Patent Publication Number: US-2009218248-A1

Title: Apparatus, system, and method for protecting a product

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to protecting a product and more particularly relates to protecting a packaged product. 
     2. Description of the Related Art 
     Products such as electronic devices are typically packaged for shipment. A product may be surrounded by cushioning materials and placed inside a container. The cushioning materials may protect the product during shipment. 
     The cushioning materials typically include a plurality of discrete cushions. For example, electronic device may be protected by two cushions. A first cushion may protect an east side of the product, a portion of a north side of the product, a portion of a south side of the product, a portion of a top of the product, and a portion of the bottom of the product. In addition, a second cushion may protect a west side a product, a portion of the north side of the product, a portion of the south side of the product, and a portion of the bottom of the product. As used herein, north, south, east, and west are used to refer to sides of a product, and do not refer to geophysical directions. 
     Alternatively, the first cushion may be configured as an open box. The product may be placed within the first cushion. In addition, the second cushion configured as a lid may be placed over the product to complete the protection of the product. 
     Unfortunately, using multiple cushions to protect the product increases the difficulty of stocking and using protective material. For example, if two cushions are used for a hard disk drive, each cushion must be ordered, stocked, and placed in production. 
     SUMMARY OF THE INVENTION 
     From the foregoing discussion, there is a need for an apparatus, system, and method that protect a product. Beneficially, such an apparatus, system, and method would protect the product on all sides using a single cushion. 
     The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available product protection methods. Accordingly, the present invention has been developed to provide an apparatus, system, and method for protecting a product that overcome many or all of the above-discussed shortcomings in the art. 
     The apparatus to protect a product is provided with a single planar foam sheet. The foam sheet includes a center member, a north member, a south member, an east member, and a west member. 
     The center member is in physical communication with a bottom of the product. The north member is in communication with the center member and comprises a north orifice. In addition, the north member is partially separated from the center member by a north proximal cut along a lower side of the sheet. The north member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a north side of the product. 
     The south member is in communication with the center member and comprises a south orifice. In addition, the south member is partially separated from the center member by a south proximal cut along the lower side of the sheet. The south member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a south side of the product. 
     The east member is in communication with the center member and comprises an east orifice. In addition, the east member is partially separated from the center member by an east proximal cut along the lower side of the sheet. The east member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with an east side of the product. The east member further comprises an east distal cut that partially separates an east distal edge from the east member and permits the east distal edge to pivot toward the center member such that the east distal edge is in physical communication with a top of the product when folded. 
     The west member is in communication with the center member and comprises a west orifice. In addition, the west member is partially separated from the center member by a west proximal cut along the lower side of the sheet. The west member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a west side of the product. The west member further comprises a west distal cut that partially separates a west distal edge from the west member and permits the west distal edge to pivot toward the center member such that the west distal edge is in physical communication with the top of the product when folded. 
     A system of the present invention. The system may be embodied in a packaging system. In particular, the system, in one embodiment, includes a container and a foam cushion. The foam cushion is fabricated from a single planar sheet and includes a center member, a north member, a south member, and east member, and a west member. 
     The center member is in physical communication with a bottom of the product. The north member is in communication with the center member and comprises a north orifice. In addition, the north member is partially separated from the center member by a north proximal cut along a lower side of the sheet. The north member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a north side of the product. 
     The south member is in communication with the center member and comprises a south orifice. In addition, the south member is partially separated from the center member by a south proximal cut along the lower side of the sheet. The south member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a south side of the product. 
     The east member is in communication with the center member and comprises an east orifice. In addition, the east member is partially separated from the center member by an east proximal cut along the lower side of the sheet. The east member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with an east side of the product. The east member further comprises an east distal cut that partially separates an east distal edge from the east member and permits the east distal edge to pivot toward the center member such that the east distal edge is in physical communication with a top of the product when folded. 
     The west member is in communication with the center member and comprises a west orifice. In addition, the west member is partially separated from the center member by a west proximal cut along the lower side of the sheet. The west member is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a west side of the product. The west member further comprises a west distal cut that partially separates a west distal edge from the west member and permits the west distal edge to pivot toward the center member such that the west distal edge is in physical communication with the top of the product when folded. The foam cushion and product are disposed within the container. 
     A method of the present invention is also presented for protecting a product. The method in the disclosed embodiments substantially includes the steps to carry out the functions presented above with respect to the operation of the described apparatus and system. 
     A stamp stamps a center member from a polyethylene sheet, the center member is in physical communication with a bottom of the product, a north member in communication with the center member, a south member in communication with the center member, an east member in communication with the center member, and a west member in communication with the center member. In addition, the stamp stamps a north orifice in the north member, a south orifice in the south member, an east orifice in the east member, and a west orifice in the west member. 
     The stamp further stamps a north proximal cut along a lower side of the sheet wherein the north member is partially separated from the center member and is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a north side of the product, a south proximal cut along the lower side of the sheet wherein the south member is partially separated from the center member and is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a south side of the product, an east proximal cut along the lower side of the sheet wherein the east member is partially separated from the center member and is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with an east side of the product, and a west proximal cut along the lower side of the sheet wherein the west member is partially separated from the center member and is configured to pivot upward to form at least a ninety degree angle to the center member and physically communicate with a west side of the product. In addition, the stamp stamps an east distal cut in the east member that partially separates an east distal edge from the east member and permits the east distal edge to pivot toward the center member such that the east distal edge is in physical communication with a top of the product when folded and a west distal cut in the west member that partially separates a west distal edge from the west member and permits the west distal edge to pivot toward the center member such that the west distal edge is in physical communication with the top of the product when folded. A packaging device and/or production worker may fold the north, south, east, and west members about the product to protect the product in a container. 
     References throughout this specification to features, advantages, or similar language do not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. 
     The present invention protects a product on all sides using a single cushion. In addition, the present invention may reduce the number of cushions required to protect a product. These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1  is a top view drawing illustrating one embodiment of a protection apparatus in accordance with the present invention; 
         FIG. 2  is a top view drawing illustrating one embodiment of an alternate protection apparatus of the present invention; 
         FIG. 3  is a top view drawing illustrating one alternate embodiment of a protection apparatus of the present invention; 
         FIG. 4  is a perspective drawing illustrating one embodiment of a protected product of the present invention; 
         FIG. 5  is a perspective drawing illustrating one embodiment of a protected product in a carton of the present invention; and 
         FIG. 6  is a schematic flow chart diagram illustrating one embodiment of a protection method of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
       FIG. 1  is a schematic block diagram illustrating one embodiment of a protection apparatus  100  in accordance with the present invention. The apparatus  100  may be stamped from a single planar foam sheet. The foam sheet may be polyethylene foam cushion. The foam sheet includes a center member  105 , a north member  110 , a south member  115 , an east member  120 , and a west member  125 . 
     The center member  105  is in physical communication with a bottom of the product (not shown). The north member  110  is in communication with the center member  105  and comprises a north orifice  130 . In addition, the north member  110  is partially separated from the center member  105  by a north proximal cut  150  along a lower side of the sheet. The north member  110  is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with a north side of the product. 
     The south member  115  is in communication with the center member  105  and comprises a south orifice  135 . In addition, the south member  115  is partially separated from the center member  105  by a south proximal cut  155  along the lower side of the sheet. The south member  115  is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with a south side of the product. 
     The east member  120  is in communication with the center member  105  and comprises an east orifice  140 . In addition, the east member  120  is partially separated from the center member by an east proximal cut  160  along the lower side of the sheet. The east member  120  is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with an east side of the product. The east member  120  further comprises an east distal cut  170  that partially separates an east distal edge  180  from the east member  120  and permits the east distal edge  180  to pivot toward the center member  105  such that the east distal edge  180  is in physical communication with a top of the product when folded. 
     The west member  125  is in communication with the center member  105  and comprises a west orifice  140 . In addition, the west member  140  is partially separated from the center member  105  by a west proximal cut  165  along the lower side of the sheet. The west member  125  is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with a west side of the product. The west member  125  further comprises a west distal cut  175  that partially separates a west distal edge  185  from the west member  125  and permits the west distal edge  185  to pivot toward the center member  105  such that the west distal edge  185  is in physical communication with the top of the product when folded. 
     In one embodiment, the north orifice  130 , south orifice  135 , east orifice  140 , and west orifice  145  may relieve pressure on the product. For example, a carton may transfer pressure to the apparatus  100 , and the apparatus  100  may transfer the pressure to the product. The orifices  130 ,  135 ,  140 ,  145  may reduce the transfer of pressure to the product. 
     In a certain embodiment, the north orifice  130 , south orifice  135 , east orifice  140 , and west orifice  145  each are cut from an area in the range of fifteen percent to forty percent (15%-40%) of an area of the north member  110 , south member  115 , east member  120 , and west member  125  respectively. Alternatively, the north orifice  130 , south orifice  135 , east orifice  140 , and west orifice  145  may be configured so that the north member  110 , south member  115 , east member  120 , and west member  125  contact in the range of fifteen to eighty-five percent (15%-85%) of the north side of the product, the south side of the product, the east side of the product, and the west side of the product respectively. 
     The product may be placed upon the center member  105  and the north member  110 , south member  115 , east member  120 , and west member  125  folded around the product as will be described hereafter. The apparatus  100  thus protects the product on all sides, while the apparatus  100  may be ordered, stocked, transported, and employed as a single unit. 
     In one embodiment, a distance from the east proximal cut  160  to the east distal cut  170  is substantially equivalent to a height of the east side of the product and a distance from the west proximal cut  165  to the west distal cut  175  is substantially equivalent to a height of the west side of the product. As used herein, substantially equivalence is within plus or minus five percent (±5%). 
       FIG. 2  is a schematic block diagram illustrating one embodiment of an alternate protection apparatus  200  of the present invention. The apparatus  200  includes the center member  105 , north member  110 , south member  115 , east member  120 , west member  125 , north orifice  130 , south orifice  135 , east orifice  140 , west orifice  145 , north proximal cut  150 , south proximal cut  155 , east proximal cut  160 , west proximal cut  165 , east distal cut  170 , west distal cut  175 , east distal edge  180 , and west distal edge  185  of  FIG. 1 . 
     The apparatus  200  further includes a center orifice  205 . In one embodiment, the center orifice  205  is cut from an area in the range of fifteen percent to forty percent (15%-40%) of an area of the center member  105 . Alternatively, the center orifice  205  may be configured so that the center member  105  contacts in the range of fifteen to eighty-five percent (15%-85%) of the bottom of the product. 
     In the depicted embodiment, the north orifice  130 , south orifice  135 , east orifice  140 , and west orifice  145  each extend outward from the center member  105 . For example, the north orifice  130 , south orifice  135 , east orifice  140 , and west orifice  145  may each begin at the north proximal cut  150 , the south proximal cut  155 , the east proximal cut  160 , and the west proximal cut  165  respectively. 
       FIG. 3  is a schematic block diagram illustrating one alternate embodiment of a protection apparatus  300  of the present invention. The apparatus  300  includes the center member  105 , north member  110 , south member  115 , east member  120 , west member  125 , north orifice  130 , south orifice  135 , east orifice  140 , west orifice  145 , north proximal cut  150 , south proximal cut  155 , east proximal cut  160 , west proximal cut  165 , east distal cut  170 , west distal cut  175 , east distal edge  180 , and west distal edge  185  of  FIG. 2 . 
     In the depicted embodiment, the east distal cut  170  comprises a north east distal cut  170   a  and a south east distal cut  170   b  and the east member  120  further comprises an east divisional cut  305  that separates the east distal edge  180  from the east member  120  between the north east distal cut  170   a  and the south east distal cut  170   b.    
     In addition, the west distal cut  175  is depicted comprising a north west distal cut  175   a  and a south west distal cut  175   b  and the west member  125  further comprises a west divisional cut  310  that separates the west distal edge  185  from the west member  120  between the north west distal cut  175   a  and the south west distal cut  175   b.    
     In the depicted embodiment, the east distal edge  180  comprises a south east edge pivot  315   b  extending east from the south east distal cut  170   b , a north east edge pivot  315   a  extending east from the north distal cut  170   a , and an east cross member  325  physically communicating between the south east edge pivot  315   b  and the north east edge pivot  315   a , wherein the east divisional cut  305  extends east from a terminus of the south east distal cut  170   b  to the east cross member  325 , north along the east cross member  325 , and west to a terminus of the north east distal cut  170   a.    
     In addition, the west distal edge  185  comprises a south west edge pivot  320   b  extending west from the south west distal cut  175   b , a north west edge pivot  320   a  extending west from the north distal cut  175   a , and a west cross member  330  physically communicating between the south west edge pivot  320   b  and the north west edge pivot  320   a , wherein the west divisional cut  310  extends west from a terminus of the south west distal cut  175   b  to the west cross member  330 , north along the west cross member  330 , and west to a terminus of the north west distal cut  175   a.    
     In the depicted embodiment, the east member  120  further comprises a north east post  335   a  disposed between the east orifice  140  and the east divisional cut  305  and a south east post  335   b  disposed between the east orifice  140  and the east divisional cut  305 , wherein a distal end of the north east post  335   a  and a distal end of the south east post  335   b  are each coplanar with a face of the east distal edge  180  when folded. 
     In addition, the west member  125  further comprises a north west post  340   a  disposed between the west orifice  145  and the west divisional cut  310  and a south west post  340   b  disposed between the west orifice  140  and the west divisional cut  310 , wherein a distal end of the north west post  340   a  and a distal end of the south west post  340   b  are each coplanar with a face of the west distal edge  185  when folded. 
       FIG. 4  is a perspective drawing illustrating one embodiment of a protected product  400  of the present invention. A product  405  is depicted surrounded by the folded apparatus  300  of  FIG. 3 . The center member  105 , north member  110 , south member  115 , west member  125 , north east edge pivot  315   a , south east edge pivot  315   b , north east post  335   a , south east post  335   b , north west edge pivot  320   a , south west edge pivot  320   b , north west post  340   a , south west post  340   b , east cross member  325 , and west cross member  330  of  FIG. 3  are shown positioned around the product  405 . 
     The apparatus  300  folds to surround the product  405 . The product  405  is protected on all sides by the apparatus  300 . 
       FIG. 5  is a perspective drawing illustrating one embodiment of a protected product in a carton  500  of the present invention. The protected product  400  of  FIG. 4  is shown within a carton  505 . In one embodiment, the apparatus  300  is placed within the carton  505 , the product  405  is placed within the carton on the apparatus  300 , and the apparatus  300  is folded about the product  405 . Alternatively, the apparatus  300  may be folded about the product  405  and the apparatus  300 /product  405  placed within the carton  505 . 
     The product  405  and apparatus  300  may be positioned within the carton  505  by an automated packaging device. Alternatively, a production worker may place the product  405  and apparatus  300  within the carton  505 . 
     The schematic flow chart diagrams that follow are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. The format and symbols employed are provided to explain the logical steps of the method and do not limit the scope of the method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown. For example, a plurality of stamping operations may be performed concurrently. 
       FIG. 6  is a schematic flow chart diagram illustrating one embodiment of a protection method  600  of the present invention. The method  600  substantially includes the steps to carry out the functions presented above with respect to the operation of the described apparatus and protected products of  FIGS. 1-5 . The described stamping operations may be carried out by one or more stamps, although for simplicity a single stamp is referenced. 
     The method  600  begins and a stamp stamps  605  the center member  105 , the north member  110 , the south member  115 , the east member  120 , and the west member  125  from a polyethylene sheet. The center member  105  is in physical communication with the bottom of the product  405 . The north member  110 , south member  115 , east member  120 , and west member  125  are in communication with the center member  105  and form a single apparatus  100 ,  200 ,  300 . 
     In addition, the stamp stamps  610  the north orifice  130  in the north member  110 , the south orifice  135  in the south member  115 , the east orifice  140  in the east member  120 , and the west orifice  145  in the west member  125 . In one embodiment, the stamp stamps  615  the center orifice  205  in the center member  105 . 
     The stamp further stamps  620  the north proximal cut  150  along the lower side of the sheet. The north member  110  is partially separated from the center member  105  and is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with the north side of the product  405 . The stamp further stamps  620  the south proximal cut  155  along the lower side of the sheet. The south member  115  is partially separated from the center member  105  and is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with the south side of the product  405 . 
     In addition, the stamp stamps  620  the east proximal cut  160  along the lower side of the sheet. The east member  120  is partially separated from the center member  105  and is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with the east side of the product  405 . The stamp further stamps  620  the west proximal cut  165  along the lower side of the sheet. The west member  125  is partially separated from the center member  105  and is configured to pivot upward to form at least a ninety degree angle to the center member  105  and physically communicate with the west side of the product  405 . 
     In one embodiment, the stamp stamps  625  the east distal cut  170  in the east member  120  that partially separates the east distal edge  180  from the east member  120  and permits the east distal edge  180  to pivot toward the center member  105  such that the east distal edge  180  is in physical communication with the top of the product  400  when folded. The stamp further stamps  625  the west distal cut  175  in the west member  125  that partially separates the west distal edge  185  from the west member  125  and permits the west distal edge  180  to pivot toward the center member  105  such that the west distal edge  185  is in physical communication with the top of the product  405  when folded. 
     In one embodiment, the east distal cut  170  comprises a north east distal cut  170   a  and a south east distal cut  170   b . The west distal cut  175  may comprise a north west distal cut  175   a  and a south west distal cut  175   b.    
     The stamp may stamp  630  posts  335 ,  340  and pivots  315 ,  320  by stamping the east divisional cut  305  that separates the east distal edge  180  from the east member  120  between the north east distal cut  170   a  and the south east distal cut  170   b . In addition, the stamp may stamp  630  the west divisional cut  310  that separates the west distal edge  185  from the west member  125  between the north west distal cut  175   a  and the south west distal cut  175   b.    
     The east distal edge  180  may comprise the south east edge pivot  315   b  extending east from the south east distal cut  170   b , the north east edge pivot  315   a  extending east from the north distal cut  170   a , and the east cross member  325  physically communicating between the south east edge pivot  315   b  and the north east edge pivot  315   a . The east divisional cut  305  extends east from a terminus of the south east distal cut  170   b  to the east cross member  325 , north along the east cross member  325 , and west to a terminus of the north east distal cut  170   a.    
     The east member  120  may further comprise a north east post  335   a  disposed between the east orifice  140  and the east divisional cut  305  and a south east post  335   b  disposed between the east orifice  140  and the east divisional cut  305 . The distal end of the north east post  335   a  and the distal end of the south east post  335   b  are each coplanar with a face of the east distal edge  180  when folded. 
     The west distal edge  185  may comprise the south west edge pivot  320   b  extending west from the south west distal cut  175   b , the north west edge pivot  320   a  extending west from the north distal cut  175   a , and the west cross member  330  physically communicating between the south west edge pivot  320   b  and the north west edge pivot  320   a . The west divisional cut  310  may extend west from a terminus of the south west distal cut  175   b  to the west cross member  330 , north along the west cross member  330 , and west to a terminus of the north west distal cut  175   a.    
     The west member  125  may further comprise the north west post  340   a  disposed between the west orifice  145  and the west divisional cut  310  and the south west post  340   b  disposed between the west orifice  140  and the west divisional cut  310 . The distal end of the north west post  340   a  and the distal end of the south west post  340   b  may each be coplanar with a face of the west distal edge  185  when folded. A packaging device and/or production worker may fold  635  the north member  110 , south member  115 , east member  120 , and west member  125  about the product  405  to protect the product  405  in the container  505 . 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.