Abstract:
A package case includes an upper and a lower case, but only a lower case can be used independently, having air cushion effect. The package case can have a thin upper case, the rear and the bottom portion can be completely or half sealed, and then directly placed in a carton tightly. The package case cannot produce gas explosion or vibration even in case of sudden shock by increasing thickness of material or forming holes when completely or half sealed. Further the package case has various projections, tabs, recesses for space for air flow in case of shock, and the bottom is also formed with various structure to contact or suspend an object to be packed. The contact places are strengthened with reinforcing means in conjunction with various foldable recesses to increase cushion effect for protecting the object packed from damaged.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a package case, particularly to one having four circumferential walls of special structure producing shock-absorbing function, and permitting the package case possess excellent buffering and shock-absorbing effect. 
     Package cases generally have material and structure for different products, from simple things to sophisticated electronic appliances. As for computers and related appliances, Styrofoam package cases are used for packing them with their thick walls, protecting them from shocks during transporting, and sometimes air bubble bags are used for small products instead of Styrofoam. However, Styrofoam package cases have to be made by means of accurate and complete molds owing to special features of Styrofoam, and may produce toxic gas and odor in manufacturing process, presenting potential danger to people and animals in a factory and its neighborhood. Light Styrofoam package cases generally have large dimensions, impossible to fold or insert in each other, resulting in high charge for transporting and storage, unprofitable for makers. 
     In addition, Styrofoam has inferior expansibility to produce easily rupture or rip off, lowering its protective effect, and if worse, losing protective function. When consumers buy a product contained in a Styrofoam package case, the Styrofoam package case becomes useless after the product is taken off, uneasy to treat or discard owing to its largeness. When it is discarded, it may produce toxic gas and odor in case of burning, making up a second public harm to the environment. As for air bubble bags, though they have good shock-absorbing effect, air bubbles may be punctured during transporting by exterior force, losing shock-absorbing function of the flattened portion, forming risk to the product therein in the remaining course of transporting. Provided air bubble bags should receive one time of large shock to damage a large portion of air bubbles, they may give rise to a large vibration to the product packaged therein to be damaged more or less. 
     So, a Patent application with filing number Ser. No. 09/342,199 was filed on Jun. 29, 1999 for a package case, in order to improve disadvantages of conventional package cases, as shown in FIG.  53 . 
     SUMMARY OF THE INVENTION 
     This invention has been devised to offer a package air cushion case, having four circumferential walls provided with stepped projecting continuous edges to let the package case having a complete and effective protective structure, ensuring to keep its outer shape and size stable, hardly changeable, enhancing strength and shock-absorbing, buffering effect. 
     Another feature of the invention is that tenons and mortises or Velcro bands fixed on an upper end of four corners of an lower case to hook or engage with those on corresponding locations of an upper case, permitting the upper and the lower case tightly and completely surrounding a product put therein, together with a cartoon containing the package case to form double coverage of the product. 
     Another feature of the invention is the case made of plastic film by means of injecting molding process to have air cushion function, having lateral and lengthwise ribs in a recess portion in the interior as a structural supplement to absorb forward and rearward and right and left vibrations, and also vertical vibrations, to perfect protective effect. 
     One more feature of the invention is sloping surfaces continually provided on the four circumferential walls to endure and disperse inclining force to the product, increasing protective effect. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     This invention will be better understood by referring to the accompanying drawings, wherein: 
     FIG. 1 is an exploded perspective view of a package case of the present invention. 
     FIG. 2 is an enlarged cross-sectional view of a large inclined surface and a folding recess in the package case of the present invention. 
     FIG. 3 is an enlarged cross-sectional view of a shaped projection in the package case of the present invention. 
     FIG. 4 is a side view of a tenon and a mortise in the package case of the present invention. 
     FIG. 5 is a cross-sectional view of two Velcro bands in the package case of the present invention. 
     FIG. 6 is a perspective view of a first recess in the package case of the present invention. 
     FIG. 7 is a side view of a second wave recess in the package case of the present invention. 
     FIG. 8 is a side view of a third recess in the package case of the present invention. 
     FIG. 9 is a perspective view of tabs on an inner surface of the side wall and two flat plates outside of the side wall in the package case of the present invention. 
     FIG. 10 is a side view of tabs and flat plates in the package case of the present invention, showing them receiving exterior force. 
     FIG. 11 is a perspective view of curved recesses formed in lower outer surface of the side wall of the lower package case of the present invention. 
     FIG. 12 is a perspective view of projecting blocks outside the side walls of a lower package case of the present invention. 
     FIG. 13 is a perspective view of long plate blocks formed to protrude out the side walls of a lower package case of the present invention. 
     FIG. 14 is a perspective view of the structure of a closed bottom of a lower package case of the present invention. 
     FIG. 15 is a partial cross-sectional view of the closed bottom of a lower package case of the present invention. 
     FIG. 16 is a perspective view of a flat long plates formed outside the side walls in a lower package case of the present invention. 
     FIG. 17 is a perspective view of a vertical post formed on an inner surface of the side wall of a lower package case of the present invention. 
     FIG. 18 is a perspective view of inclined side edges of the side walls of an upper package case of the present invention. 
     FIG. 19 is a cross-sectional view of the inclined side edges of the side walls of an upper package case combined with a lower package case of the present invention. 
     FIG. 20 is a cross-sectional view of the inclined side edges of an upper package case and a conventional package case of the present invention. 
     FIG. 21 is a first perspective view of stepless projecting edges of the upper package case and the lower package case of the present invention. 
     FIG. 22 is a first cross-sectional view of stepless projecting edges of the upper package case combined with the lower package case of the present invention. 
     FIG. 23 is a second perspective view of stepless projecting edges of the upper package case and the lower package case of the present invention. 
     FIG. 24 is a second cross-sectional view of stepless projecting edges of the upper package case combined with the lower package case of the present invention. 
     FIG. 25 is a cross-sectional view of left case and right case of the present invention. 
     FIG. 26 is a perspective view of reinforcing projecting-up members in a lower packed case of the present invention. 
     FIG. 27 is a cross-sectional view of the reinforcing projecting-up member in a lower package case of the present invention. 
     FIG. 28 is a perspective view of multi-layer reinforcing projecting-up members in a lower package case of the present invention. 
     FIG. 29 is a cross-sectional view of multi-layer reinforcing projecting-up ribs in a lower package case of the present invention and showing them receiving exterior force. 
     FIG. 30 is a perspective view of shallow round recesses in a lower package case of the present invention. 
     FIG. 31 is a cross-sectional view of the shallow round recesses in a lower package case of the present invention and showing them receiving exterior force. 
     FIG. 32 is a perspective view of many tabs formed on a bottom of a lower package case of the present invention. 
     FIG. 33 is a cross-sectional view of the tabs on the bottom of a lower package case of the present invention. 
     FIG. 34 is a perspective view of large slopes formed in a meddle section of the side walls of a lower package case of the present invention. 
     FIG. 35 is a cross-sectional view of the large slopes in the side walls of a lower package case of the present invention and showing them receiving exterior force. 
     FIG. 36 is a perspective view of flat receiving surfaces with curved recesses in a lower package case of the present invention. 
     FIG. 37 is a perspective view of the flat receiving surfaces provided with convex projections in a lower package case of the present invention. 
     FIG. 38 is a magnified view of the convex projection of each flat receiving surface of the present invention. 
     FIG. 39 is a magnified view of the convex projection of each flat receiving surface of the present invention. 
     FIG. 40 is a perspective view of a first embodiment of a medium lower package case of the present invention. 
     FIG. 41 is a perspective view of a second embodiment of a medium lower package case of the present invention. 
     FIG. 42 is a perspective view of a third embodiment of a medium lower package case of the present invention. 
     FIG. 43 is a cross-sectional view of the medium lower package case packed with an upper package case placed in a carton of the present invention. 
     FIG. 44 is a cross-sectional view of the third embodiment of a lower package case packed with a lower package case placed in a carton of the present invention. 
     FIG. 45 is a perspective view of a first embodiment of a small lower package case of the present invention. 
     FIG. 46 is a perspective view of a second embodiment of a small lower package case of the present invention. 
     FIG. 47 is a perspective view of a third embodiment of a small lower package case of the present invention. 
     FIG. 48 is a cross-sectional view of a small lower package case packed in a carton of the present invention. 
     FIG. 49 is a perspective view of another embodiment of a lower package case of the present invention. 
     FIG. 50 is a partial cross-sectional view of the other embodiment of a lower package case of the present invention. 
     FIG. 51 is a cross-sectional view of a first example of the package case packed in a carton of the present invention. 
     FIG. 52 is a cross-sectional view of a second example of the package case packed in a carton of the present invention. 
     FIG. 53 is an exploded perspective view of a package case of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A preferred embodiment of a package case in the present invention, as shown in FIG. 1, includes an upper case  1  and a lower case  2 . The upper case  1  is made of a tough material (such as plastic, cardboard, EPE, etc.) formed into hollow case shape by means of molding process, having four peripheral walls  11 , four projecting-down corner walls  12  formed at four corners, a large sloped surface  13  formed inside between two projecting corner walls  12 . The projecting corner walls  12  and the large sloped surface  13  all have plural concave and convex surfaces  14  to reinforce the upper case  1 , and a horizontal folding recess  15  extends in the sloped surface  13  as another directional reinforcement. (Force receiving and dispersing is shown in FIG. 2) And a shaped projection  16  is formed inside on a sloped surface on the bottom, defining a shallow recess  17  to function as a vertical buffer (its structure, force receiving dispersing are shown in FIG.  3 ). Further a tenon  18  is provided in a lower end of the four corner walls  12 . But the tenon  18  can be replaced with a Velcro band, as shown in FIGS. 2 and 3. 
     The lower case  2  is made of a tough material (such as plastic, cardboard, EPE, etc.) formed into a preset hollow case, having stepped projecting edges  21  (one or more steps) around an outer lower end of the four peripheral side walls  22  provided with concave and convex surfaces  221  alternately, four projecting up corner walls  222 , a shorter wall  223  formed between every two corner walls  222 . Each corner wall  222  has a mortise  23 , and each shorter wall  223  has plural holes  24  spaced apart, as shown in FIG.  6 . The mortise  23  can be replaced with a Velcro band as shown in FIG. 5 . The recesses  223  can be shaped to have an outer wave recess  241  (its structure, receiving force and force dispersing is shown in FIGS. 7 and 8) or two holes  242  connected with each other. Further, the stepped projecting-out edges  21  may provide with plural tabs  211  to let it have air cushion function to increase shock-absorbing and strengthening the structure, as shown in FIG.  6 . 
     Further, convex projections  25  are provided inside the side walls  22  for contacting an object to be packed to secure it in a lower package case  2 , as shown in FIGS. 9 and 10. The four side walls each have a flat plate  212  projecting thereout and flush with or a little lower than the flat receiving surface  20  so that the flat plates  212  can endure exterior force and deform properly to buffer the force. Thus, the side walls and their upper sides may not directly receive exterior force, nor the objected packed inside may directly receive exterior force. (Receiving and dispersing force is shown in FIGS. 9 and 10.) 
     Next, referring to FIG. 11, a large concave surface  213  may be formed on an outer intermediate portion of the side walls  22 , letting the four corners of the lower case  2  to contact with a carton, and the concave surfaces  213  avoid shocking force from directly transmitted to the four sides of the lower case  2 , augmenting buffer function to reduce harm. (Receiving and dispersing force is shown in FIG. 11.) 
     Next, as shown in FIG. 12, the lower case  2  may be provided with a plurality of projecting square blocks  214  extending out from the side walls  22  or an elongate plate  215  on every side wall  22  (shown in FIG. 13) for absorbing shocks by their elasticity to disfigure first, then by the side walls  22  for a second time, so as to keep the product therein safe. (Receiving and dispersing force is shown in FIGS. 12 and 13. 
     Next, as shown in FIGS. 14 and 15, the lower case  2  may have a sealed bottom wall  216  with plural air holes  2161  to increase air cushion effect. (Force receiving and dispersing is shown in FIG. 15.) 
     Next, as shown in FIGS. 16 and 17, the four side walls  22  of the lower case  2  may have a projecting-out flat elongate members  217  to receive external force to disfigure to stave off direct shock to the product therein. The upper case  1  has the side walls  22  provided with posts  251  for increasing enduring strength against exterior force, and upright posts  252  may be added to the posts  251  to augment the enduring force. (Force receiving and dispersing is shown in FIGS. 16 and 17. 
     As shown in FIG. 18, the upper package case  1  may be provided with an inclined flat long edge  10  on an outer peripheral side to form a large inclined surface when the upper package case is put in a carton as shown in FIG.  19 . Thus the inclined flat long edge  10  can save material much (as shown in a left case in FIG. 20, especially in case of two cases piled up, needing less cost than a conventional case shown in a right side case in FIG.  20 ). In addition, it can save much expense for makers of export products, and lets a package case look pretty and fresh, obtaining various gains. 
     Next, as shown in FIGS. 21 and 22, an upper and a lower case  80  and  81  both have stepless projecting edge side walls, but have flat side walls  801 ,  811 , and flat side walls may have sloped surfaces or projections or recesses  802 ,  812  to function as reinforcement. In addition, the upper case  80  have two opposite sloped upper lengthwise surfaces  803 , lessening the height of the carton when the upper and the lower case are placed in the carton. 
     FIGS. 23 and 24 show an upper and a lower case  82  and  83  having the different structure from those  80  and  81  just described above. They have no projections and recesses but have flat and straight side walls  821 ,  831 , and the upper case  82  has two opposite sloped upper lengthwise surfaces  822  to lessen the height of the carton. 
     Next, FIG. 25 shows a left case  84  and a right case  85  to suit to an object to be packed, having a feature that their upper side wall has a sloped surface  841 ,  851  so as to form a sloped upper surface of a carton to lessen the height of the carton. 
     Next, as shown in FIGS. 26 and 27, the lower case  2  may have reinforcing ribs  262  extending in crossing manner on the bottom wall  261  of the recess portion  26 . And the recess portion  26  and each rib  262  preferably have sloping sides, as shown enlarged in FIG.  27 . Besides, as shown in FIGS. 28 and 29, the height of the bottom plate  261  may be the same as that of the flat receiving surface  20 , forming multi-layer walls  201  to increase shock-absorbing and buffering effect. 
     FIG. 30 shows plural shallow round recesses  263  may be formed on the bottom plate  261  of the recess area  26  instead of the reinforcing ribs  262 , arranged in a parallel or non-parallel condition. Sides of the shallow recesses  263  and the recess area  26  preferably are sloped (forcing receiving and dispersing is shown in FIG.  31 ), and the four corners of the side walls  22  are formed as a little higher corner walls  222 . 
     FIGS. 32,  33  show that the lower case  2  may have the bottom wall  261  provided with many tabs  264  for absorbing vertical vibration, and the recess portion  26  may have a comparatively large sloped surface  265  at four sides, with lateral ribs  266  added on the surfaces  265  to form a strong construction with the side walls  22 . The large sloped surfaces  265  have a recessed flat surface  260  flush with the flat receiving surface  20  to absorb horizontal shock or a little lower than the flat receiving surface  20  to let shock force avoid the packed product and to let the bottom absorb it. FIG. 36 shows side walls  202  of the flat receiving surface  20  may have plural curved recesses  203  to increase vertical receiving force of the flat receiving surface  20 . (Force receiving and dispersing is shown in FIGS. 34 and 35) 
     In addition, the lower case  2  may have projecting ridges  267  or other projecting means formed in outer sides of the recess portion  26  to contact directly a product, as shown in FIGS. 37 and 38. Additionally, as shown in FIG. 39, small grooves  268  may be added at two sides of the projecting ridges  267 , giving buffer and shock-absorbing effect and thus lessen damage to a product laid flat on the bottom wall. 
     Further, a groove  27  or an angled vertical surface  271  may be provided at every corner wall  222 , or an elongate semi-curved groove  272  may be formed along a side of the recess portion  26 , for increasing enduring function of shocks. 
     In addition, the surface of the side wall  22  and the concave and convex surface  221  may be added with rough patterns to increase strength. Further, projecting ridges  267  can be recessed grooves and the small grooves  268  can be small projecting ridges. 
     Further, as shown in FIG. 40, a medium lower package case  3  is formed to have concave surfaces  31  continuously on outer surfaces of the side walls  32  to reinforce them, and a deep curved opening  33  or a shallow recess  34  (shown in FIG. 41) is formed in an intermediate portion of each side wall  32 , and lateral ribs  331  may be added on the deep curved opening  33 . Then the deep curved openings  33  or the shallow recesses  34  may disfigure and absorb a part of shock pr force, and a step recessed bottom portion  35  may absorb the rest shock or force. The medium lower package case can be combined with an upper package case  4  shown in FIG. 43 or with a thin shallow upper package case  5  shown in FIGS. 42 and 44. The thin shallow upper package case  5  has multi-layers of step flat surfaces  51  of different dimensions and plural grooves  52  formed in the surfaces  51  so to protect a product with good effect. 
     Further, as shown in FIG. 45, a small lower package case  6  has plural concave surfaces  62  on outer surfaces of the four side walls  61  to reinforce the concave surfaces  62 . A deep opening  63  may be formed in an intermediate portion of two lengthwise side walls  61 , as shown in FIG.  46 . Moreover, the small lower package case  6  may have four sloped side walls as shown in FIG.  47 . When a product is packed therein, the small case  6  can absorb and disperse shock and force effectively, as shown in FIG. 48, to protect the product from moving. 
     Referring to FIGS. 49 and 50, they provide a lower package case  7  without high side walls. The lower package case  7  provides shallow side walls  71 , and ribs  73  are radially provided around a central hollow recess  72  for being a configuration absorbing any force from all directions. 
     The package case in the invention has the following advantages, as can be understood from the aforesaid description, and referring to FIGS. 51 and 52. 
     1. In order to attain or increase effect produced by air cushion of the present invention, the backs or the bottom a package case are sealed or half sealed with various kinds of plates. Moreover, the package case itself directly and tightly contact the inside surface of a carton, or air cushion is made by directly blowing in air. 
     2. The whole package case can have its wall made thicker or be provided with holes in order to ensure the invention sealed or half sealed not to explore or vibrate strongly by sudden shock, and formed with projections, recesses of various kinds to have enough hollow space for receiving shock and for air to circulate. 
     3. Its bottom is provided with various structures for a product to contact or suspend, ribs are made at places to contact to reinforce shock-absorbing, in addition to many folding recesses, enabling the package case of the invention strengthened in the whole structure to keep a product packed therein safe. 
     4. The recess folding extending across the large sloped surface of the upper case provides strengthening structure in other directions, staving off exterior force against the package case to reach a product packed therein, capable to disperse external force to protect the product. 
     5. The projecting base on the interior of the upper case is provided with a shallow recess so that the upper end of the projecting base have not only an original enduring force, but increases vertical shock enduring force, resulting in multi-layer buffers effect. 
     6. The projection edges of the four circumferential walls of the lower case keeps the lower case configuration and size stable, increasing suffering force against shocks. 
     13. The ribs crisscrossing on the bottom wall or the shallow recesses of the recess portion of the lower case may strengthen absorbing and dispersing of shocks received, hampering shocks from directly reach a product therein. 
     25. With the configuration of the sloped surfaces of the cartons piled with opposite sloped surfaces are able to reduce the dimensions of container when the goods are transported by container ship so as to decrease the costs of the transportation. 
     26. Except the side walls with concave and convex surface of the upper and lower package cases, they also can be formed in smooth and straight so as to decrease the costs of molds. 
     27. Except the upper package cases with sloped surfaces, a left and a right package cases or a front and a rear package cases with sloped surfaces also can be formed to hold the goods and achieve the effect as above descriptions.