Patent Publication Number: US-2011049004-A1

Title: Box insert

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a specialized insert to be placed in a generally rectangular box to enable a single product from a set of products with a variety of shapes and sizes to be safely secured within the box. 
     2. Description of the Prior Art 
     Rectangular boxes are advantageous for storing and transporting many different products. Since boxes with a rectangular shape are more economical to produce and easier to stack and transport than boxes of other shapes, products of many different shapes are fit into such a standard box. It is important to properly cushion non-rectangular products within a box, to prevent damage due to pressures which may be applied to the box during transport, such as when the box is dropped or when another box is stacked on top of it. Even when rectangular shaped products are transported in a rectangular box, the box may be somewhat bigger than the product in one or more dimensions, providing opportunities for the product to shift and be damaged during transit. In order to protect an enclosed product from damage due to being bounced around within a moving box, specialized inserts are typically devised to support a product in a safe place within the box, while providing cushioning from blows to the box. 
     Thus, it is well known in the prior art to construct an insert, typically of cardboard or foam or some combination thereof, the exterior sides of which fit snugly against the interior walls of a rectangular box, but the interior walls of which are specially shaped to snugly fit around a particular product to be shipped in the box. Such inserts allow products of many different sizes and shapes to be safely shipped in generally rectangular boxes. Typically, once the product arrives at its destination, the insert is thrown into the garbage. 
     To enable box inserts to be used multiple times, and thus avoid the waste of disposing of an insert after a single use, it is advantageous to utilize an insert that can be used to protect and safely ship products of more than one shape or size. A particular example of this general concept provided the challenge that led to the invention of the insert claimed herein. Electronic equipment used in homes to receive internet service or cable service may need to be upgraded from time to time. In these cases, it is frequently efficient to use a common carrier to deliver a new piece of equipment which can typically be installed by the consumer. It may be useful to return the old piece of equipment which is being replaced to the company which supplied the new equipment, to allow the returned unit to be reconditioned and re-used. Although the box in which the new equipment is delivered is a convenient possible container to ship the old equipment back, the insert designed to safely hold the new equipment is unlikely to also fit the old equipment that needs to be shipped back. 
     The claimed insert is designed to fit one product, such as a new piece of electronic equipment, when the insert is fit into a box with the top side of the insert in an upwards position. By simply flipping the insert over, a different size and shape product, such as the old electronic equipment being replaced, can be securely held on top of the same insert oriented in an inverted position within the same box. An accessory opening in the middle of the insert allows accessories such as a cable or remote control device to be slipped under the insert for transport. 
     By using the insert with its specialized capability of safeguarding and holding products of more than one size and shape within a box, the insert and the box in which it is placed are more likely to be re-used, avoiding the waste and disposal problems associated with using a new insert for each product. Furthermore, using one insert for multiple products results in cost savings as fewer inserts are needed to be manufactured and stored to safely ship the same number of various-shaped products. 
     SUMMARY AND OBJECTS OF THE INVENTION 
     A primary object of the present invention is to provide a box insert which will allow a single product from a set of multiple products of different sizes and shapes to be safely stored and transported within the same box. The insert can be repeatedly used to accommodate more than one shaped product, thus alleviating the waste of inserts which are typically thrown out after a single use. 
     Another object of the present invention is to provide such an insert which can be easily used without training or complicated instructions. Simply by turning the insert upside down, a different product may be safely held in a cushioned position on the top-facing side of the insert to avoid damage during transport within the same box. 
     Another object of the present invention is to provide such an insert which provides a secure area for accessories such as remote control devices and cables to be shipped in a box containing a related product. 
     These objects are achieved by a specialized box insert having a substantially flat, rectangular and rigid base component to which supports are attached to provide multiple different secure areas of different shapes and sizes. Although the rigid component and supports can be made from a variety of different materials, corrugated cardboard is an ideal material from which to economically make a sturdy rigid sheet, while foam is an ideal material from which to economically make supports which will securely hold a product in place while providing cushioning to protect the product. 
     The rigid sheet should fit from side to side within a rectangular box which is sufficiently large to accommodate the largest of the multiple products to be carried in the box. The length and width of the rigid sheet of the insert are beneficially designed to fit snugly within the box when the rigid sheet is parallel to the bottom of the box. In this manner, the rigid sheet is snugly held in a desired place within the box. 
     Supports are strategically placed on the top side of the rigid sheet to accommodate one or more products of a particular size and shape, and are similarly placed on the bottom side of the rigid sheet to accommodate a different product or products. In this manner, the same insert can be used to support and safeguard more than one size and shape of product, depending on whether the insert is placed in the box with the top side facing up or the bottom side facing up. The supports mounted on whichever side of the rigid sheet is closest to the bottom of the box provide cushioning between the bottom of the box and the insert, while the insert holds a product in a secure position between the insert and the top of the box. 
     When the primary product to be supported by the insert is substantially rectangular, supports will typically be placed near opposite ends of the length of the top side of the rigid sheet and at opposite ends of the width of the top side of the rigid sheet, to create an area between the four supports into which the primary product can snugly fit. A different sized alternate product can easily be accommodated by the bottom side of the same insert by placing opposing supports on the bottom side of the rigid sheet to accommodate the length of the alternate product, and placing opposing supports on the bottom side of the rigid sheet to accommodate the width of the alternate product, to create an area matching the size of the alternate product to be supported by the bottom side of the insert. Thus, the insert can be inverted to enable the alternate product to be supported by the bottom side of the insert when it is desirable to use the insert to support the alternate product instead of the primary product. 
     Still other products with other shapes and sizes can be supported by the same insert. Products with different lengths and widths can be supported by the same side of the insert by using a support that contains a base support at one distance from an opposing support and support extensions on either end of the base support that are a different distance from the opposing support. In these cases, the base support is beneficially designed so that the width of the product which has a length extending to the base support snugly fits within the support extensions extending from either end of that base support. 
     Ideally, an accessory opening is formed in the rigid sheet to allow accessories, such as cables or remote control devices, to be inserted through the accessory opening so that the accessories may be carried in the box beneath a product supported by the insert. A variety of shapes and sizes, including octagons, pentagons, circles, and rectangles, are possible for the accessory opening. Yet another example would be an accessory opening with a U-shaped side suitable for receiving a round accessory such as a coiled cable, and an opposite straight edge suitable for receiving a substantially rectangular accessory such as a remote control device. An octagonal accessory opening has proven to be particularly flexible for receiving a variety of accessories, without harming the structural integrity of the insert. Additional openings may be formed in the rigid sheet to provide a receptacle for protuberances such as supporting feet which extend from the bottom of the product supported by the insert. 
     In this manner, the insert of the present invention provides an economical and easy-to-use support which can hold one of multiple products in a secure position within a box during storage and transit, with a single insert providing potential support for multiple products having different sizes and shapes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective top and side view of a box that has been cut away to view an insert according to the present invention. 
         FIG. 2  is a top view of an insert, according to the present invention. 
         FIG. 3  is a bottom view of the insert of  FIG. 2 . 
         FIG. 4  is a top view of the top side of an insert of the present invention, holding a primary product. 
         FIG. 5  is a top view of the top side of the insert shown in  FIG. 4 , shown holding an alternate product. 
         FIG. 6  is a top view of the bottom side of the insert shown in  FIGS. 4 and 5 , which insert has been inverted to hold yet another alternate product. 
         FIG. 7  is a top view of an insert of the present invention on which supports have been attached in a continuous fashion to snugly hold a non-rectangular product. 
         FIG. 8  is a top view of a top side of an insert of the present invention, showing a moveable support positioned in a first position. 
         FIG. 9  is a top view of the top side of the insert shown in  FIG. 8 , with the moveable support positioned in a second position. 
         FIG. 10  is a perspective top and side view of a box that has been cut away to view an insert according to the present invention shown with accessories, having been placed through an accessory opening, being held under the insert. 
     
    
    
     In the drawings, the following legend has been used: 
       10  Insert 
       11  rigid sheet of insert 
       12  top of rigid sheet 
       13  bottom of rigid sheet 
       14  width end of rigid sheet 
       15  length end of rigid sheet 
       16  length of rigid sheet 
       17  width of rigid sheet 
       18  box 
       19  primary product 
       20  length of primary product 
       22  width of primary product 
       24  depth of primary product 
       28  alternate product 
       30  length of alternate product 
       32  width of alternate product 
       35  support 
       36  top support 
       37  bottom support 
       38  depth of support 
       39  top length support 
       40  top width support 
       41  bottom length support 
       42  bottom width support 
       43  distance between opposing supports 
       46  base support 
       47  end of base support 
       48  accessory opening in insert 
       51  scored area surrounding insert opening 
       52  cuts in area surrounding insert opening 
       53  protuberance opening in insert to receive foot of equipment 
       54  fixed support extension 
       56  movable support extension 
       58  distance between opposing support extensions 
       60  hinge on movable support extension 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention concerns a method and apparatus for holding and protecting a product within a rectangular box. As shown in  FIG. 1 , the apparatus consists of a specialized insert  10 , which may be used to secure a product  19  within a box  18 , and which can be reused to secure another product  28  of a different shape and size than the first product  19 . The method consists of simply positioning the insert  10  within the box  18  so that a top side  12  or a bottom side  13  of the insert  10  faces upwards, depending on which side best accommodates the size and shape of the product  19 ,  28  to be held within the box  18 . 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced without these specific details. Some well-known methods and structures have not been set forth in order not to unnecessarily obscure the description of the present invention. 
     The device  10  for holding and protecting a product  19 ,  28  within a box  18  includes a substantially flat, rectangular, and rigid sheet  11  to which supports  35  have been attached, as shown in  FIG. 2 . The rigid sheet  11  can advantageously be made of any substantially rigid material, such as cardboard or other corrugated materials. The supports  35  can advantageously be made of any material which will provide stability and cushioning to a product  19  being held within the box  18 , such as foam. The length  16  and width  17  of the rigid sheet  11  ideally fits snugly within the sides of the box  18  so that the rigid sheet  11  maintains a stationery position within the box  18 , as shown in  FIGS. 1 and 10 , despite possible forces acting on the box  18  during transit or storage. 
     Supports  36  are mounted on the top side  12  of the rigid sheet  11 , as shown in  FIG. 2 , in a manner different than supports  37  are mounted on the bottom side  13  of the rigid sheet  11 , as shown in  FIG. 3 . As a result, products of different sizes and shapes  19 ,  28  can be held between the top of the box  18  and whichever side of the rigid sheet  12 ,  13  is in a upwards position. The configuration of the supports illustrated in the accompanying figures is merely one of many possible such configurations. The configuration of supports  35  will be chosen to fit snugly around a particular product  19  to be held in place on the insert  10 . Opposing length supports  39  can beneficially be mounted on the top side  12  of the rigid sheet  11  near the two length ends  15  of the rigid sheet  11 , as best shown in  FIG. 4 . Opposing width supports  40  can be attached to the top side  12  of the rigid sheet  11  near the two width ends  14 , as also shown in  FIG. 4 . In this manner, an area between the four opposing supports  39 ,  40  is created that corresponds to the length  20  and width  22  of the primary product  19  to be held between the supports  39 ,  40 . 
     Similarly, supports  37  are mounted on the bottom side  13  of the rigid sheet  11  to snugly fit around the length  30  and width  32  of an alternate product  28 , as shown in  FIGS. 3 and 6 . The distance  43  between opposing length supports  41  mounted to the bottom side  13  of the rigid sheet  11  should be approximately the same as the length  30  of the alternate product  28 , and the distance  43  between opposing width supports  42  mounted to the bottom side  13  should be approximately the same as the width  32  of the alternate product  28 . Similarly, the depth  38  of each support  35  is generally equal to or less than the depth  24  of each product  19 ,  28  to be secured by the supports  35 , as best shown in  FIG. 1 . In this manner, a product  19 ,  28  can be held securely between opposing supports  35  which have been positioned on the insert  10  so as to create an area between the opposing supports  35  that snugly accommodates a particular product  19 ,  28 . 
     Still other alternate products  28  can be held securely by the same insert  10  by providing specialized supports  35  with a base  46  and an extension  54 , as shown in  FIGS. 2 and 5 . While a primary product  19  may be fit longitudinally on one side  12 ,  13  of the insert  10  between opposing length supports  39  as shown in  FIG. 4 , an alternate product  28  may be fit securely on top of the same side  12 ,  13  of the insert  10  when oriented perpendicular to the primary product  19 , as shown in  FIG. 5 . As shown in  FIG. 2 , the extensions  54  of opposing supports  36  are advantageously spaced apart from each other a distance  58  corresponding to one dimension  20 ,  22  of primary product  19 , while opposing base supports  46  are mounted with a distance  43  between them so that the base supports  46  fit snugly against sides of alternate product  28 . As best shown in  FIG. 4 , the extensions  54  ideally extend from each end  47  of each base support  46  to provide an area between extensions  54  on the same side of the insert  10  which is suitable for snugly holding an alternate product  28  with width  32 . 
     Further flexibility in securing a variety of shapes and sizes of products  19 ,  28  can be achieved by using supports  35  with a fixed base  46  and a moving support extension  56 , as shown in  FIGS. 8 and 9 . Each moving support extension  56  is connected to a base support  46  by a hinge  60 , as best shown in  FIG. 9 , allowing the support extension  56  to be moved between multiple positions to fit against a variety of shaped products  19 ,  28 . 
     It is possible to configure the various supports  35  in an unlimited number of different ways, to snugly support products of many different sizes and shapes. For example, an irregularly shaped product  28  as shown in  FIG. 7  may best be supported by a continuous insert  36  surrounding the product  28   
     One or more openings  53  may be made in the rigid sheet  11  to accommodate protuberances (not shown), such as feet extending below a product  19 ,  28 , when the main body of the product rests on the insert  10 . 
     An accessory opening  48  may beneficially be formed in the rigid sheet  11  as best shown in  FIGS. 8 and 10 . The shape of the accessory opening  48  advantageously corresponds to the shape of auxiliary items to be carried in the box  18 . For example, if an electronic product  19  is to be secured by the insert  10  within the box  18 , accessories such as a coil of cable or rectangular remote control device may be safely received into the area beneath the insert  10  by placing those items through the accessory opening  48 . In this case, the shape of the accessory opening may ideally be an octagon which will accommodate a circular coil of cable or a rectangular remote control device, as best shown in  FIG. 10 . A scored area  51  surrounding the accessory opening  48  may be created by making straight cuts  52  in that area extending outward from the opening  48 , and by forming creased lines on the exterior of the area  51  opposite the opening  48 . In this manner, the scored area  51  may be easily pushed downward to more conveniently receive accessories through the opening  48 . By advantageously forming the accessory opening  48  in an octagonal shape, the rigid sheet  11  retains sufficient structural integrity to cause the scored area  51  to resume its original position after being pushed down to receive an accessory. 
     Thus, the present invention provides an insert which can be reused multiple times, each time securing a product from a set of products of different sizes and shapes within the same box for storage or transport. The method of securing each product is simply to orient the insert in the appropriate direction to place upwards a side of the insert with supports matching the size and shape of the product to be secured in the box, so that the product can be snugly held on top of the insert by those supports. Supports mounted on the opposite side of the insert may rest against the bottom of the box to provide cushioning and support. 
     Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the invention, various alterations, modifications, or alternative applications of the invention will, no doubt, be suggested to those skilled in the art after having read the preceding disclosure. Accordingly, it is intended that the following claims be interpreted as encompassing all alterations, modifications, or alternative applications as fall within the true spirit and scope of the invention.