Abstract:
A dunnage-free product-shipping assembly comprising a support member securable to the product in a substantially fixed position. A shipping container has an interior area sized to removably contain the support member. The shipping container has a base and sidewalls projecting from the base. The sidewalls restrict lateral movement of the support member relative to the base. A closure member is movable between an open position and a closed position. The closure member is out of engagement with the support member and the product when in the closed position. A retention flap is connected to one of the sidewalls and is movable between engaged and released positions. The retention flap, when in the engaged position, restricts movement of the support member and the product in a direction normal to the base. When the retention flap is in the released position, the support member and product can be moved normally relative to the base for removal from the shipping container.

Description:
This application is a divisional of U.S. patent application Ser. No. 10/836,640, filed on Apr. 30, 2004. 
    
    
     TECHNICAL FIELD 
     The present invention is directed to apparatus and methods for packing and shipping of products without requiring dunnage in the shipping container for safe transport. 
     BACKGROUND 
     Consumer and retail products are often packed and shipped directly to consumers or retailers using conventional shipping boxes. The shipping boxes typically include protective packing material in the shipping box to protect the products against shipping and handling hazards. The protective packing material is often crumpled paper, liners, plastic air pillows, bubble-wrap, Styrofoam, compressible foam “peanuts,” or other dunnage. The dunnage can effectively immobilize the products within the shipping box and can absorb external loads to protect the products. The dunnage, however, can be difficult to handle and labor-intensive when packing a box, thereby adding to the cost of shipping the products. The dunnage also results in excessive waste material that can be messy, bothersome, and difficult to dispose of after the products are removed from the shipping box. 
     Other conventional packaging systems include specially shaped restraints designed to immobilize the product within the shipping box. The specially shaped restraints can be created by molding or pre-forming the restraint structure so as to fully or partially enclose the product when packed. These restraints, however, are specially shaped to correspond to the particular products, so that each specially shaped restraint is limited to use with only products of certain shapes and sizes. Creating specially shaped restraints for large numbers of consumer products having different shapes could be cost-prohibitive. In addition, the packaging of products in such specially shaped restraints can be very labor-intensive, thereby adding to the cost of shipping. 
     Another approach to protecting products during shipping is known as suspension packing. An object to be shipped is suspended between two sheets of plastic film material in a face-to-face relationship. The sheets are usually attached to frames that fit securely within a box of a selected size. Accordingly, the product does not contact any substantially rigid surfaces within the box and is protected from physical shock. Examples of suspension packing systems are disclosed in U.S. Pat. Nos. 4,852,743; 4,923,065; 5,071,009; 5,388,701; 5,287,968; and 5,678,695. 
     Other packaging systems immobilize a product on a frame structure that fits within the shipping box. The frames are shaped and sized to engage the top, bottom, and sides of the shipping box, so there is a minimum amount of movement of the frame within the shipping box. Examples of frame packing systems are disclosed in U.S. Pat. Nos. 5,678,695; 5,893,462; 6,010,006; 6,148,590; and 6,148,591. The suspension packing systems and frame packing systems can be effective at protecting the products being shipped, although the systems can be fairly complex, and expensive. The systems can also be labor-intensive, particularly when shipping products of all shapes and sizes in large volumes and in multiple shipping boxes of different sizes. Accordingly, there is a need for an easy, inexpensive packing and shipping system that securely immobilizes and protects the products and that minimizes the amount of waste that must be disposed of by the recipient. 
     SUMMARY 
     The present invention is directed to apparatus and methods for dunnage-free packing and shipping of products. Under one aspect of the invention, a product-shipping assembly comprises a support member securable to the product with the product being in a substantially fixed position relative to the support member. The assembly has a shipping container with an interior area sized to removably contain the support member when the product is secured to the support member. 
     The shipping container comprises a base and sidewalls projecting from the base. The support member is shaped and sized so the sidewalls restrict lateral movement of the support member relative to the base when the support member is in the interior area. A closure member is movable relative to the sidewalls between an open position and a closed position. The closure member is out of engagement with the support member and the product when in the closed position. 
     A retention flap is connected to one of the sidewalls and is movable relative to the sidewall between an engaged position and a released position. The retention flap, when in the engaged position, is spaced apart from the base and is engagable with an edge portion of the support member to restrict movement of the support member in a direction normal to the base. In the released position, a free edge of the retention flap is spaced apart from the edge portion of the support member, allowing movement of the support member and removal from the interior area of the shipping container. 
     Under another aspect of the invention, a method is provided for packing a product for shipping. The method of one embodiment comprises securing the product on a support member with an edge portion of the support member projecting beyond the product. The product is substantially restricted from moving relative to the support member. The product and the support member define a product unit. 
     The product unit is positioned into a shipping container. The container has a base, sidewalls connected to the base, a retention flap connected to a first sidewall, and a closure member movable between an open position and a closed position. The retention flap is positionable within the interior area and movable between a released position and an engaged position. The retention flap is moved to the released position as the product unit is positioned into the interior area. The product unit is positioned in a packed position with the support member substantially adjacent to the base. The product unit is restricted by the sidewalls from moving laterally relative to the base when the product unit is in the packed position. The retention flap is moved to the engaged position after the product unit is in the packed position. The retention flap is immediately adjacent to the edge portion of the support member and restricted from moving normally relative to the base. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a dunnage-free shipping assembly with a shipping box and product unit contained therein in accordance with one embodiment of the present invention. 
         FIG. 2  is an isometric view of the shipping assembly of  FIG. 1  with a product unit shown removed from the shipping box. 
         FIG. 3  is an enlarged top plan view of the product unit of  FIG. 1  shown removed from the shipping box. 
         FIG. 4  is an isometric view of the shipping box of  FIG. 1  with major flaps shown in an open position and minor flaps shown in an inwardly folded position. 
         FIG. 5  is an enlarged cross-sectional view taken substantially along line  5 - 5  of  FIG. 1  showing the minor flaps in an engaged position securely retaining the product unit within the shipping box. 
         FIG. 6  is an enlarged cross-sectional view similar to  FIG. 5  showing the minor flaps in a released position for removal of the product unit from the shipping box. 
         FIG. 7  is an isometric view of a shipping box in accordance with one embodiment having support tabs on endwalls of the shipping box. 
         FIG. 8  is an enlarged isometric view of the shipping box of  FIG. 7  in the closed configuration ready to be shipped. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes product packing and shipping components, systems, and methods. Several specific embodiments are set forth in the following description and in  FIGS. 1-8  to provide a thorough understanding of certain embodiments of the invention. One skilled in the art, however, will understand that the present invention may have additional embodiments, and that other embodiments of the invention may be practiced without several of the specific features explained in the following descriptions. 
       FIG. 1  is a top isometric view of a product shipping system  10  in accordance with one embodiment of the present invention. The system  10  includes a shipping box  12  configured to releasably retain and immobilize a product unit  14 , which includes one or more products  16  secured to a support member  18 .  FIG. 2  is a top isometric view of the system  10  of  FIG. 1  with the product unit  14  shown removed from the shipping box  12 . The system  10  allows for one or more products  16  to be packed into the shipping box  12  in an immobilized position within the shipping box, thereby eliminating the need for excess packing material, such as air pillows, foam inserts, crushed paper, or other dunnage. Accordingly, the system  10  is dunnage-free and allows for efficient and inexpensive shipping of products  16 . 
     In the illustrated embodiment, the product unit  14  includes multiple products  16  releasably secured to a substantially rigid support member  18 . In other embodiments, a single product  16  can be secured to the support member  18 . The support member  18  is a flat sheet of rigid, corrugated cardboard shaped and sized to closely fit within the interior length and width of the shipping box  12 . In other embodiments, the support member  18  can be made of other rigid or semi-rigid materials suitable for restricting movement of the product unit  14  within the shipping box, as discussed in greater detail below. 
     The products  16  are substantially immobilized on the support member  18  by a wrapping material  20  that fully or partially encases the products and the support member. In the illustrated embodiment, the wrapping material  20  is a shrink wrap film that encases the products  16  and the support member  18  upon being heated to a selected temperature that will not damage the products. In other embodiments, other wrapping material  20  could be used to hold the products  16  on the support member  18 . In yet other embodiments, other securing materials or mechanisms can be used to releasably secure the products  16  onto the support member  18 . 
     After the products  16  are secured to the support member  18  in some embodiments, the products may be able to slide laterally a small distance relative to each other or relative to the support member. But, the products  16  are securely retained so they will not impact the sides of the shipping box  12  as a result of loads from handling and shipping of the shipping box. 
       FIG. 3  is an enlarged top plan view of the support member  18  having the products  16  held in place with the wrapping material  20 . The support member  18  has a peripheral edge portion  24  that extends around a central support portion  22 . The products  16  are positioned on the central support portion  22  so the peripheral edge portion  24  projects laterally beyond the products. In one embodiment, if any of products  16  are positioned to cover the peripheral edge portion  24 , the products are repositioned to expose the peripheral edge portion. If the products  16  are too large to fit within the boundaries of the central support portion  22 , then a larger support member  18  and shipping box  12  are used to ship the product unit  14 . Accordingly, when the products  16  are secured to the support member  18 , the peripheral edge portion  24  may be covered by the wrapping material  20  but is engagable by the shipping box to restrict lateral movement of the product unit  14 , as discussed in greater detail below. 
     As best seen in  FIGS. 1 and 2 , the support member  18  is shaped and sized with a specific length and width that substantially correspond to the length and width of the interior area  26  of the shipping box  12 . The shipping box  12  of the illustrated embodiment has a base  30  connected to a plurality of sidewalls  32  to define the interior area  26 . The shipping box  12  of the illustrated embodiment is made of a substantially rigid, corrugated cardboard die-cut and folded to provide the base  30  and the sidewalls  32 . 
     The sidewalls  32  include opposing left and right side panels  36  and  38  and a pair of opposing end panels  40  extending between the left and right side panels. The left and right side panels  36  and  38  are spaced apart by a distance slightly greater than the width of the support member  18 . The end panels  40  are spaced apart by a distance slightly greater than the length of the support member  18 . In one embodiment, the distance between the end panels  40  is greater than the length of the support member  18  by a distance substantially corresponding approximately to the thickness of the cardboard forming the shipping box  12 . 
     When the support member  18  is placed into the interior area  26 , the peripheral edge portion  24  is substantially adjacent to sidewalls  32  of the shipping box  12 . Accordingly, the support member  18  is substantially restricted from lateral movement within the shipping box  12 . Because the support member  18  does not move laterally within the shipping box  12 , the products  16  secured to the support member are also restricted from moving laterally within the shipping box. 
     While the close fit between the sidewalls  32  and the support member  18  restricts lateral movement of the product unit  14 , the sidewalls do not substantially restrict movement of the product unit in a direction normal to the base  30 . This movement of the product unit  14  normal to the base  30  is restricted by flaps on the shipping box  12 . Upper portions  42  of the end panels  40  are integrally connected to a pair of minor flaps  44 . Upper portions  46  of the left and right side panels  36  and  38  are integrally connected to a pair of closure flaps referred to as major flaps  48 . Each of the minor flaps  44  is pivotable about a hingeline  50  at the upper portion  42  of the respective end panel  40 . The minor flaps  44  can fold into the interior area  26  of the shipping box  12 , as shown in  FIG. 4 , before the product unit  14  is placed into the interior area. Each of the major flaps  48  is pivotable about a hingeline  52  at the upper portion  46  of the respective left and right side panels  36  and  38 . The major flaps  48  can move between an open position (FIG.  2 ) and a closed position ( FIG. 8 ) to cover the interior area  26  and the product unit  14  within the shipping box  12 . 
     The product unit  14  is securely held down within the shipping box&#39;s interior area  26  by the minor flaps  44 . Prior to placing the product unit  14  into the shipping box  12 , the minor flaps  44  are positioned in an inwardly folded position, as shown in  FIG. 4 . The minor flaps  44  are biased away from the end panels  40  toward the inwardly folded position. The minor flaps  44  can be pivoted about the hingeline  50  to a released position, so the minor flaps are substantially flush against the inner surface  56  of the respective end panel. When the minor flaps  44  are released, the minor flaps will seek to move away from the released position toward the inwardly folded position. 
       FIG. 5  is an enlarged cross-sectional view taken substantially along line  5 - 5  of  FIG. 1  showing the product unit  14  securely retained in the shipping box  12 . The minor flaps  44  have a height that is shorter than the height of the end panel  40 . Accordingly, when the minor flap  44  is folded into the interior area  26  and positioned generally adjacent to the inner surface  56  of the end panel  40 , a free edge  60  of the minor flap is spaced above the base by a selected distance. In the illustrated embodiment, the distance between the minor flap&#39;s free edge  60  and the base  30  is slightly greater than the thickness of the support member  18 . 
     When the product unit  14  is placed into the interior area  26  of the shipping box  12  substantially flush against the base  30 , the peripheral edge portion  24  of the support member  18  is located in the space between the base and the free edge  60  of the minor flap  44 . When the minor flaps  44  are in an engaged position, as shown in  FIG. 5  in solid lines, the free edges  60  of the minor flaps are positioned immediately above the product unit  14  at the peripheral edge portion  24 . In one embodiment, the free edges  60  of the minor flaps  44  frictionally engage the product unit  14  at the peripheral edge portion  24 . Accordingly, the minor flaps  44  releasably lock the product unit  14  down in place within the shipping box  12  and prevent the product unit from moving in a direction normal to the base  30 . The products  16  in the shipping box  12 , therefore, are substantially immobilized from lateral and normal movement relative to the base  30 . 
     In the illustrated embodiment, the support member  18  is positioned flush against the base  30  of the shipping box  12 . In other embodiments, the support member  18  can be shaped so a portion of the support member is supported on the base  30  and the peripheral edge portion  24  is spaced a selected distance above the base. The minor flaps  44  in this other embodiment are shaped and sized so their height substantially corresponds to the distance between the peripheral edge portion  24  and the hingeline  50  of the minor flaps  44 . The minor flaps  44  are positionable in the engaged position immediately above the peripheral edge portion  24 , so the product unit  14  is secured in place and restricted from normal and lateral movement relative to the base  30 . 
     As best seen in  FIG. 5 , when the product unit  14  is to be placed into the interior area  26  of the shipping box  12  and secured in place, the minor flaps  44  are initially in the inwardly, folded position shown in phantom lines. The product unit  14  with the products  16  therein is locked into place within the shipping box  12  simply by pressing the product unit downwardly in the interior area  26 . The peripheral edge portions  24  of the support member  18  press against the minor flaps  44 , and the minor flaps pivot about the hingelines  50  and move to a released position, shown in  FIG. 6 . The minor flaps  44 , when in the released position, are immediately adjacent to the inner surface  56  of the end panels  40 . 
     After the product unit  14  is pressed downwardly fully into the interior area  26  with the support member  18  substantially flush against the base  30 , the peripheral edge portion  24  of the support member is below the free edges  60  of the minor flaps  44 . The minor flaps  44 , which are biased toward the inwardly, folded position, pivot a short distance inwardly to an engaged position, so the free edges  60  are directly over the peripheral edge portions  24 . Accordingly, the minor flaps  44  automatically lock the product unit  14  in the interior area  26  until released. This automatic locking of the product unit  14  in place allows for fast, efficient packing of the shipping box  12  with a minimum amount of labor required. 
     The product unit  14  remains locked in place in the shipping box  12  so the products  16  substantially do not move relative to the shipping box while the shipping box is in transit. Accordingly, the products  16  are protected from damage due to loads that may be exerted on the shipping box during handling and shipping. In one embodiment, a shock absorptive layer can be provided between the support member  18  and the base  30  to help reduce impact loads to the products  16  if, as an example, the shipping box  12  is dropped and lands flat on its base  30 . 
     The product unit  14  can easily and quickly be released from the shipping box  12  by pressing the minor flaps  44  outwardly from the engaged position, shown in  FIG. 5 , to the released position, shown in  FIG. 6 . In the released position, the free edges  60  of the minor flaps  44  are spaced laterally apart from the peripheral edge portion  24  of the support member  18 . Accordingly, the minor flaps  44  no longer block the product unit  14  from moving in a direction normal to the base  30 . The product unit  14  can then be easily lifted out of the shipping box&#39;s interior area  26 . The wrapping material  20  can then be removed from the support member  18  to get to the products  16 . In one embodiment, the wrapping material  20  can be cut or otherwise opened while the product unit  14  remains in the shipping box  12 , so the products  16  could be removed without having to remove the entire product unit. As indicated above, the shipping box  12  and the support member  18  are made of cardboard, which can be recycled. In one embodiment, the wrapping material  20  can also be a recyclable material, such as paper. After the products  16  are removed from the shipping box  12  in this embodiment, the remaining components of the system  10  could all be recycled. 
     In one embodiment, the minor flaps  44  each have one or more alignment tab  61  (shown in phantom lines in  FIG. 4 ) extending from the free edge  60 . The tab  61  extends substantially to the base  30  and is integrally connected to the free edge  60 . The tab  61  can be provided as an alignment member for use in the manufacturing of the shipping box  12 . As an example, when shipping boxes  12  are die cut and stacked in a flat configuration, the tabs  61  can help align the flat, stacked shipping boxes in a desired position for subsequent automated processing of the shipping boxes. 
     In this embodiment with the tab  61 , the support member  18  is provided with a matching notch  63  (shown in phantom lines in  FIG. 3 ). The notch  63  is positioned and sized to receive the tab  61  therein when the minor flap  44  is in the engaged position. Accordingly, the tab  61  ( FIG. 4 ) does not block the minor flap  44  from moving to the engaged position from the released position. The tab  61 , however, can act as a stop that helps block the minor flap  44  from moving past the engaged position away from the end panel  56 . 
     In another embodiment, the minor flaps  44  each have an alignment tab  61  extending from the free edge  60 , and a cut is formed in the minor flap adjacent to the flap. The cut allows the tab  61  and a flex portion of the minor flap remain substantially in the released position when the rest of the minor flap moves to the engaged position. The free end of the tab  61  in one embodiment has a perforated hinge line about which the tab can partially fold to accommodate the edge of the support member  19  when positioned in the shipping box adjacent to the base. Accordingly, the support member  18  does not need a notch to receive the tab  61 . When the support member  18  is placed into the shipping box  12  adjacent to the base  30 , the support member  19  presses against the tab  61  and holds the tab and the flex portion of the minor flap  44  next to the end panel. The remainder of the minor flap  44  is in the engaged position to securely retain the support member  19  in the interior area  26  of the shipping box  12 . 
     As best seen in  FIG. 4 , corner areas  70  of the minor flaps  44  are beveled so they do not have a sharp point at the ends of the free edges  60 . The beveled corner areas  70  do not damage the wrapping material  20  or other retention member that holds the products  16  on the support member  18 . The beveled corner areas  70  also help prevent the minor flap  44  from hanging up on the wrapping material  20  before reaching the engaged position. In other embodiments, the corner areas  70  are rounded or have other shapes to help ensure that the minor flaps  44  will properly move between the released and engaged positions. 
     As best seen in  FIGS. 1 and 3 , the support member  18  also has beveled or otherwise shaped corner portions  72  positioned adjacent to an end panel  40  and the left or right side panel  36  or  38 . The beveled corner portions  72  provide an access area  74  adjacent to the edge of the support member  18 . The access area  74  is sized so a person can place a finger into it, engage the support member  18 , and lift the product unit  14  upwardly away from the base  30  after the minor flaps  44  have been moved to the released position. In other embodiments, other features can be provided on the support member  18  that allow a user to grasp or engage the support member to facilitate removal of the product unit  14  from the shipping box  12  when the minor flaps  44  are in the released position. 
       FIG. 7  is an isometric view of the shipping box  12  containing the product unit  14 , and one of the major flaps  48  is shown in a closed position. The other major flap  48  is shown in the open position. In the illustrated embodiment, the product unit  14  is placed into the interior area  26  of the shipping box  12  when the major flaps  48  are in the open position. When the major flaps  48  are in the closed position, as shown in  FIG. 8 , the major flaps  48  cover the interior area  26 . 
     In the illustrated embodiment, the major flaps  48  have a height corresponding to approximately one-half of the width of the interior area, so the two major flaps abut each other when closed. The height of each major flap  48  is greater than the height of each minor flap  44 . In other embodiments wherein the shipping box has a very deep interior area, the height of the minor flaps  44  may be greater than the height of the major flaps  48 . In yet other embodiments, a single major flap  48  may be used to cover the interior area  26  and close the shipping box  12 , while the minor flaps  44  releasably lock the product unit within the interior area, as discussed above. 
     As best seen in the  FIG. 7 , when the major flaps  48  are in the closed position, edges  76  of the major flaps are adjacent to the upper edge portions  42  of the end panels  40 . The major flap  48  can be shaped so the edges  76  are substantially parallel with the end panels  40 . In other embodiments, all or portions of the edges  76  of the major flap  48  can be formed at an angle relative to the end panels  40 , so portions of the major flap generally adjacent to the hingeline  52  extend over and rest atop the end panels  40 . Accordingly, each major flap  48  is at least partially supported by the end panels  40  when in the closed position. When the major flaps  48  are in the closed position, the angled portions of the edges form a recessed portion (shown in phantom lines in  FIGS. 7 and 8 ). The recessed portion is shaped and sized to receive shipping tape applied to the shipping box  12 . The recess allows the shipping tape to smoothly transition over the edges  76  of the major flaps  48  to the end panels  40  without gapping. The recess also helps to prevent the shipping tape from peeling breaking or being cut by the edges  76  of the major flaps. 
     In the illustrated embodiment of  FIG. 7 , the shipping box  12  has a pair of support tabs  78  integrally connected to the upper portions  42  of the end panels  40 . The support tabs  78  support the major flaps  48  along at least a portion of the edges  76 . In the illustrated embodiment, the support tabs  78  are formed by a die cut made in the minor flaps  44 , so the support tabs extend inwardly from the hingelines  50  of the end panels  40 . 
     The support tabs  78  provide a surface on which a portion of the major flaps  48  can rest when in the closed position and when the minor flaps  44  are in the engaged position. The support tabs  78  block the major flaps  48  from moving past the closed position and into the interior area  26  of the shipping box  12 . The support tabs  78  also provide a structure at the intersection of the major flaps  48  and the end panels  40  that restricts visibility into the interior area  26  of the shipping box  12 . For example, if some gapping occurs between the major flaps  48  and the end panels  40  when the major flaps are secured in the closed position, the support tabs  78  block visibility into the shipping box  12 , thereby maintaining a level of privacy as to the contents in the shipping box  12 . In the illustrated embodiment, one support tab  78  is provided on each end panel  40 . In other embodiments, more than one support tab  78  can be provided along each of the end panels  40  as needed to support the major flaps  48  when in the closed position. 
     From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the invention. For example, in one embodiment, the shipping box  12  may be made from a unitary sheet of cardboard, die-cut, and folded. In another embodiment, the shipping box  12  may be made from a plurality of panel portions connected and glued or otherwise adhered together. The support member  18  can be a shaped frame structure or, in other embodiments, a planar structure that supports the products  16  in the central support portion  22  radially inward from the peripheral edge portion  24 . In other embodiments, the support member  18  can have peripheral edge tabs extending from the support member engagable with the minor flaps  44  when the minor flaps are in the engaged position. Accordingly, the invention is not limited except as by the appended claims.