Patent Publication Number: US-2023150718-A1

Title: Suspension packaging

Description:
FIELD 
     This disclosure relates to packages, more specifically to packaging, e.g., suspension packaging. 
     BACKGROUND 
     Certain article benefit from suspension packaging that creates an air cell inside an outer package to suspend a product within the package. Traditional suspension packaging utilizes a flexible plastic liner attached to a structure to suspend the article. 
     Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved suspension packaging. The present disclosure provides a solution for this need. 
     SUMMARY 
     A suspension package insert can include a suspension pouch configured to receive an article therein. The suspension pouch can be formed of at least a first flexible suspension panel and a second suspension panel, a first sidewall structure attached to a first side of the suspension pouch, and a second sidewall structure attached to a second side of the suspension pouch. The first and second sidewall structures can be configured to stand and suspend the suspension pouch therebetween. 
     The first flexible suspension panel can include a cut matrix defined therein configured to increase the flexibility of the first flexible panel. The second suspension panel can be uncut and/or is otherwise less flexible than the first flexible suspension panel. 
     The suspension package insert can be made of a fiber material. For example, the fiber material can be paper. Any other suitable material is contemplated herein. 
     In accordance with at least one aspect of this disclosure, a blank can be configured to form a suspension package insert as disclosed herein (e.g., as described above). In accordance with at least one aspect of this disclosure, a blank for a suspension package insert can include a first portion and a second portion foldably connected to the first portion. The first portion and the second portion can be configured to be attached together to form a suspension pouch and a sidewall assembly to suspend the suspension pouch. 
     The first portion can include a first flexible suspension panel having a cut matrix defined therein to increase a flexibility of the first flexible suspension panel. The first portion can include a first side panel and a second side panel foldably connected to the first flexible suspension panel. 
     The first portion can include a first end panel and a second end panel foldably connected to the first flexible suspension panel. The first portion can include a plurality of first end corner panels and a plurality of second end corner panels foldably connected to a respective end panel and a respective side panel. 
     The second portion can include a second suspension panel. The second portion can include a first side panel and a second side panel foldably connected to the second suspension panel. 
     The second portion can include a first end panel configured to fold relative to the second suspension panel. The second portion can include a second end panel foldably connected to the second suspension panel. 
     The second portion can include an opening disposed between the first end panel of the second portion and the second suspension panel. The second portion can include a plurality of first end corner panels and second end corner panels foldably connected to a respective end panel of the second portion and a respective side panel of the second portion. The first end panel of the second portion can be foldably connected to the first and second side panels of the second portion via the first end corner panels of the second portion. 
     The second portion can include a first extension side panel foldably connected to the first side panel of the second portion and a second extension side panel foldably connected to the second side panel of the second portion. The first and second extension side panels can be each twice as wide as the first and second side panels of the second portion, respectively. 
     The second end panel of the second portion can be foldably connected to the second end panel of the first portion. Additionally and/or alternatively, the second end corner panels of the second portion can be foldably connected to the second end corner panels of the first portion. 
     These and other features of the embodiments of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein: 
         FIG.  1    is a perspective view of an embodiment of a suspension packaging insert in accordance with this disclosure, shown being placed in a box; 
         FIG.  2    is a plan view of an embodiment of a blank in accordance with this disclosure; and 
         FIGS.  3 A- 3 H  show the blank of  FIG.  2    being assembled into the suspension packaging insert of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a suspension packaging insert in accordance with the disclosure is shown in  FIG.  1    and is designated generally by reference character  100 . Other embodiments and/or aspects of this disclosure are shown in  FIGS.  2 - 3 H . Certain embodiments described herein can be used to provide suspension packaging using a single, semi-rigid material (e.g., a paper blank). 
     Referring to  FIGS.  1 - 3 H , a suspension package insert  100  can include a suspension pouch  101  configured to receive an article therein. For example, the suspension pouch  101  can be open on one end or both ends to allow insertion of a product into the pouch  101 . The suspension pouch  101  can be formed of at least a first flexible suspension panel  103  and a second suspension panel  105  under panel  103  in  FIG.  1   ). 
     The suspension pouch  101  can include a first sidewall structure  107   a  attached to a first side of the suspension pouch  101 . The suspension pouch  101  can include a second sidewall structure  109  attached to a second side of the suspension pouch  101 . The first and second sidewall structures  107 ,  109  can be configured to stand and suspend the suspension pouch  101  therebetween. 
     The first flexible suspension panel  103  can include a cut matrix  111  defined therein configured to increase the flexibility of the first flexible panel  103 . For example, the first flexible panel  103  can be a paper panel of a blank that would otherwise be semi-rigid. Having a cut matrix (e.g., and array of cuts in any suitable pattern or array) allows the semi-rigid material to flex (e.g., similar to a hammock). 
     In certain embodiments, the second suspension panel  105  can be uncut and/or is otherwise less flexible than the first flexible suspension panel. For example, the second suspension panel  105  can be a flat uncut, continuous sheet (e.g., of paperboard or other suitable material). 
     The suspension package insert  100  can be made of a fiber material. For example, the fiber material can be paper. For example, in certain embodiments, the insert  100  can be made of paperboard, corrugate, and/or any other suitable sheet material. Any other suitable material is contemplated herein. 
     In accordance with at least one aspect of this disclosure, referring to  FIG.  2   , a blank, e.g.,  200 , can be configured to form a suspension package insert as disclosed herein (e.g., insert  100  as described above). In accordance with at least one aspect of this disclosure, a blank  200  for a suspension package insert, e.g.,  100 , can include a first portion  100   a  and a second portion  100   b  foldably connected to the first portion  100   a . The first portion  100   a  and the second portion  100   b  can be configured to be attached (e.g., glued) together to form a suspension pouch  101  and a sidewall assembly (e.g.,  107 ,  109 ) to suspend the suspension pouch  101  (e.g., such that the suspension pouch  101  is only supported at a plurality of its sides by the sidewall assembly as shown in  FIG.  1   ). 
     The first portion  100   a  can include a first flexible suspension panel  103  having a cut matrix  111  (e.g., a die-cut matrix) defined therein to increase a flexibility of the first flexible suspension panel  103 . The characteristics and/or arrangement of cuts can define the rigidity of the first flexible suspension panel  103 . For example, if the cuts of a constant size are spaced out more, the suspension panel  103  will be more rigid. A type, size of cuts (length and/or width), and/or cut shape can be modified to achieve a desired rigidity. In certain embodiments, at shape of the cut matrix  111  can be shaped to match a profile of a product (e.g., bottle shaped for a bottle). The individual cuts can be any suitable shape (e.g., a Y-shape as shown, T-shape, curve shape, etc.). The cut matrix  111  can be formed in the first suspension panel  103  in any suitable manner (e.g., die cutting). 
     The first portion  100   a  can include a first side panel  107   a  and a second side panel  109   a  foldably connected (e.g., at a fold line as shown) to the first flexible suspension panel  103 . The first portion  100   a  can include a first end panel  113   a  and a second end panel  115   a  foldably connected (e.g., at a fold line as shown) to the first flexible suspension panel  103 . The first portion  100   a  can include a plurality of first end corner panels  117   a ,  119   a  and a plurality of second end corner panels  121   a ,  123   a  foldably connected (e.g., at a fold line as shown) to a respective end panel  113   a ,  115   a  and a respective side panel  107   a ,  109   a  (e.g., as shown). 
     The second portion  100   b  can include a second suspension panel  105 . The second portion  100   b  can include a first side panel  107   b  and a second side panel  109   b  foldably connected (e.g., at a fold line as shown) to the second suspension panel  105 . 
     The second portion  100   b  can include a first end panel  113   b  configured to fold relative to the second suspension panel  105 . The second portion  100   b  can include a second end panel  115   b  foldably connected (e.g., at a fold line as shown) to the second suspension panel  105 . 
     The second portion  100   b  can include an opening  125  disposed between the first end panel  113   b  of the second portion  100   b  and the second suspension panel  105 . The opening  125  can form the opening to the pouch  101  when the blank  200  is assembled into a suspension pouch, e.g.,  100  for example. 
     The second portion  100   b  can include a plurality of first end corner panels  117   b ,  119   b  and second end corner panels  121   b ,  123   b  foldably connected (e.g., at a fold line as shown) to a respective end panel  113   b ,  115   b  of the second portion  100   b  and a respective side panel  107   b ,  109   b  of the second portion  100   b  (e.g., as shown). As shown, the first end panel  113   b  of the second portion  100   b  can be foldably connected to the first and second side panels  107   b ,  109   b  of the second portion  100   b  via the first end corner panels  117   b ,  119   b  of the second portion  100   b.    
     The second portion  100   b  can include a first extension side panel  127  foldably connected (e.g., at a fold line as shown) to the first side panel  107   b  of the second portion  100   b . The second portion  100   b  can include a second extension side panel  129  foldably connected (e.g., at a fold line as shown) to the second side panel  109   b  of the second portion  100   b . In certain embodiments, the first and second extension side panels  127 ,  129  can be each twice as wide as the first and second side panels  107   b ,  109   b  of the second portion  100   b , respectively (e.g., which can allow the suspension pouch  101  to be centered between ends of the sidewall structures  107 ,  109 ). Any other suitable dimensions are contemplated herein. 
     The second end panel  115   b  of the second portion  100   b  can be foldably connected (e.g., at a middle fold line  131  as shown) to the second end panel  115   a  of the first portion  100   a . Additionally and/or alternatively, the second end corner panels  121   b ,  123   b  of the second portion  100   b  can be foldably connected (e.g., at a middle fold line  131  as shown) to the second end corner panels  121   a ,  123   a  of the first portion  100   a.    
     The first portion  100   a  and the second portion  100   b  can include a plurality of relief holes  133  placed to allow smooth folding of the corner panels  117   a, b ,  119   a, b ,  121   a, b ,  123   a, b , when forming the blank  200  into a suspension package insert  100 . For example, the relief holes  133  can be placed at locations where there are intersections of fold lines connecting the panels of each portion  100   a ,  100   b . As shown, opening  125  can be defined to perform the same function of relief holes  133  for the corner panels  117   b ,  119   b.    
     Referring to  FIGS.  3 A- 3 H , an embodiment of a process of folding and assembling a suspension packaging insert  100  from a blank  200  is shown. In  FIG.  3 A , the blank is unfolded. As shown in  FIG.  3 B , the first portion  100   a  can be folded the second portion  100   b . The side panels  107   a ,  107   b  and side panels  109   a ,  109   b  can be connected together (e.g., via glue) such that a sandwich is made and the pouch  101  is formed between the first suspension panel  103  and the second suspension panel  105 . Any other suitable panels can be connected at this portion of the process as well (e.g., end panels  113   a, b , and/or  115   a, b ). Opening  125  creates an opening for an article to be inserted into the pouch  101 . 
     As shown in  FIGS.  3 C and  3 D , the end panels  113   a, b , and  115   a, b  can be folded over about 180 degrees. As shown in  FIGS.  3 E and  3 F , the first side panels  107   a, b  and second side panels  109   a, b , can then be folded up (e.g., above the first suspension panel  103  as shown) about 90 degrees. The corner panels  117   a, b ,  119   a, b ,  121   a, b ,  123   a, b , will all be folded inwardly at this point, e.g., as shown in  FIG.  3 F . As shown in  FIGS.  3 F and  3 G , the extension panels  127 ,  129  can be folded down over an outside of the respective side panels  107   b ,  109   b  about 180 degrees to complete the formation of the sidewall structures  107 ,  109 . As shown in  FIG.  3 H , the insert  100  can then be placed in a suitable box with an article inside the pouch  100  (not shown). 
     Certain embodiments, e.g., as shown, can create sidewalls having a double thickness above a bottom panel (e.g., second suspension panel  105 ) which can be mostly rigid. In this regard, the double panel sidewalls will be positioned where the product would contact should the product contact the sidewalls, and thus the product can be more protected. 
     Any suitable adhesive can be applied to any suitable panel disclosed herein for any suitable purpose. Any suitable foldable line types are contemplated herein (e.g., perforated, creased, cut/creased, etc.). While the figures may include a legend indicating the line types of the embodiments of the figures, any other suitable line types for the lines shown in the drawings are contemplated herein. While the figures may include an embodiment of dimensions, any other suitable dimensions and relative sized are contemplated herein. Any other suitable panel arrangement (e.g., more or less panels in any suitable location) is contemplated herein. 
     While embodiments have been described and shown above, any suitable panels and/or other design for a blank to form a device as disclosed above is contemplated herein. Any suitable material for use (e.g., paper, cardboard, plastic board, etc.) and/or one or more combinations thereof are contemplated herein. 
     Embodiments can create an airspace under, over, and on all sides of a product. The pouch  101  can be defined by the suspension panels, and can bend, e.g., like a hammock. Such a system can maintain the article suspended in a box, for example. If the box tilts, the product can stay immobilized in the suspension pouch  101 . A rigidity of one or more of the suspension panels can be selected based on the size, weight, and/or shape of the article to be placed inside. In certain embodiments, a blank can be folded over and glued flat (e.g., as shown in  FIG.  3 B or  3 C and  3 D ), and shipped to a user in a flat, partially assembled state. Any other suitable condition of the blank is contemplated herein. 
     Embodiments can include a folded insert that can form a custom/semi-flexible hammock, cocooning the product, surrounded by air, and enclosed. Embodiments can be used for a ship-receive-reship container and/or can be used for fragile “ship one” items. Any other suitable use is contemplated herein. Certain embodiments can include an all fiber and/or renewable construction. 
     Those having ordinary skill in the art understand that any numerical values disclosed herein can be exact values or can be values within a range. Further, any terms of approximation (e.g., “about”, “approximately”, “around”) used in this disclosure can mean the stated value within a range. For example, in certain embodiments, the range can be within (plus or minus) 20%, or within 10%, or within 5%, or within 2%, or within any other suitable percentage or number as appreciated by those having ordinary skill in the art (e.g., for known tolerance limits or error ranges). 
     The articles “a”, “an”, and “the” as used herein and in the appended claims are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article unless the context clearly indicates otherwise. By way of example, “an element” means one element or more than one element. 
     The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. 
     As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” 
     Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure. 
     The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the subject disclosure includes reference to certain embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.