Abstract:
A modular corrugated container integrates product cushioning with a product support surface formed from corrugated paper and having features that absorb transverse accelerations. The support surface has scored tabs that bend perpendicular to an interior support portion, forming feet that elevate the interior portion relative to a container bottom. The interior portion has perforations that absorb accelerations, such as a perforations formed around the outside perimeter of the location at which a product rests, perforations extending from corners of the support surface towards a central location of the support surface, and perforations at the scoring of the tabs. Voids formed along the tabs remove portions of the feet from contact with the container bottom to encourage constant dissemination of accelerations across the support surface.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates in general to the field of product packaging, and more particularly to a modular corrugated container having integrated cushioning. 
     Description of the Related Art 
     As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems. 
     Information handling systems come in a variety of sizes and weights. In response to market demands, portable information handling systems have shrunk in size and weight by squeezing smaller and more capable components into housings of decreased size. One difficulty that arises with lighter weight and thinner housings is that smaller accelerations can cause greater flexures, leading to breakage at the circuit board or other components in the housing. In particular, large sudden accelerations applied at a housing during shipping can result in bending of the housing if the edges of the housing have greater support than the middle of the housing. 
     Conventional packaging of an information handling system typically involves supports designed into corrugated cardboard material that fit a particular housing. Designing packaging to fit each information handling system product can involve long packaging development times, thus adding to product costs. System-specific packaging creates an inventory problem of matching system orders to packaging orders and storing system-specific packaging at manufacture locations in adequate but not excessive quantities. Although each information handling system may have a corrugated package designed to fit the system housing, the individual packaging designs tend to follow common guidelines that tend to result in greater amounts of corrugated material in each package design than may be needed. These guidelines may added additional materials to offset variations in packaging material qualities available in different regions. Excess packaging material has an undue environmental impact and creates a disposal problem for the customer. Excess packaging material also impacts logistics by increasing the amount of pallet space that each package consumes and the weight of each package. Since packages are often shipped by air, small incremental decreases in package size and weight may have a substantial combined impact when loaded into an aircraft. 
     Ultimately, packaging success for an information handling system or other product depends upon safe arrival of a package to a customer. Safe arrival depends upon adequate exterior strength to allow stacking of packages during shipping and adequate interior strength to keep the packaged product from harm in the event of excessive accelerations, such as dropping of the package. Increasing the amount of packaging material used to build the exterior of the packaging tends to increase stack strength but also increases the footprint of the package. Increasing internal packaging components can improve interior strength, but often result in foam and other cushioning materials added to the interior of the packaging. For example, foam cushion end-cap designs fit around the perimeter of an information handling system housing and are intended to protect the housing from side impacts and to cushion the housing during vertical accelerations. A typical end-cap design fits onto the corners of the information handling system housing to protect the central regions of the information handling system housing from impact; however, the lack of support in the central region of the housing can result in flexing under high accelerations that can damage internal circuit boards and components. 
     SUMMARY OF THE INVENTION 
     Therefore a need has arisen for a system and method which packages products to protect against damage using corrugated material shaped to cushion the impact of accelerations passing through the packaging to the product. 
     In accordance with the present invention, a system and method are provided which substantially reduce the disadvantages and problems associated with previous methods and systems for packaging a product in corrugated material. A modular corrugated container has integrated cushioning to absorb accelerations applied to the product in the container. A support surface formed of perforated corrugated material aids translation of transverse accelerations as a constant across the product to reduce product flexure in response to the accelerations. 
     More specifically, a corrugated container to ship a portable information handling system includes a support surface on which the portable information handling system rests. The support surface has tabs scored along an outer edge, the tabs bending perpendicular to the support surface to form feet that rest on the container bottom surface to hold the support surface in an elevated position. The tabs have voids formed so that portions of the feet contact the bottom surface while other portions do not. In addition, the tabs include perforations along the score so that the voids and cuts from the perforations coordinate to aid dissemination of accelerations applied to the product in a constant manner that reduces product flexure. A perforation is formed in the support surface that is substantially collocated with the information handling system perimeter, such as in a shape that parallels the shape of the information handling system. Additional perforations formed in the support surface aid cushioning of the information handling system by the support surface under the influence of accelerations, such as perforations cut diagonally from each corner of a rectangular shaped support surface towards a central position of an internal portion of the support surface. 
     The present invention provides a number of important technical advantages. One example of an important technical advantage is that information handling system housings built to have reduced weight and size are adequately reinforced by packaging during transport to reduce flexure under accelerations. Packaging development times are reduced with a readily adapted form that is optimized on a product-by-product basis. The amount of packaging material needed for a given level of product protection is reduced relative to conventional packaging, and the use on less-readily recycled materials, such as foam, is reduced. Packages for a given level of product protection take up less space than conventional packaging with increased stack strength so that pallet room and weight is reduced per package and product height stacking is increased, thus allowing more efficient use of transport resources, such as aircraft pallet room. Another example is that the container provides a symmetrical solution so that an information handling system is protected equally whether placed with its front or rear at the front of the container. Further, the geometry of the lower and upper supports is the same, so that manufacture and use of the supports is less complex and less costly. For instance, the bottom support is simply place upside down at the top of the container to provide the same level of protection to the product placed in the container whether the product is oriented up or down. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element. 
         FIG. 1  depicts a blown-up view of a system for supporting a portable information handling system in a container; 
         FIG. 2  depicts a side view of flexure induced at an information handling system supported in the container with end caps; 
         FIG. 3  depicts a side view of an example of constant support across an information handling system with a corrugated material support; 
         FIGS. 4A and 4B  (generally referred to herein as  FIG. 4 ) depict an example of a support formed from corrugated material and the acceleration response at the support; 
         FIGS. 5A and 5B  (generally referred to herein as  FIG. 5 ) depict an example of a support having tab feet and the acceleration response at the support; 
         FIGS. 6A and 6B  (generally referred to herein as  FIG. 6 ) depict an example of a support having tabbed feet symmetrical perforations at the perimeter of a supported device and the acceleration response at the support; 
         FIG. 7  depicts a side view of tabbed feet with voids to adopt a desired acceleration response; 
         FIGS. 8A and 8B  (generally referred to herein as  FIG. 8 ) depict a support having perforation cuts along a tabbed feet bend and the acceleration response at the support; 
         FIGS. 9A and 9B  (generally referred to herein as  FIG. 9 ) depict a support having diagonal perforation cut lines and the acceleration response at the support; 
         FIG. 10  depicts an upper perspective view of a container prepared to accept an information handling system; and 
         FIG. 11  depicts an upper perspective view of the container having an information handling system. 
     
    
    
     DETAILED DESCRIPTION 
     .A negative edge modular container for shipping portable information handling systems has a pair of top and bottom corrugated material trampoline-like cushions with regulated deflection to limit excessive flexure of an information handling system housing in response to accelerations. For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components. 
     Referring now to  FIG. 1 , a blown-up view depicts a system for supporting a portable information handling system  10  in a container  12 . Portable information handling system  10  is, for example, a laptop, tablet or other device that processes information with a processor and stores information with a memory. In alternative embodiments, other types of information handling systems and other types of products may be shipped. Container  12  is, for example, a corrugated cardboard box or other type of shipping container made from other types of materials. The interior of container  12  is sized to accept a support  14  that provides a support surface  16  on which portable information handling system  10  rests. In the example embodiment, information handling system  10 , container  12  and support  14  each have a generally rectangular shape; however in alternative embodiments, products disposed in container  12  may have alternative shapes that container  12  and support  14  may or may not adopt. 
     In the example embodiment of  FIG. 1 , support  14  has tabbed feet  18  formed by bending material of support  14  along a score. For example, support  14  is cut from corrugated cardboard or other corrugated material and scored to define bending locations for forming tabbed feet  18 . Tabbed feet  18  are bent substantially 90 degrees to contact the bottom surface of container  12  and raise support surface  16  relative to container  12 . One or more perforations  20  formed in support surface  16  and support  14  promotes constant distribution of accelerations across support surface  16  so that even support is provided to information handling system  10 . In the example embodiment, an inverted support  22  having a similar structure to support  14  provides constant distribution of accelerations that are directed between a container lid  24  and information handling system  10 . When information handling system  10  is placed between support  14  and inverted support  22 , it is held in position by foam cushions  26 , which rest between information handling system  10  and the side walls of container  12 . In alternative embodiments, alternative positioning devices may be used to hold information handling system  10  in place. 
     Referring now to  FIG. 2 , a side view depicts flexure induced at an information handling system  10  supported in the container with end caps  28 . A transverse force F Y  is introduced at the container, such as by a dropping of the container. End caps  28  maintain each end of information handling system  10  substantially in place, however, the weight of information handling system  10  distributed between end caps  28  causes deflections at the housing of information handling system  10 . Flexure at the housing can translate into internal components, such as circuit boards, that can experience damage and failure. 
     Referring now to  FIG. 3 , a side view depicts an example of constant support across an information handling system  10  with a corrugated material support  14 . Support  14  has a footprint that supports and encompasses the entire product unit&#39;s surface area. Constant support across the product surface area prevents and/or reduces deflection with the sag and bow response found in end cap packaging. By absorbing transverse accelerations at the Y-axis with a “trampoline” effect of the support  14 , deflection or flexure in the X-axis is reduced or kept constant in the X-axis across the plane of the product held by support surface  16 . An innate holistic suspension system is provided with minimal corrugated material. The constant deflection provided by the support surface means high G-levels can be accepted at container  12  because bending of information handling system  10 &#39;s housing is reduced under the influence of accelerations. Support surface  16 &#39;s trampoline-like cushion effect encompass the entire information handling system housing area to provide a constant an evenly-distributed force. 
     To obtain the trampoline cushion effect, cut-outs, scores and perforations are added to corrugate paper material that provides a desired deflection and unit input G-level. Cut-outs, scores and perforations for particular product are deduced by testing in various configurations and adopting a configuration that provides acceptable results. Features of a support  14  are tuned with different lengths, perimeters and cut sizes so that dynamic behavior and response are achieved on the application of accelerations.  FIGS. 4-9  describe an iterative process for testing various features added to a support  14  for a product by adding features and testing the acceleration response. Alternative products might have different iterations to arrive at a desired acceleration response. Thus, alternative features to provide a trampoline cushion effect fall within the intended scope of the present disclosure. 
     Referring now to  FIG. 4 , an example is depicted of a support formed from corrugated material and the acceleration response at the support. Support  14  is cut from corrugated paper to have a tab  30  on each side of a rectangle shaped support surface  16 . A score  32  is made along each tab  30  at its intersection with support surface  16  so that the tabs  30  are readily bent into feet to hold support surface  16  raised above the container bottom. In the example embodiment, a score is made by pressing against the corrugated material without cutting the corrugated material. In alternative embodiments, perforations or cuts may be used through part or all of the corrugated material thickness. Acceleration chart  34  depicts accelerations detected at an information handling system disposed on support surface  16  as configured in  FIG. 4 . For example, a container  12  is dropped from a defined height with an information handling system  10  resting on a support surface  16  with tabs  30  bent into feet, and an accelerometer coupled to information handling system  10  to measure accelerations. As is depicted by acceleration chart  34 , a top acceleration of approximately 175 G&#39;s is detected with the support surface  16  of  FIG. 4 . 
     Referring now to  FIG. 5 , an example is depicted of a support having tab feet and the acceleration response at the support. In the example embodiment of  FIG. 5 , a void  36  is cut from each tab  30  so that at least part of the tabbed feed will not contact the bottom of the container  12 . The voids are cut in a symmetrical pattern that leaves a void across the center of the rectangle sides having the shortest length and has contact at the center point of the rectangle sides having the greater length. The voids aid in the distribution of acceleration forces across support surface  16  so that a maximum acceleration of approximately 150 G&#39;s is experienced at information handling system  10 . 
     Referring now to  FIG. 6 , an example is depicted of a support  14  having tabbed feet  30  and symmetrical perforations  38  at the perimeter of a supported device, and the acceleration response at the support surface  16 . Voids  36  are cut to a greater depth to define  10  contact points when tabs  30  are folded into feet. Perforation  38  is cut in a rectangular shape that has a perimeter of substantially that of the information handling system that rests on support surface  16 . The precise relationship of the size of the perimeter of perforation  38  relative to the size of information handling system  10  may vary based on test results. In one embodiment, information handling system  10  has a smaller perimeter than that of perforations  38 ; in alternative embodiments, the perimeters are the same size or the perimeter of information handling system  10  is greater than the perimeter of perforations  38 . A diagonal score  40  is added at each corner of support surface  16  inwards to perforation  38  to further enhance dynamic action of support surface  16  in response to accelerations. As is depicted by acceleration chart  34 , the introduction of enhanced voids  36 , perforations  38  and diagonal scores  40  reduce the maximum acceleration experienced by information handling system  10  to approximately 140 G&#39;s. 
     Referring now to  FIG. 7 , a side view depicts tabbed feet  30  with voids  36  to adopt a desired acceleration response. A contact point  42  is established between each void  36  to contact the bottom (or top) of container  12 . The depth of each void may vary to achieve constant acceleration across support surface  16 . Similarly, cuts may be added along the score that forms tab  30  to achieve a desired cushion effect. Other types of alterations may include the use of more voids and feet spaced in symmetrical or unsymmetrical patterns. 
     Referring now to  FIG. 8 , an example is depicted of a support having perforation cuts along a tabbed feet bend and the acceleration response at the support. The score  32  that forms tabs  30  has cuts  42  added along its length. Three cuts are made along each long side of the rectangular shape and one longer cut is made along each short side of the rectangular shape. The cuts  42  aid in distribution of acceleration forces as a constant across support surface  16 . In alternative embodiments, perforations may be added along all or parts of the score  32 . As is depicted by acceleration chart  34 , adding cuts to the score reduces the maximum acceleration experienced by the information handling system to approximately 125 G&#39;s. 
     Referring now to  FIG. 9 , an example is depicted of a support having diagonal perforation cut lines  44  and the acceleration response at the support surface  16 . Cut lines  44  are each a straight cut that extends from each corner of the rectangular perforation  38  towards a central position of support surface  16 . The length of each cut  44  may vary to achieve a desired cushion effect. In an alternative embodiment, multiple diagonal cuts  44  may be made at each corner with varying angles towards the center of support surface  16 . In other alternative embodiments, perforations may be used instead of cuts or cuts  44  may extend to include the scored area  42 . As is depicted by acceleration chart  34 , the addition of diagonal cuts  44  further decreases the maximum acceleration at information handling system  10  to slightly more than 100 G&#39;s. 
     Referring now to  FIG. 10 , an upper perspective view depicts a container  12  prepared to accept an information handling system  10 . In the example embodiment, support surface  16  has slits  46  that accept documentation  48  for delivery with the package, such as user manuals. Foam  26  rests against the container  12  so that the information handling system will stay stationary in a desired position that has cushioning. A negative edge built into container  12  allows storage of hardware, such as a power adapter. In one embodiment, support  14  has one or more tab feet integrated with container  12 . 
     Referring now to  FIG. 11 , an upper perspective view depicts the container  12  having an information handling system  10 . Foam  26  secures information handling system  10  from movement. An upper support  14  couples to a lid  24  of container  12  so that an upper support surface  26  presses against information handling system  10 . Sandwiching information handling system  10  between upper and lower supports  14  aids in maintaining a constant acceleration across information handling system  10 . Each of the upper and lower supports  14  may be tuned with its own features based upon expected accelerations and to cooperate with each other for dampening acceleration forces. 
     Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.