Source: http://www.google.com/patents/US5738216?dq=6,977,809&ei=-AObT5vAOoSgiQL_5qznDg
Timestamp: 2016-10-28 19:06:59
Document Index: 666354767

Matched Legal Cases: ['art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 21', 'art 25', 'art 25', 'art 25', 'art 25', 'art 25']

Patent US5738216 - Adjustable and reusable protective packaging system - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsA reusable shipping container assembly for protecting a plurality of articles during shipping is disclosed. The container assembly includes a semi-rigid rectangular corrugated box having a top wall, a bottom wall and side walls. Within the corrugated box are a plurality of interlocking cushioned "clamps;"...http://www.google.com/patents/US5738216?utm_source=gb-gplus-sharePatent US5738216 - Adjustable and reusable protective packaging systemAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS5738216 APublication typeGrantApplication numberUS 08/805,797Publication dateApr 14, 1998Filing dateFeb 25, 1997Priority dateJun 15, 1995Fee statusPaidAlso published asEP0748747A1, US5641068Publication number08805797, 805797, US 5738216 A, US 5738216A, US-A-5738216, US5738216 A, US5738216AInventorsGary J. WarnerOriginal AssigneeHewlett-Packard CompanyExport CitationBiBTeX, EndNote, RefManPatent Citations (22), Referenced by (39), Classifications (11), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetAdjustable and reusable protective packaging system
US 5738216 AAbstract
A reusable shipping container assembly for protecting a plurality of articles during shipping is disclosed. The container assembly includes a semi-rigid rectangular corrugated box having a top wall, a bottom wall and side walls. Within the corrugated box are a plurality of interlocking cushioned "clamps;" one such clamp per article to be shipped. Each interlocking cushioned clamp contains a convoluted foam set consisting of a pair of rectangular-shaped interlocking convoluted foam cushions. Each pair of convoluted foam cushions holds one of the articles to be shipped. Completing the cushioned clamp and enclosing the convoluted foam cushions is a cushioned sleeve having a rectangular cross section. The cushioned sleeve is adapted to snugly enclose the convoluted foam cushions on four sides and to maintain the interlocking convoluted foam cushions in place during shipping. The plurality of cushioned clamps fits snugly within the corrugated box leaving only a narrow recess between the top wall of the box and the top of the interlocking cushions to provide a region of expansion for compensating odd sized or bulky articles.
1. A reusable shipping container assembly for protecting a plurality of articles during shipping, said reusable shipping container assembly comprising:a semi-rigid rectangular corrugated box providing a top wall, a bottom wall and side walls; and, a plurality, equal in number to said plurality of articles, of interlocking cushioning devices disposed within said semi-rigid rectangular corrugated box, each interlocking cushioning device comprising:a convoluted foam set including a pair of rectangular-shaped interlocking convoluted foam cushions, each interlocking convoluted foam cushion having at least one convoluted side for engaging a convoluted side of its corresponding pair, said pair of rectangular-shaped interlocking convoluted foam cushions for cushioning therebetween one of said plurality of articles, and a rectangularly-shaped cushion sleeve adapted to snugly enclose said convoluted foam set on four sides and to retain said interlocking convoluted foam cushions in place; wherein the shape of each of said interlocking cushioning device relative to the overall dimensions of said semi-rigid rectangular corrugated box being such that when disposed within said semi-rigid rectangular corrugated box only a single recess is produced between the top wall of said semi-rigid rectangular corrugated box and said interlocking cushioning devices thus providing a region of expansion for compensating bulging produced by said articles within said interlocking cushioning devices. 2. A reusable shipping container assembly as defined in claim 1 wherein said plurality of articles is two and said cushioning devices are disposed side-by-side within said semi-rigid rectangular corrugated box such that only said cushion sleeves abut said side walls of said semi-rigid rectangular corrugated box.
3. A reusable shipping container assembly as defined in claim 2 wherein only one side of each of said pair of rectangular-shaped interlocking convoluted foam cushions is convoluted.
4. A reusable shipping container assembly as defined in claim 3 wherein said interlocking cushioning devices are made of polyurethane foam and have the same foam density.
5. A reusable cushioned shipping container as defined in claim 4 wherein each of said interlocking cushioning devices is fabricated from a single block of polyurethane foam.
6. A reusable shipping container assembly for protecting an article during shipping, said container assembly comprising:a semi-rigid rectangular corrugated box providing a top wall, a bottom wall and side walls; a cushioned sleeve for covering at least a substantial portion of the interior of said side walls, said first flexible cushion having a uniform thickness sufficient to provide lateral shock protection to an article placed within said corrugated box; a first convoluted foam set including a pair of rectangular-shaped convoluted foam cushions disposed upon said top and bottom walls of said corrugated box, each cushion having at least one convoluted side facing the interior of said corrugated box for cushioning therebetween said article; a second convoluted foam set including a second pair of rectangular-shaped convoluted foam cushions disposed interior to said cushioned sleeve upon opposing side walls thereof, each cushion having at least one convoluted side facing the interior of said corrugated box for cushioning therebetween said article; said corrugated box having a height relative to the size of said second convoluted foam set such that the force applied by closing said top and bottom walls causes said second convoluted foam set to partially bow to conform to the shape of said article disposed therein and thereby provide lateral and axial support thereto. 7. A reusable shipping container assembly as defined in claim 6 wherein said a cushioned sleeve further comprise a pair of cushioned sleeves positioned adjacent each other such that one contacts a portion of said bottom wall and the other cushioned sleeve is positioned near said top wall.
8. A reusable shipping container assembly as defined in claim 6 wherein said interlocking cushion means are made of polyurethane foam and have the same foam density.
9. A reusable shipping container assembly as defined in claim 7 wherein said first and second convoluted foam sets are each fabricated from a single rectangular block of polyurethane foam.
10. A reusable shipping container assembly as defined in claim 8 wherein said article is in the shape of an hour glass.
This is a divisional of application Ser. No. 08/490,842 filed on Jun. 15, 1995, and which is issued as U.S. Pat. No. 5,641,068 on Jun. 24, 1997.
This invention pertains generally to protective packaging and shipping container systems, and more particularly, to an economical reusable protective packaging system particularly well suited in packing and shipping delicate parts that can be damaged by impact and/or vibration encountered during transit.
In manufacturing finished products some form of packaging is typically needed to handle, store, or transport the manufactured parts and from manufacturing and distribution sites to customer locations, and often, from customer locations back to the manufacturer. In the electronics and related industries, packaging must not only provide a convenient container for shipping or storage, but must also protect against physical damage caused by impact shock and/or vibration. Although specialty containers are sometimes used for products having odd shapes or for ultra-delicate parts, corrugated boxes (sometimes called cardboard cartons) with some form of is internal cushioning or resilient restraints are the basic vehicle primarily used to provide the packaging for the vast majority of manufactured products.
What is also needed is a reusable packaging design that will also accommodate virtually any pad or product shape and has multiple packaging configurations to reduce the variety of different containers and packaging systems to be procured, inventoried and warehoused.
In accordance with the teachings of the present invention, these and other objectives are achieved through a novel shipping container assembly for protecting an article during shipping and storage. The container assembly has an outer semi-rigid corrugated box with a top and bottom wall and a plurality of side walls of depth "d." The box has a plurality of corrugated flaps that are folded and fastened together to form the top and bottom walls. On the interior of the box, in the simplest form of the invention, are three resilient cushions employed in such a manner to produce an integral block of cushion material that protect all sides of an article to be shipped. The first cushion acts as a sleeve or interior wall liner. It covers at least a substantial portion of the corrugated box side walls and forms a hollow center section. The first cushion provides supplementary lateral shock protection to any article placed within the hollow center section thereof. The second and third flexible cushions are made of pliable convoluted foam and fit within the hollow center section of the box. The second cushion rests on the bottom wall of the box and abuts the cushion liner when properly disposed within the box. The third or uppermost cushion has a conforming convoluted bottom surface for mating with the convoluted upper surface of the second cushion. The article to be shipped goes between the convoluted surfaces of the second and third cushions to protect it from shock loads. The present invention seeks to mitigate the drawback of convoluted cushions allowing the article to shift from side to side by clamping the article securely in place. This is the effect of the cushioned sleeve in combination with the pair of mating convoluted cushions. In addition, both second and third cushions have an average thickness <1/2 d so that when disposed within the box, a recess is created between the top of the box and the upper portion of the associated cushion. The provision of a recess advantageously permits the container assembly to accommodate articles of varying shapes and sizes.
FIG. 3 is a cross-sectional view of the container assembly taken along center line 1.1 of FIG. 2 in a completely assembled configuration;
For a better understanding of the subject invention, reference is made to the following description and to the above-described drawings. FIG. 1 depicts one aspect of the present invention in which three component parts are shown in a partially assembled relationship. FIG. 2 depicts all four components of one embodiment of a shipping container assembly 10 in an exploded relationship with a typical part 21 having an irregular contour (shown as a pc board) assembly to be packaged and readied for shipment or storage. Referring to both figures, the container assembly 10 consists of an outer semi-rigid corrugated box 12, a flat flexible cushion liner 15 (acting as an inner sleeve), a bottom (as shown) convoluted foam cushion 20 and an upper mating convoluted foam cushion 22 (shown only in FIG. 2). Corrugated box 12 is a standard rectangular box design having four top flaps, as shown, and four bottom flaps (not shown). The four top flaps form the top wall when properly folded and fastened together, and the four bottom flaps form the bottom wall when properly folded and fastened together. When closed the top and bottom walls seal the contents of box 12 prior to shipment or storage. The wall thickness, glue type, and other design variables of box 12 are all defined by the normal parameters used to determine these items (e.g., burst requirements). Cushion liner 15 is a removable foam cushion that when properly disposed within box 12 covers a major portion of the inside walls thereof. In the preferred embodiment, liner 15 is made by taking a rectangular block or brick-like piece of polyurethane foam and cutting through it along its outer edge to form a single picture frame type of liner having a nominal 2.5 cm to 8.5 cm thickness. This serves variously as lateral protective cushioning for shock absorption of part 21 and as a locator and guide sleeve for inner foam cushions 20 and 22. Cushions 20 and 22 are preferably formed from the same foam block from which liner 15 is made. Cushions 20 and 22 have convoluted foam, "finger-like" surfaces which mate with each other and perform a clamping function when pressed together. As shown in FIG. 2 cushions 20 and 22, being virtually identical in size and shape, can be interchanged from one position to the other. And, being made of a foam material will conform to the outer contour of a wide range of parts to be packaged. (The preferred foam density is typically a function of the weight of part 21 to be shipped, which is customary in the trade.)
The three cushions 15, 20 and 22 when properly assembled in the configuration shown in FIG. 2 within box 12 serve to protect part 21 by providing shock absorption on all sides thereof-not just the top and bottom faces. Cushion liner 15 serves to protect part 21 on four of its six faces, typically left, right, front and rear. Convoluted foam cushion 20 serves as a bed to protect the bottom portion of part 21. Cushion 22 serves to protect the top portion of part 21, and acts as a sort of "clamp," as will be explained, to hold part 21 securely in place. Cushion 22 may be adjustably positioned either in or out of the peripheral constraining walls of cushion liner 15 variously to suit the size and/or shape of the part being packaged. An important aspect of this invention is that cushion 22 in conjunction with cushion liner 15 clamps part 21 securely to the mating convoluted cushion 20. This is due to the frictional forces of the foam fingers being engaged and the frictional forces of the side walls of cushions 20 and 22 against liner 15. The initial clamping force is provided either manually or by an automated packaging machine during the packaging of the part or during a loading operation. As the flaps of corrugated box 12 or other closure means are pressed against the assembly, it clamps cushions 22 and 20 to permanently secure the pad in its cushioned nest until it is opened by a customer or end user. FIG. 3 depicts a cross section of box 12 taken along section 1.1 to illustrate the cushioned nest produced by container assembly 10.
The embodiment heretofore described is intended to be applicable to a wide variety of parts of any practical size--nominally 1 to 40 lbs and less than 75 cm in length. Yet there are admittedly a class of delicate parts that have to be shipped and that are too small to be economically handled by the family of standard sizes heretofore described. To this end there are alternative embodiments that employ the modularity concept and that are designed to provide tooling economy by establishing a range of packaging sizes. Such alternative embodiments would provide packaging for a much larger number of part types and sizes for a particular business, such as in the field of computers and electronic instrument support. Common tooling can be designed and sized to manufacture all of the respective foam set sizes.
FIG. 5 illustrates, in accordance with the present invention, a further application of the basic container assembly heretofore described. Except for corrugated box 12e and pad 21, the container assembly depicted in FIG. 5 is made from a single block of foam material similar to that used to make the foam structure shown in FIG. 2. In FIG. 5 cushion liner 15 is the same liner as that which is shown in FIG. 2 and performs the same function. Convoluted foam set 40, 44 is similar to cushions 20, 22 shown in FIG. 2, except that two additional convoluted foam sets have been made therefrom, namely, 81, 82 and 84, 88. Both foam sets have associated cushion liners 85 and 86 respectively. The two additional convoluted foam sets and their associated liners are cut or stamped from foam set 40, 44 and are situated for packing purposes in the void left in foam cushion 44 after it has been cut. As shown in the figure this structure accommodates a standard size article (depicted as a pc board 21) and two much smaller parts (not shown) situated between two foam sets 81, 82 and 84, 88. The final assembly includes part 21, which is disposed upon cushion 40 and voids 41 and 42 therein; upper cushion 44, which is disposed immediately above part 21 and cushion 40; and foam sets 81, 82 and 84, 88 (and liners 85 and 86) which are disposed partially within the voids created within cushion 44 created during fabrication. The upper part of foam sets 81, 82 and 84, 88 (and liners 85 and 86) occupy a recess left between the top surface of cushion 44 and the top wall of box 12e. (Box 12e has to be slightly extended over the height dimension of box 12 in FIG. 2 to produce a wider recess to accommodate the 2 additional foam sets.) Once all cushions are in place with the parts to be shipped enclosed therein, the flaps of box 12e are closed and sealed to exert a force on upper cushions 82 and 84 for holding the assembly, and the pads to be shipped, in their final configuration. Although only two smaller foam sets are shown in FIG. 5, a greater number would be possible depending upon the dimensions of the added foam sets (81, 82 and 84, 88) relative to the dimensions of foam set 40, 44.
The above illustrated and described preferred embodiments of the invention may be altered in a variety of ways and still remain within the spirit and scope of the invention. Yet another example of the versatility of this invention is shown in FIGS. 6a and 6b. The container assembly shown in these two figures uses the modularity concept in a somewhat different manner to obtain mutual restraint of an hour-glass shaped part 25 in both the vertical (or axial) direction and in lateral directions. FIG. 6a is a partially exploded view of the container assembly shown in FIG. 6b. In this configuration two matching foam sets are employed 33,34 and 35, 36 with matching foam sleeves 16 and 17. The two sleeves 16 and 17 are preferably cut from the same foam block as the two foam sets and form a bifurcated sleeve whose total length equals the combined length of the two. A recess 37 above the upper foam sleeve 17 and the top of corrugated box 12f is reserved for compensating the bulge to be expected when the part 25 is inserted. FIG. 6a is provided to illustrate the preferred manner of assembling the container assembly. The two sleeves 16 and 17 are preferably inserted first, and then lower foam cushion 33 is placed on the bottom of box 12f as illustrated. Next the convoluted foam set 35, 36 is disposed on opposite sides of box 12f as illustrated. Then part 25 is carefully inserted into the empty cavity of the box and upper foam cushion 34 is placed on top of part 25 for clamping the part within box 12f in conjunction with the top flaps of box 12f. The upper foam cushion 34 pushes down on part 25 and the two lateral foam cushions to cause a temporary deformation of the cushions. As can be seen an inward lateral clamping action on the part results as well as the vertical clamping action illustrated in the previous examples. It should be observed that the overall effect is a fully supported part that is cushioned in all directions.
Another major advantage of the subject invention is that when the boxes are too worn to be reused, they may be shredded for recycling. Similarly the foam sets and liners may also be recycled. When they are too worn to be reused, they get shredded by a recycler for use in other commercial products.
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