Patent Description:
<CIT> describes packaging that has a plain rear panel parallel to the long axis of the bottle. A front panel has two areas having a connecting tongue parallel to the first panel. An upper panel, perpendicular to the long axis of the bottle, is connected to the front and rear panels and has an opening of the same size as the bottle body. An intermediate upper panel, parallel to the upper panel, has a similar sized opening. An intermediate lower panel parallel to the upper panels, has a smaller hole corresponding to the end of the bottle neck. A lower panel parallel to the end of the bottle neck, has an intermediate sized hole.

<CIT> describes packaging that is created starting from small-sized punched cardboard that is refolded and assembled, in order to protect the glass bottles from damage due to impacts or accidental drops during the transport or storage phase. In particular, the packaging consists of two distinct tubular elements that are each assembled starting from a punched cardboard sheet; a first element forms the upper part or so-called cap, while the second, lower element forms the base. Instead of a superimposed double tubular structure, in this improved version, material is removed in unnecessary points and the thickness is reinforced in the points found to be more subject to stress during transport. This leads to the upper tubular section of the cap which is open on the front, presenting only a support flap which permits the formation of support protuberances.

This specification relates to shipping container and packaging cushion assemblies. Embodiments include packaging for a shipping container as defined in claim <NUM>.

In some implementations of the shipping container, each of the first, second, third, fourth, and fifth sets of perforations form lines between a first common edge and a second common edge. The first common edge and the second common edge are each common to the first region, the second regions, and the third regions.

In some implementations, the second sidewall regions include retaining tab structures formed at each of the first common edge and the second common edge.

In some implementations, each of the sixth, seventh, and eight sets of perforations form lines between a third common edge and a fourth common edge. The third common edge and the fourth common edge are each common to the fourth region and the fifth regions.

In some implementations, the fifth sidewall regions include retaining tab structures formed at each of the third common edge and the fourth common edge. Related Implementations of the present disclosure also include a shipping container assembly. The shipping container assembly includes a shipping container, a bottom structure, and a top structure. The bottom structure retains multiple objects in a spaced-apart arrangement within the shipping container. The bottom structure includes a first paperboard sheet folded to form a first set of layers. The first set of layers includes a first horizontal layer including multiple first apertures. Each of the first apertures are sized to retain a first end of one of the objects. The first set of layers includes a second horizontal layer below and spaced apart from the first horizontal layer. The second horizontal layer includes a substantially flat surface below the first apertures. The first set of layers includes a third horizontal layer below and spaced apart from the second horizontal layer. The top structure retains the multiple objects in a spaced-apart arrangement within the shipping container. The top structure includes a second paperboard sheet folded to form a second set of layers. The second set of layers includes a fourth horizontal layer including multiple second apertures. Each of the second apertures are sized to retain a second end of one of the objects. Each of the second apertures are arranged to align with one of the first apertures of the bottom structure when the bottom structure and the top structure are positioned in the shipping container. The second set of layers includes a fifth horizontal layer above and spaced apart from the fourth horizontal layer.

In some implementations, the second apertures are smaller than the first apertures.

In some implementations, the first apertures and the second apertures are the same shape.

In some implementations, the first apertures and the second apertures are a shape of a circle, a square, or a rectangle.

In some implementations, each of the bottom structure, the top structure, and the shipping container are double walled corrugated cardboard.

In some implementations, the bottom structure includes first sidewalls coupling the first horizontal layer to the third horizontal layer, second sidewalls coupling the third horizontal layer to the second horizontal layer, and a height of the first sidewalls is greater than a height of the second sidewalls.

In some implementations, at least one of the second sidewalls include a retaining tab to create a friction fit with another one of the second sidewalls and retain the bottom structure in a folded form.

In some implementations, the first sidewalls are sized to maintain the first horizontal layer spaced apart from the third horizontal layer.

In some implementations, the second sidewalls are sized to maintain the second horizontal layer spaced apart from the third horizontal layer.

In some implementations, at least one of the second sidewalls include at least one support tab extending between the second horizontal layer and the first horizontal layer.

In some implementations, a height of the at least one support tab is substantially the same as a distance by which the second horizontal layer is spaced apart from the first horizontal layer.

In some implementations, the second sidewalls include a first pair of sidewalls and a second pair of sidewalls. The first pair of sidewalls is located at opposite outer edges of the second horizontal layer and the second pair of sidewalls is located approximately midway between the first pair.

In some implementations, the second pair of sidewalls include retaining tabs to create a friction fit between the second pair of sidewalls and retain the bottom structure in a folded form.

In some implementations, each sidewall of both the first pair and the second pair of sidewalls include at least one support tab extending between the second horizontal layer and the first horizontal layer.

In some implementations, the top structure includes third sidewalls coupling the fourth horizontal layer to the fifth horizontal layer. The third sidewalls are sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer.

In some implementations, the third sidewalls include at least four sidewalls of substantially equal height.

In some implementations, at least one of the third sidewalls include a retaining tab to create a friction fit with another one of the third sidewalls and retain the top structure in a folded form.

In some implementations, the first apertures are sized to form a friction fit with the first end of the objects.

In some implementations, the second apertures are sized to form a friction fit with the second end of the objects.

In some implementations, the objects are breakable vessels.

In some implementations, a width and a length of the bottom structure substantially match inner dimensions of the shipping container and a width and a length of the top structure substantially match the inner dimensions of the shipping container.

Further implementations of the present disclosure include a shipping assembly. The shipping assembly includes a shipping container, bottom structure, and a top structure.

The bottom structure retains multiple objects in a spaced-apart arrangement within the shipping container. The bottom structure includes a first paperboard sheet folded to form a first set of layers. The first set of layers includes a first horizontal layer including multiple first apertures. Each first aperture is sized to retain a first end of one of the objects. The first set of layers includes a second horizontal layer below and spaced apart from the first horizontal layer. The second horizontal layer includes a substantially flat surface below the first apertures. The bottom structure includes at least one support tab extending between the second horizontal layer and the first horizontal layer. The bottom structure includes a third horizontal layer below and spaced apart from the second horizontal layer. The bottom structure includes first sidewalls coupling the first horizontal layer to the third horizontal layer. The first sidewalls are sized to maintain the first horizontal layer spaced apart from the third horizontal layer. The bottom structure includes second sidewalls coupling the third horizontal layer to the second horizontal layer. The second sidewalls are sized to maintain the second horizontal layer spaced apart from the third horizontal layer.

The top structure retains the multiple objects in a spaced-apart arrangement within the shipping container. The top structure includes a second paperboard sheet folded to form a second set of layers. The second set of layers includes a fourth horizontal layer including multiple second apertures. Each second aperture is sized to retain a second end of one of the objects. Each second aperture is arranged to align with one of the first apertures of the bottom structure when the bottom structure and the top structure are positioned in the shipping container. The top structure includes a fifth horizontal layer above and spaced apart from the fourth horizontal layer. The top structure includes third sidewalls coupling the fourth horizontal layer to the third horizontal layer. The third sidewalls are sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer.

Particular implementations of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages and address the shortcomings of existing product packaging. Implementations provide a shipping assembly that uses environmental friendly, recyclable, and sustainable materials to economically ship fragile consumer goods directly to consumers. For example, implementations of the present disclosure can be made from recyclable paperboard for lightweight items or corrugated board for heavyweight items. In addition, implementations can be unfolded and reused for different size/shape objects. Implementations provide sufficient shock and vibration absorption or packaging cushion to prevent or minimize damage during transit. For example, implementations are configured to include shock absorbing zones and/or retain objects in a fixed position spaced away from each other and from the sides of a shipping box where the objects could be impacted if the box is mishandled. Implementations can also be manufactured at significantly lower cost than current engineered packaging cushion solutions. For example, implementations of shipping assemblies disclosed herein do not require expensive upfront-tooling setups required for engineered solutions. Instead, implementations can be formed simply press cutting and perforating flat sheets paperboard or corrugated board. In addition, implementations of the packaging can be stored and shipped as flat sheets, thereby, making more efficient use of storage and shipping space for the shipping assembly components themselves. Because the shipping assemblies are formed from flat paperboard, or corrugated board, the apertures used to secure objects can be cut to various sizes to accommodate many different size/shaped objects without the need to retool a manufacturing line and/or replace molding dies.

A distribution channel for sending and receiving shipments generally employs shipping containers and packaging cushions to protect the shipped objects. The objects can include breakable objects. Breakable objects can crack, fracture, or shatter when a threshold force or repetitive threshold force is transmitted to the breakable object. The breakable objects can be glass. Some breakable objects can be filled with liquid. When the threshold force or the repetitive threshold force breakable object cracks, fractures, or shatters, the breakable object cracks, fractures, or shatters and the contents (e.g., liquid, powder, gas) can flow out of the breakable object and contaminate other breakable objects. Additionally, pieces of broken objects or the contents of the broken objects can harm the user.

While most shipping containers for breakable objects are made of recyclable corrugated boards, some of the traditional shipping containers for breakable objects are made of plastic or wood which make recycling shipping containers difficult and costly. If not recycled, those plastic or wood shipping containers may be sent to land-fills directly, end up at land-fills, or are dumped into the ocean where they remain and do not be decomposed, polluting the land or ocean. Additionally, these plastic materials may contaminate water and/or injure fish or other marine animals.

The present disclosure describes a shipping assembly (e.g., packaging) that can be made from flat sheets of paperboard or corrugated board. The paperboard or corrugated board is cut and perforated according to unique patters that permit it to be folded into top and bottom cushion support structures that provide shock absorption for breakable objects placed in a shipping container.

<FIG> illustrates a perspective view of an exemplary shipping assembly <NUM>. The shipping assembly <NUM> includes a shipping container <NUM>, a bottom cushion support structure <NUM>, and a top cushion support structure <NUM>. One or more objects 110a - 110f can be placed in the shipping container <NUM> for shipment.

The shipping container <NUM> can be a box. The shipping container <NUM> is defined by six surfaces. A first surface (not shown) is a bottom to the box. A second surface 104a, a third surface 104b, a fourth surface 104c, and a fifth surface 104d define the sides of the box. A top surface <NUM> of the shipping container is defined by four top panels 108a - 108d which fold together to create the top surface. Two or more of the top panels 108a - 108d are fastened together to seal the shipping container <NUM> shut. For example, top panels 108a and 108c can be folded toward an interior of the shipping container <NUM> and then the top panels 108b and 108d can be folded toward each other and taped together with a packing tape (not shown) by the user.

The shipping container <NUM> can be rectangular (as shown). Alternatively, the shipping container <NUM> can be square, triangular, or circular. The shipping container <NUM> can be paperboard, corrugated board. The corrugated board can be single walled or double walled. The corrugated board can be paper or plastic.

The shipping assembly <NUM> includes the bottom cushion support structure <NUM> and the top cushion support structure <NUM>. The cushion support structures <NUM>, <NUM> retain the objects 110a-110f in a spaced-apart arrangement within the shipping container <NUM> and provides shock absorption for the objects 110a-110f.

<FIG> is a top view an example unfolded bottom cushion support structure <NUM> of <FIG> and <FIG> is a side view an example folded bottom cushion support structure of <FIG>. The unfolded bottom cushion support structure <NUM> is a paperboard sheet <NUM> which can be folded to form a folded bottom cushion support structure <NUM> (e.g., as shown in <FIG>). Alternatively, the paperboard sheet <NUM> can be a corrugated board sheet. The sheet <NUM> is formed into multiple regions <NUM>, 228a, 228b, 226a, 226b, 230a, 230b, 218a, 218b, 230c, and 230d each separated by perforations <NUM>. The regions, when folded at the perforations <NUM>, form multiple layers (e.g., first or top layer <NUM>, second or middle layer <NUM>, and third or bottom layer <NUM>). The center region forms the first or top layer <NUM>. The top layer <NUM> includes multiple apertures <NUM>. A pair of sidewall regions 228a, 228b border the center region (e.g., layer <NUM>) on opposite sides. When folded, the sidewall regions 228a, 228b will form outer sidewalls <NUM> of the bottom cushion support structure <NUM>. A pair of second regions 226a, 226b border each of the two sidewall regions 228a, 228b. When folded, the second regions 226a, 226b will form the bottom layer <NUM> of the bottom cushion support structure <NUM>. A second pair of sidewall regions 230a, 230b border the second regions 226a, 226b. When folded, the second pair of sidewall regions 230a, 230b will from a first set of sidewalls <NUM> that support the middle layer <NUM> and separate the middle layer <NUM> from the bottom layer <NUM>. A pair of third regions 218a, 218b, border the second set of sidewall regions 230a, 230b. When folded the third pair of regions 218a, 218b will form the middle layer <NUM> of the support structure. A third pair of sidewall regions 230c, 230d border the third regions 218a, 218b. When folded the third pair of sidewall regions will form a second set of sidewalls <NUM> that support the middle layer <NUM> and separate the middle layer <NUM> from the bottom layer <NUM>.

In some implementations, one or both of the second and third pairs of sidewall regions 230a-230d can include support tabs <NUM>. The support tabs <NUM> are sized such that when the bottom cushion support structure is folded, the support tabs <NUM> provide additional structural support to the bottom of the top layer <NUM>. As shown in <FIG>, the support tabs <NUM> extend between the middle layer <NUM> and the top layer <NUM> and act as pillars to support the top layer <NUM> above the middle layer <NUM>.

In some implementations, the second pair of sidewall regions 230a, 230b can include interlocking tabs 234a-234d. The interlocking tabs 234a-234d can be used to retain the bottom cushion support structure <NUM> in the folded configuration, e.g., as shown in <FIG> and <FIG>.

<FIG> illustrate the steps of folding the bottom cushion support structure <NUM> of <FIG>. The first paperboard sheet <NUM> is folded to form a first set of layers <NUM>, <NUM>, <NUM>. The first set of layers <NUM>, <NUM>, <NUM> includes a first horizontal layer <NUM>. The horizontal layer <NUM> includes multiple first apertures <NUM>. Each of the first apertures <NUM> are sized to retain first ends 210a - 210f of each of the shipping objects 110a - 110f, respectively.

Each of the first apertures <NUM> can be the shape of a circle (e.g., as shown in <FIG>), a square, or a rectangle. Each of the first apertures <NUM> can be the same shape. Alternatively, one or more of first apertures <NUM> can be different shapes. Each of the first apertures <NUM> are sized to form a friction fit with the respective first ends 210a - 210f of the shipping objects 110a - 110f.

The first set of layers <NUM>, <NUM>, <NUM> includes a second horizontal layer <NUM>. The second horizontal layer <NUM> is below the first horizontal layer <NUM>. The second horizontal layer <NUM> is spaced apart from the first horizontal layer <NUM> by a height <NUM>. The second horizontal layer <NUM> serves as a floor upon which the objects <NUM> sit when place in the apertures <NUM> of the bottom cushion support structure <NUM>. The second horizontal layer <NUM> is a substantially flat surface below the multiple first apertures <NUM>. The second horizontal layer <NUM> is formed by a pair of second regions 218a and 218b.

The first set of layers <NUM>, <NUM>, <NUM> includes a third horizontal layer <NUM>. The third horizontal layer <NUM> is below the second horizontal layer <NUM>. The third horizontal layer <NUM> is spaced apart from the second horizontal layer <NUM> by a distance <NUM>. This distance <NUM> provides separation between the objects <NUM> and the outer packaging of a shipping box in which the objects <NUM> are contained. The distance <NUM> between layers <NUM> and <NUM> also absorbs shock and provides some protection for the objects <NUM> against impact to the shipping container <NUM>. The third horizontal layer <NUM> is a substantially flat surface below the second horizontal layer <NUM>. The third horizontal layer <NUM> is formed by a pair of third regions 226a and 226b.

The bottom cushion support structure <NUM> includes sidewalls coupling each of the three horizontal layers <NUM>, <NUM>, and <NUM>. For instance, a first set of sidewalls <NUM> couple the first horizontal layer <NUM> to the third horizontal layer <NUM>. A second set of sidewalls <NUM> couple each of the pair of the third regions 226a and 226b which make up the third horizontal layer <NUM> to each of the pair of second regions 218a and 218b which make up the second horizontal layer <NUM>.

A height <NUM> of the first sidewalls <NUM> is greater than the height <NUM>. The height <NUM> also corresponds to the height of the second sidewalls <NUM>. In the illustrated example, the first sidewalls <NUM> are sized to maintain the first horizontal layer <NUM> spaced apart from the third horizontal layer <NUM> and from the second horizontal layer <NUM>. The second sidewalls <NUM> are sized to maintain the second horizontal layer <NUM> spaced apart from the third horizontal layer <NUM>.

Bottom cushion support structure <NUM> includes a first retaining tab 234a on one of the second sidewalls <NUM>. The first retaining tab 234a creates a friction fit with the opposing/adjoining other second sidewall <NUM> to retain the bottom cushion support structure <NUM> in a folded form. The first retaining tab 234a can engage a second retaining tab 234b on the other second sidewall <NUM>, substantially similar to the first retaining tab 234a to create the friction fit. The first retaining tab 234a and the second retaining tab 234b form a pair of retaining tabs. Another pair of retaining tabs 234c and 234d can be positioned on an opposite side of the second sidewalls <NUM> to create another friction fit to retain the bottom cushion support structure <NUM> in the folded form.

The second sidewalls <NUM> can include two pair of sidewalls <NUM> supporting and extending between the second horizontal layer <NUM> and the third horizontal layer <NUM>. One pair of sidewalls <NUM> are located at opposite outer edges (e.g., 238a, 238b shown in <FIG>, respectively, of the second horizontal layer <NUM>. The other pair of sidewalls <NUM> are located approximately midway between the first pair of sidewalls <NUM>. This second pair of sidewalls <NUM> are adjacent to each other, when the bottom cushion support structure <NUM> is in a folded configuration, and can include retaining tabs 234a-234d.

The second pair of sidewalls <NUM> can include the pair of retaining tabs 234c and 234d previously described. The pair of retaining tabs 234c and 234d are positioned on an opposite side of the second sidewalls <NUM> from the sidewalls <NUM> to create another friction fit to retain the bottom cushion support structure <NUM> in the folded form.

In some cases, each sidewall <NUM> of both the first pair and the second pair of sidewalls <NUM> include at least one of support tabs <NUM> extending between the second horizontal layer <NUM> and the first horizontal layer <NUM>.

Bottom cushion support structure <NUM> includes support tabs <NUM>. In some examples, the support tabs <NUM> are coupled to and extend from one of the pair of second regions 218a which make up the second horizontal layer <NUM>. The support tabs <NUM> are coupled to and extend from the other of the pair of second regions 218b which make up the second horizontal layer <NUM>. In some examples, the support tabs <NUM> are coupled to and extend from the sidewall regions (e.g., 230a-230d shown in <FIG>) that form the second sidewalls <NUM>. In either example, the support tabs <NUM> extend between the second horizontal layer <NUM> and the first horizontal layer <NUM>. The support tabs <NUM> support and space the first horizontal layer <NUM> from the second horizontal layer <NUM>. The height of at least one of the support tabs <NUM>, which is the same as height <NUM>, can be substantially the same as a distance by which the second horizontal layer <NUM> is spaced apart from the first horizontal layer <NUM>.

Each of the portions of the bottom cushion support structure <NUM> (the first horizontal layer <NUM>, the first sidewalls <NUM>, the pair of the third regions 226a and 226b, the second sidewalls <NUM>, the pair of second regions 218a and 218b, and the second pair of sidewalls <NUM>) have two common edges 246a and 246b. Referring to <FIG>, each of the regions of the bottom cushion support structure <NUM> are separated from each other by perforations <NUM>. The regions of the unfolded bottom cushion support structure <NUM> are folded along the perforations <NUM> to form the folded bottom cushion support structure <NUM>. The perforations <NUM> extend from the common edge 246a to the common edge 246b.

Referring to <FIG>, the shipping assembly <NUM> includes the top cushion support structure <NUM>. The top cushion support structure <NUM> retains the one or more shipping objects 110a - 110f in a spaced-apart arrangement within the shipping container <NUM>. The top cushion support structure <NUM> is generally similar to the bottom cushion support structure <NUM> previously described.

<FIG> is a top view an example unfolded top cushion support structure <NUM> of <FIG> and <FIG> is a side view an example folded top cushion support structure <NUM> of <FIG>. The unfolded top cushion support structure <NUM> is a paperboard sheet <NUM> which can be folded to form a folded top cushion support structure <NUM> (e.g., as shown in <FIG>). The paperboard sheet <NUM> can be a corrugated board sheet. The sheet <NUM> is formed into multiple regions <NUM>, 322a, 322b, 320a, 320b, 322c, and 322d each separated by perforations <NUM>. The regions, when folded at the perforations <NUM>, form multiple layers (e.g., fourth or bottom layer <NUM>, and fifth or top layer <NUM>) and sidewalls. The center region forms the fourth or bottom layer <NUM> of the top cushion support structure <NUM>. The bottom layer <NUM> includes multiple apertures <NUM>. A pair of sidewall regions 322a, 322b border the center region (e.g., layer <NUM>) on opposite sides. When folded, the sidewall regions 322a, 322b will form outer sidewalls <NUM> of the top cushion support structure <NUM>. A pair of second regions 320a, 320b border each of the two sidewall regions 322a, 322b. When folded, the second regions 320a, 320b will form the top layer <NUM> of the top cushion support structure <NUM>. A second pair of sidewall regions 322c, 322d border the second regions 320a, 320b. When folded, the second pair of sidewall regions 322c, 322d will from a second set of sidewalls <NUM> that support the top layer <NUM> and separate the top layer <NUM> from the bottom layer <NUM>.

In some implementations, the second pair of sidewall regions 322c, 322d can include interlocking tabs 324a-324d. The interlocking tabs 324a-324d can be used to retain the top cushion support structure <NUM> in the folded configuration, e.g., as shown in <FIG> and <FIG>.

<FIG> illustrate the steps of folding the top cushion support structure of <FIG>. As explained in reference to <FIG> above, the top cushion support structure <NUM> includes a second paperboard sheet <NUM> folded to form a second set of layers <NUM> (shown in <FIG>) to retain the one or more shipping objects 110a - 110f in a spaced-apart arrangement within the shipping container <NUM>.

Referring to <FIG>, the second set of layers <NUM> includes a fourth horizontal layer <NUM>. The fourth horizontal layer <NUM> includes multiple second apertures <NUM>. The second aperture <NUM> is sized to retain a second end 308a of the first shipping object 110a. Likewise, each of the second apertures <NUM> are sized to retain second ends 308b - 308f of each of the objects 110b - 110f, respectively. Each of the second apertures <NUM> are arranged to align with one of the first apertures <NUM> of the bottom cushion support structure <NUM> when the bottom cushion support structure <NUM> the top cushion support structure <NUM> are positioned in the shipping container <NUM>.

Each of the second apertures <NUM> can be the shape of a circle (as shown in <FIG>), a square, or a rectangle. Each of the second apertures <NUM> can be the same shape. Alternatively, one or more of second apertures <NUM> can be different shapes. Each of the second apertures <NUM> are sized to form a friction fit with the respective second ends 308a - 308f of the shipping objects 110a - 110f.

In some cases, the first apertures <NUM> and the second apertures <NUM> are the same shape. For example, as shown in <FIG> and <FIG>, the shipping object is a circular glass bottle and both the first apertures <NUM> and the second apertures <NUM> are round. In other cases, the first apertures <NUM> and the second apertures <NUM> are the different shapes. For example, the first ends 210a - 210f of the shipping objects 110a - 110f can be square (not shown), while the respective second ends 308a - 308f of the shipping objects 110a - 110f are circular, such as shown in <FIG> with a cap 310a covering an opening (not shown) of the shipping object 110a for pouring the contents out of the shipping object 110a.

In some cases, the second apertures <NUM> are smaller than the first apertures <NUM>. For example, a diameter <NUM> (shown in <FIG>) of the second aperture <NUM> can be smaller than a diameter <NUM> (shown in <FIG>) of the first aperture 208a. Sometimes, the second apertures <NUM> are larger than the first apertures <NUM>. For example, a diameter <NUM> (shown in <FIG>) of the second aperture <NUM> can be larger than the diameter <NUM> (shown in <FIG>) of the first aperture <NUM>. Still in other examples, the second apertures <NUM> are the same size as the first apertures <NUM>. For example, a diameter <NUM> (shown in <FIG>) of the second aperture <NUM> is the same as the diameter <NUM> (shown in <FIG>) of the first aperture <NUM>.

As shown in <FIG>, the second set of layers <NUM> includes a fifth horizontal layer <NUM>. The fifth horizontal layer <NUM> is above fourth horizontal layer <NUM>. The fifth horizontal layer <NUM> is spaced apart from the fourth horizontal layer <NUM> by a height <NUM> (shown in <FIG> and <FIG>). In some cases, the fifth horizontal layer <NUM> includes two separate regions 320a and 320b.

The top cushion support structure <NUM> includes third sidewalls <NUM>. The third sidewalls <NUM> couple the fourth horizontal layer <NUM> to the fifth horizontal layer <NUM>. The third sidewalls <NUM> are sized to maintain the fourth horizontal layer <NUM> spaced apart from the fifth horizontal layer <NUM>. In some implementations, the third sidewalls comprise at least four sidewalls. In some cases, all of the third sidewalls <NUM> (e.g., sidewall regions 322a-322d) are all of substantially equal height.

The top cushion support structure <NUM> includes a retaining tab 324a. The retaining tab 324a is mechanically coupled to the third sidewall <NUM>. The retaining tab 324a creates a friction fit with the third sidewalls <NUM>. When the retaining tab 324a is engaged to the middle two sidewalls <NUM>, the retaining tab 324a retains the top cushion support structure <NUM> in a folded form. The top cushion support structure <NUM> includes retraining tabs 324b - 324d, substantially similar to retaining tab 324a. Referring to <FIG> and <FIG>, retaining tabs 324a and 324b engage to retain the top cushion support structure <NUM> in a folded form. Likewise, retaining tabs 324c and 324d engage to retain the top cushion support structure <NUM> in a folded form.

As shown in <FIG>, a width <NUM> and a length <NUM> of the bottom cushion support structure <NUM> substantially match inner dimensions of the shipping container <NUM>. A width <NUM> and a length <NUM> of the top cushion support structure <NUM> substantially match the inner dimensions of the shipping container <NUM>.

Each of the portions of the top cushion support structure <NUM> (the fourth horizontal layer <NUM>, the sidewall portions 322a-322d of the third sidewall <NUM>, and the two regions 320a and 320b of the fifth horizontal layer <NUM>) have two common edges 328a and 328b. Referring to <FIG>, each of the regions of the top cushion support structure <NUM> are separated from each other by perforations <NUM>. The regions of the unfolded top cushion support structure <NUM> are folded along the perforations <NUM> to form the folded top cushion support structure <NUM>. The perforations <NUM> extend from the common edge 328a to the common edge 328b.

<FIG> illustrate a method of folding the unfolded paperboard sheet bottom cushion support structure <NUM> (shown in <FIG>) into the folded paperboard sheet bottom cushion support structure <NUM> (shown in <FIG>). <FIG> progressively show the second pair of sidewalls <NUM> folded over the pair of second regions 218a and 218b, which then continue to fold over the second sidewalls <NUM> to contact the pair of the third regions 226a and 226b and fully expose the support tabs <NUM>. The folding continues until the support tabs <NUM> contact the first horizontal layer <NUM> and the first sidewalls <NUM> contact. Finally, the retaining tab 234a is engaged to the retaining tab 234b and the retaining tab 234c is engaged to the retaining tab 234d to retain the bottom cushion support structure <NUM> in a folded form.

<FIG> illustrate a method of folding the unfolded paperboard sheet top cushion support structure <NUM> (shown in <FIG>) into the folded paperboard sheet top cushion support structure <NUM> (shown in <FIG>). <FIG> progressively show the first portion 322c and a second portion 322d (the third sidewall <NUM>) folded inward over two separate regions 320a and 320b of the fifth horizontal layer <NUM>, respectively. These are then folded over the third sidewalls 318a and 318b until the sidewall region 322c and the sidewall region 322d contact (shown in <FIG>). Finally, in <FIG>, the retaining tab 324a is engaged to the retaining tab 324b and the retaining tab 324c is engaged to the retaining tab 324d to retain the top cushion support structure <NUM> in a folded form.

<FIG> illustrate steps of a method of assembling the shipping assembly of <FIG>. <FIG> progressively show the shipping objects 110a - 110f being coupled to the folded bottom cushion support structure <NUM> and the folded top cushion support structure <NUM> without a shipping container <NUM> for illustrative purposes. Referring to <FIG>, the folded bottom cushion support structure <NUM> and the folded top cushion support structure <NUM> are shown. The first apertures <NUM> are visible on the first horizontal layer <NUM>. The second horizontal layer <NUM> is visible through the first apertures <NUM>.

Referring to <FIG>, the shipping objects 110a - 110f are placed in the first apertures <NUM>. The shipping objects 110a - 110f are pressed through the first apertures <NUM> until the shipping objects 110a - 110f contact the second horizontal layer <NUM>.

Referring to <FIG>, the second apertures <NUM> are placed over the shipping objects 110a - 110f and couple to the shipping objects 110a - 110f.

<FIG> shows the second ends 308e and 308f of two shipping objects 110e and 110f inside the top cushion support structure <NUM>. <FIG> show the first ends 210e and 210f of two shipping objects 110e and 110f inside the bottom cushion support structure <NUM>.

<FIG> progressively show the shipping objects 110a - 110f being coupled to the folded bottom cushion support structure <NUM> and the folded top cushion support structure <NUM> into the shipping container <NUM>. <FIG> shows the folded bottom cushion support structure <NUM>, the folded top cushion support structure <NUM>, and the shipping container <NUM> prepared for loading the shipping objects 110a - 110f. <FIG> shows the folded bottom cushion support structure <NUM> placed inside the shipping container <NUM>. <FIG> shows the shipping objects 110a - 110f placed into the folded bottom cushion support structure <NUM> inside the shipping container <NUM>. <FIG> shows the folded top cushion support structure <NUM> placed onto the shipping objects 110a - 110f (no longer seen) inside the shipping container <NUM>.

Claim 1:
Packaging for a shipping container comprising:
a first paperboard sheet (<NUM>) configured to be folded into a bottom structure (<NUM>) for objects placed in the shipping container, the first paperboard sheet comprising:
a first region (<NUM>) comprising a plurality of first apertures (<NUM>);
a pair of first sidewall regions (<NUM>), each of the first sidewall regions coupled to an opposite side of the first region and separated therefrom by a first set of perforations (<NUM>);
a pair of second regions (<NUM>), each of the second regions coupled to different ones of the first sidewall regions (<NUM>) and separated therefrom by a second set of perforations (<NUM>);
a pair of second sidewall regions (<NUM>), each of the second sidewall regions (<NUM>) coupled to different ones of the second regions (<NUM>) and separated therefrom by a third set of perforations (<NUM>); and
a pair of third regions (<NUM>), each of the third regions coupled to different ones of the second sidewall regions (<NUM>) and separated therefrom by a fourth set of perforations (<NUM>); and
a pair of third sidewall regions (<NUM>), each of the third sidewall regions coupled to different ones of the third regions (<NUM>) and separated therefrom by a fifth set of perforations (<NUM>); and
a second paperboard sheet (<NUM>) configured to be folded into a top structure (<NUM>) for the objects, the second paperboard sheet comprising:
a fourth region (<NUM>) comprising a plurality of second apertures (<NUM>);
a pair of fourth sidewall regions (322a, b), each of the fourth sidewall regions coupled to an opposite side of the fourth region (<NUM>) and separated therefrom by a sixth set of perforations (<NUM>);
a pair of fifth regions (<NUM>), each of the fifth regions coupled to different ones of the fourth sidewall regions (322a, b) and separated therefrom by a seventh set of perforations (<NUM>); and
a pair of fifth sidewall regions (322c, d), each of the fifth sidewall regions coupled to different ones of the fifth regions (<NUM>) on opposite sides of the fourth region (<NUM>) and separated from the different ones of the fifth regions (<NUM>) by an eighth set of perforations (<NUM>).