Patent Publication Number: US-6340087-B1

Title: Flap retention apparatus and method for packaging systems

Description:
TECHNICAL FIELD OF THE INVENTION 
     The present invention generally relates to packaging systems. More particularly, the invention relates to flaps used in packaging systems, and to an apparatus and method for retaining such a flap in a desired position. 
     BACKGROUND OF THE INVENTION 
     Computer systems and other electronic systems are commonly shipped as several separate components packaged in a single shipping box or container. The separate components may include the computer chassis and its associated enclosure, a keyboard, a mouse, and system software and documentation. The computer chassis may be loaded into a protective sling within the main box. This sling may have a bottom panel, at least two side panels, and two sling flaps, one sling flap connected to each side panel. The sling flaps fold or pivot with respect to the respective side panel to an open position in which the chassis may be placed in the sling. Once the chassis is loaded, the sling flaps are folded down to a closed position to secure the chassis in a well-protected position in the main box. With the sling flaps folded down, additional padding or spacing elements, or smaller boxes containing the other system components may be placed in the volume of the main box remaining above the sling and previously loaded chassis. 
     In all packaging systems, particularly computer packaging systems, the speed at which the products may be packaged and readied for shipping is critical. All components of the packaging system, including the main box and any protective sling or other packaging components must be easy to load, close, and seal for shipping. Difficulties or inefficiencies in the packaging system can reduce the number of units which may be packaged and shipped in a given period, and thus reduce overall productivity. 
     In the situation where a first packaging component, such as a protective sling, is first loaded in a main box, it is important that the flaps associated with the first packaging component be easy to close within the main box. This ability to easily close the flaps is particularly important where additional components are loaded on top of the first packaging component. In the computer packaging system described above, it is important that the flaps of the protective sling be easy to fold down into the closed position to allow the additional components or padding to be quickly added to the main box above the sling. However, problems may arise due to the mechanical resiliency of the sheet of material forming the sling flaps. This mechanical resiliency at the pivot or fold points for the sling flap may cause the flap to return to an open or partially open position after the loader places the flap in the closed position. This open or partially open sling flap position may prevent the additional components or padding from being added quickly to the main box. The loader may be forced to hold the sling flap down with one hand while using the free hand to place additional components or padding in the main box. Having to load the portion of the main box above the protective sling in this one-handed fashion slows the loading process. 
     For these reasons it is desirable in a packaging system utilizing a sling or similar packaging device to provide some mechanism by which the flap or flaps may be securely retained in the closed position. More specifically, it is desirable to provide a mechanism to prevent the flaps from springing back from the closed position to an open or partially open position. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a flap retention apparatus and a method for retaining a flap in a desired position with respect to a panel to which the flap is connected. Another object of the invention is to provide a packaging system utilizing a flap retention arrangement. 
     In accordance with the present invention, a packaging device includes a flap retention arrangement having a retention member and a capture element. The packaging device incorporating the retention arrangement includes a panel and a flap member. The flap member is connected to the panel and adapted to move between a first position with respect to the panel and a second position with respect to the panel. For example, the first position may comprise an open position for the flap member while the second position may comprise a closed position for the flap member. The retention member portion of the retention arrangement is mounted on one of the flap member or panel, while the capture element is located on the other one of the flap member or panel. Regardless of which portion of the retention arrangement is mounted on the flap member or panel, the retention member and capture element are situated so as to make contact with each other when the flap member is moved to the second position. This contact automatically retains the flap member in the second position. 
     In one preferred form of the invention, the retention member comprises an elongated member mounted on the flap portion of the packaging device. This elongated retention member includes an anchor portion connected to the flap member and a catch portion which extends over an edge of the flap member adjacent to the panel portion of the packaging device. In this preferred form of the invention, the capture element comprises an opening or aperture located in the panel for receiving and engaging the catch portion of the retention member as the flap is moved to the second position with respect to the panel. The elongated retention member may be formed from a resilient material with the catch portion flared outwardly so as to have a transverse dimension larger than a corresponding dimension of the opening making up the capture element. This enlarged catch portion ensures a good frictional engagement between the catch portion and the opening to securely retain the flap member in the second position. 
     The invention may be incorporated in a packaging system including a container and a sling assembly adapted to be received in the container. One or more side panels may be included in the sling assembly with each side panel having an associated flap which is adapted to fold from an open first position to a closed second position. A separate flap retention arrangement according to the invention may be associated with each panel and flap pair in this container/sling assembly packaging system. 
     The present flap retention arrangement automatically holds the flap member securely in a desired position with respect to the associated panel. When used in the container/sling assembly packaging system, the flap retention arrangement automatically holds the flap member in the closed second position so that additional packages or packaging material may be easily added to the container portion not occupied by the sling assembly. Yet the present flap retention arrangement may be located on the panel and associated flap member so as not to interfere with the step of loading an object into the sling assembly. Furthermore, the present flap retention arrangement may be easily incorporated into existing sling assembly and other packaging device designs. 
     These and other objects, advantages, and features of the invention will be apparent from the following description of the preferred embodiments, considered along with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded isometric view illustrating a packaging system including a container and a sling assembly, the sling assembly featuring a flap retention arrangement according to one preferred form of the invention. 
     FIG. 2 is a partial side view illustrating the flap retention arrangement of FIG. 1, with the flap in a first or open position. 
     FIG. 3 is a partial side view similar to FIG. 1, but with the flap moved to a second or closed position. 
     FIG. 4 is a partial section view through line  4 — 4  in FIG. 3 showing the engagement between the retention member and capture element. 
     FIG. 5 is a partial side view of a panel and flap along with an alternate form of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIGS. 1-4 illustrate a packaging system  1  including a flap retention arrangement  30  embodying the principles of the invention. The packaging system  1  further includes a container  10  and a sling assembly  20  adapted to be received in the container  10 . As discussed in greater detail below, the sling assembly  20  receives an object or objects (hereinafter collectively referred to as “object(s)”) within the container  10 , and holds the object(s) in a well-protected and stable position within the container. The illustrated sling assembly  20  includes two panels  22 , each with a flap member  26 . Each flap member  26  is connected to the respective panel  22  and is adapted to move between a first position and a second position with respect to the panel  22 . 
     In the preferred embodiment illustrated in FIGS. 1 through 4, the container  10  comprises a shipment container, such as a shipment container for shipping computer systems. As shown in FIG. 1, the container  10  is defined by a series of walls  15 . The container  10  is sufficiently large to enclose the sling  20  and preferably additional packages or objects which may be shipped together. For example, the container  10  may be adapted to contain various components of a computer system such as a computer chassis, a keyboard, mouse, and system documentation (not shown in the figures). The container  10  provides a convenient receptacle for transporting various components together and also protects the various components from the elements. 
     A separate flap retention arrangement  30  according to the invention is associated with each panel  22  and flap member  26  pair. The flap retention arrangement  30  automatically maintains the flap member  26  in the second position once the flap member  26  is moved to the second position. The flap retention arrangement  30  thus ensures that the flap member  26  retains a desired spatial orientation or position with respect to the respective panel  22 . 
     In addition to its use in a sling assembly, those of ordinary skill in the art will appreciate that a flap retention arrangement according to the invention may be used in any other packaging device which includes a panel with a flap which is adapted to move between various positions with respect to the panel. For example, a flap retention arrangement embodying the principles of the invention may be provided for a flap associated with an outer container such as the container  10 . 
     The sling assembly  20  includes at least one spacer element  29 , and preferably several spacer elements  29  arranged about the sling assembly. The spacer elements  29  help hold object(s) in a desired position within the sling assembly  20  and also function to hold the sling assembly itself in a desired position with in the container  10 . 
     As indicated in FIG. 1, the sling assembly  20  includes a single piece of material, such as corrugated cardboard for example, folded to form the panels  22  and flaps  26 . The respective flap member  26  may pivot with respect to the respective panel  22  by folding along a fold line  21  shown in FIG.  1 . The fold line  21  thus forms a pivot connection between the respective flap  26  and panel  22 . Other embodiments of the invention contemplate the panels  22  and flaps as a separate members that are connected together to form the sling assembly  20 . For example, the panels  22  may be connected to a bottom member of the sling assembly by adhesive tape, a hinge, or a mortise and tenon joint. Each flap  26  may be connected to the respective panel  22  by adhesive tape, a hinge, or any other structure which enables the flap to pivot with respect to the respective panel from a first position to a second position. 
     FIGS. 2 and 3 show a top portion of one side of the sling assembly  20 , with the sling assembly received in the container  10 . In a first or open position shown in FIG. 2, the flap member  26  is arranged for allowing object(s) to be loaded into the sling assembly  20  within the container  10 . In the preferred form of the invention shown in FIG. 2, the flap member  26  is so dimensioned as to contact the container wall  15  when in the first position. Specifically, the flap member  26  includes a gripping edge  28  which frictionally engages the container wall  15  when the flap member  26  is in the first position shown in FIG.  2 . This frictional engagement with container wall  15  holds the flap member  26  in the open, first position. 
     FIG. 3 shows the flap member  26  arranged in the second position. In this second position the flap member  26  extends perpendicular to the panel  22  over a top opening of the sling assembly  20  in position to secure object(s) within the sling assembly  20 . In the illustrated form of the invention, the flap retention arrangement  30  (FIG. 1) is adapted to retain the flap member  26  in this second or closed position shown in FIG.  3 . 
     As shown in FIGS. 1 through 4, the flap retention arrangement  30  includes a retention member shown generally at reference numeral  33  and a capture element shown at reference numeral  37 . The retention member  33  and capture element  37  make contact with each other when the flap member  26  is in the second position shown in FIG. 3, and this contact holds the flap member in the second position. 
     As shown best in FIGS. 2 through 4, the retention member  33  preferably comprises an elongated member with a catch portion  34  and an anchor portion  35 . The anchor portion  35  is secured to the flap member  26 , whereas the catch portion  34  extends outwardly from the anchor portion  35  and a peripheral edge of the flap member  26 . In the preferred embodiment, the retention member  33  is composed of a resilient foam material although any suitable material may be used. 
     The preferred capture element  37  comprises an opening located on the panel  22  of the sling assembly  20 . The opening comprising capture element  37  is adapted to receive at least part of the catch portion  34  of the retention member  33  when the flap member  26  is in the second position. That is, the opening comprising the capture element  37  is located on the panel  22  and sized so that when the flap member  26  is moved to the second position, at least part of the periphery of the opening engages the peripheral surface of the catch portion  34 . This contact between the catch portion  34  and the capture element  37  holds the flap member  26  in a fixed position with respect to the panel  22 . Thus, the flap member  26  remains in the second position until intentionally repositioned with sufficient force to disengage the catch portion  34  from the capture element  37 . 
     In order to provide the desired frictional engagement between the catch portion  34  and the opening comprising the capture element  37 , the catch portion includes a transverse dimension at least equal to a corresponding dimension of the opening. In the preferred form of the invention in which the catch portion  34  is made of a resilient material, the catch portion  34  has a transverse dimension somewhat greater than a corresponding dimension of the opening comprising the capture element  37 . This larger transverse dimension of the catch portion ensures good frictional engagement with the capture element opening  37 . Preferably, the catch portion  34  tapers from a narrower transverse dimension to a wider transverse dimension toward a distal end  39  of the catch portion  34  as shown in FIG.  4 . 
     FIG. 5 shows an alternate form of the invention in which the positions of the retention member  33  and capture element  37  are switched with respect to the embodiment shown in FIGS. 1 through 4. In this alternate form of the invention the retention member  33  is connected to the panel  22  while the capture element is located on the flap member  26 . The first position of the flap  26  member is shown in phantom lines in FIG.  5  and the second or closed position of the flap member  26  is shown in solid lines. As the flap member  26  is pivoted from the open position to the second position, the catch portion  34  of the retention member  33  extends into and engages the opening comprising the capture element  37  on the flap member  26 . This engagement between the retention member  33  and capture element  37  holds the flap member  26  in the second position. 
     In either the form of the invention shown in FIGS. 1 through 4 or the form shown in FIG. 5, it is important that the retention member be positioned in a location in which it does not interfere with either the loading of the sling assembly  20  or the closure of the flap member  26  over an object received in the sling assembly  20 . Thus, as noted from FIGS. 1 through 4, the retention member  33  is located near one side of the flap member  26 . In this position, the catch portion  34  of the retention member  33  does not interfere with an object being loaded into the sling assembly  20 . Furthermore, an object properly received in the sling assembly  20  will not contact and interfere with the retention member  33  as the flap member  26  is moved to the second position shown in FIG.  3 . The retention member  33  in the form of the invention shown in FIG. 5 may similarly be located near a side of the panel  22  on which it is mounted. This position form the retention member  33  prevents the member from interfering with an object being loaded into the sling assembly  20 . 
     Although the illustrated form of the invention relies on frictional engagement between the retention member  33  and the capture element  37 , the invention encompasses other types of engagement. In another alternate embodiment of the retention arrangement  30 , a hook and loop type connector such as a VELCRO brand connector is employed to provide the desired engagement between the retention member  33  and the capture element  37 . Specifically, one half of the hook and loop type connector, the hook members for example, may be positioned on the distal end of catch portion  34 . The other half of the hoop and loop type connector is positioned on the panel  22  or flap member where the capture element opening is positioned on the illustrated embodiments. In this alternate form of the invention, the hook and loop connector components make contact when the flap member  26  is moved to the closed, second position and this contact automatically holds the flap in the closed position. 
     Although the present invention has been described in terms of the foregoing embodiments, such description has been for exemplary purposes only. As will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention as defined by the following claims.