifying the corresponding components of the container  102  in  FIGS. 1-7  and  10 - 13 , except that an “a” has been added to the reference numerals. The above description applies equally to the common elements unless otherwise indicated. Therefore, a further description of the container  102   a  is not necessary for one of ordinary skilled in the art to practice the invention. 
     As shown in  FIGS. 21-24 , the first suspension support  104   a  is constructed similarly to the first suspension support  104  shown in  FIGS. 1-7  and  10 - 13  except as noted below. Thus, the reference numerals used to designate the various components, for example, componenets  212   a ,  214   a ,  216   a ,  222   a ,  224   a ,  230   a ,  232   a ,  234   a , and  236   a , of the first suspension support  104   a  are identical to those used for identifying the corresponding components of the first suspension support  104  in  FIGS. 1-7  and  10 - 13 , except that an “a” has been added to the reference numerals. The above description applies equally to the common elements unless otherwise indicated. Therefore, a further description of the common elements is not necessary for one of ordinary skilled in the art to practice the invention. However, anchor panels will further be described below. 
     With reference to  FIGS. 21 ,  23  and  24 , in one embodiment, the first suspension support  104   a  can further include foldable anchor panels  270   a ,  272   a  that are connected to the ridge panels  262   a ,  260   a  along a fold line  274   a ,  276   a , respectively. In some embodiments, the ridge portions  262   a  and the anchor panel  270   a  can be folded towards the side panel  224   a  such that the anchor  270   a  and the side panel  224   a  are generally parallel to each other. Similarly, the ridge portions  260   a  and the anchor panel  272   a  can be folded towards the side panel  222   a  such that the anchor  272   a  and the side panel  222   a  are generally parallel to each other. As shown in  FIG. 21 , in one embodiment, the anchor panel  272   a  can be folded while the first frame  104   a  is being received in the container  102   a . In some embodiments, the frame  104   a  can be received in the container  102   a  once the folding of the foldable portions of the support  104   a  is completed. 
     With reference to  FIG. 24 , once the folded formation of the first suspension support  104   a  is completed and received in the container  102   a , the anchor panel  272   a  is located between the end wall  128   a  and the side panel  222   a , while the anchor panel  270   a  is located between the end wall  126   a  and the side panel  224   a . The anchor panels  270   a ,  272   a  aid in anchoring the position of the first support  104   a  in the container. 
       FIG. 24  illustrates an embodiment, in which a second suspension support  106   a  constructed substantially identically to the second suspension support  106  shown in  FIG. 1  can be used, but not limited thereto. It can be easily understood by one of the ordinary skilled in the art that other second suspension supports shown in  FIGS. 14-20  can be used. 
     Although the present inventions have been described in terms of certain embodiments, other embodiments apparent to those of ordinary skilled in the art also are within the scope of these inventions. Thus, various changes and modifications may be made without departing from the spirit and scope of the inventions. For instance, various components may be repositioned as desired. Moreover, not all of the features, aspects and advantages are necessarily required to practice the present inventions.