Patent ID: 12214950

Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

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.1illustrates a perspective view of an exemplary shipping assembly100. The shipping assembly100includes a shipping container102, a bottom cushion support structure112, and a top cushion support structure114. One or more objects110a-110fcan be placed in the shipping container102for shipment.

The shipping container102can be a box. The shipping container102is defined by six surfaces. A first surface (not shown) is a bottom to the box. A second surface104a, a third surface104b, a fourth surface104c, and a fifth surface104ddefine the sides of the box. A top surface106of the shipping container is defined by four top panels108a-108dwhich fold together to create the top surface. Two or more of the top panels108a-108dare fastened together to seal the shipping container102shut. For example, top panels108aand108ccan be folded toward an interior of the shipping container102and then the top panels108band108dcan be folded toward each other and taped together with a packing tape (not shown) by the user.

The shipping container102can be rectangular (as shown). Alternatively, the shipping container102can be square, triangular, or circular. The shipping container102can be paperboard, corrugated board. The corrugated board can be single walled or double walled. The corrugated board can be paper or plastic.

The shipping assembly100includes the bottom cushion support structure112and the top cushion support structure114. The cushion support structures112,114retain the objects110a-110fin a spaced-apart arrangement within the shipping container102and provides shock absorption for the objects110a-110f.

FIG.2Ais a top view an example unfolded bottom cushion support structure112ofFIG.1andFIG.2Bis a side view an example folded bottom cushion support structure ofFIG.1. The unfolded bottom cushion support structure112is a paperboard sheet202which can be folded to form a folded bottom cushion support structure112(e.g., as shown inFIGS.2C-2G). Alternatively, the paperboard sheet202can be a corrugated board sheet. The sheet202is formed into multiple regions206,228a,228b,226a,226b,230a,230b,218a,218b,230c, and230deach separated by perforations244. The regions, when folded at the perforations244, form multiple layers (e.g., first or top layer206, second or middle layer212, and third or bottom layer220). The center region forms the first or top layer206. The top layer206includes multiple apertures208. A pair of sidewall regions228a,228bborder the center region (e.g., layer206) on opposite sides. When folded, the sidewall regions228a,228bwill form outer sidewalls228of the bottom cushion support structure112. A pair of second regions226a,226bborder each of the two sidewall regions228a,228b. When folded, the second regions226a,226bwill form the bottom layer220of the bottom cushion support structure112. A second pair of sidewall regions230a,230bborder the second regions226a,226b. When folded, the second pair of sidewall regions230a,230bwill from a first set of sidewalls228that support the middle layer212and separate the middle layer212from the bottom layer220. A pair of third regions218a,218b, border the second set of sidewall regions230a,230b. When folded the third pair of regions218a,218bwill form the middle layer212of the support structure. A third pair of sidewall regions230c,230dborder the third regions218a,218b. When folded the third pair of sidewall regions will form a second set of sidewalls228that support the middle layer212and separate the middle layer212from the bottom layer220.

In some implementations, one or both of the second and third pairs of sidewall regions230a-230dcan include support tabs236. The support tabs236are sized such that when the bottom cushion support structure is folded, the support tabs236provide additional structural support to the bottom of the top layer206. As shown inFIG.2B, the support tabs236extend between the middle layer212and the top layer206and act as pillars to support the top layer206above the middle layer212.

In some implementations, the second pair of sidewall regions230a,230bcan include interlocking tabs234a-234d. The interlocking tabs234a-234dcan be used to retain the bottom cushion support structure112in the folded configuration, e.g., as shown inFIGS.2B and2G.

FIGS.2C-2Gillustrate the steps of folding the bottom cushion support structure112ofFIG.1. The first paperboard sheet202is folded to form a first set of layers206,212,220. The first set of layers206,212,220includes a first horizontal layer206. The horizontal layer206includes multiple first apertures208. Each of the first apertures208are sized to retain first ends210a-210fof each of the shipping objects110a-110f, respectively.

Each of the first apertures208can be the shape of a circle (e.g., as shown inFIG.2A), a square, or a rectangle. Each of the first apertures208can be the same shape. Alternatively, one or more of first apertures208can be different shapes. Each of the first apertures208are sized to form a friction fit with the respective first ends210a-210fof the shipping objects110a-110f.

The first set of layers206,212,220includes a second horizontal layer212. The second horizontal layer212is below the first horizontal layer206. The second horizontal layer212is spaced apart from the first horizontal layer206by a height216. The second horizontal layer212serves as a floor upon which the objects110sit when place in the apertures208of the bottom cushion support structure112. The second horizontal layer212is a substantially flat surface below the multiple first apertures208. The second horizontal layer212is formed by a pair of second regions218aand218b.

The first set of layers206,212,220includes a third horizontal layer220. The third horizontal layer220is below the second horizontal layer212. The third horizontal layer220is spaced apart from the second horizontal layer212by a distance224. This distance224provides separation between the objects110and the outer packaging of a shipping box in which the objects110are contained. The distance224between layers212and220also absorbs shock and provides some protection for the objects110against impact to the shipping container102. The third horizontal layer220is a substantially flat surface below the second horizontal layer212. The third horizontal layer220is formed by a pair of third regions226aand226b.

The bottom cushion support structure112includes sidewalls coupling each of the three horizontal layers206,212, and220. For instance, a first set of sidewalls228couple the first horizontal layer206to the third horizontal layer220. A second set of sidewalls230couple each of the pair of the third regions226aand226bwhich make up the third horizontal layer220to each of the pair of second regions218aand218bwhich make up the second horizontal layer212.

A height232of the first sidewalls228is greater than the height224. The height224also corresponds to the height of the second sidewalls230. In the illustrated example, the first sidewalls228are sized to maintain the first horizontal layer206spaced apart from the third horizontal layer220and from the second horizontal layer212. The second sidewalls230are sized to maintain the second horizontal layer212spaced apart from the third horizontal layer220.

Bottom cushion support structure112includes a first retaining tab234aon one of the second sidewalls230. The first retaining tab234acreates a friction fit with the opposing/adjoining other second sidewall230to retain the bottom cushion support structure112in a folded form. The first retaining tab234acan engage a second retaining tab234bon the other second sidewall230, substantially similar to the first retaining tab234ato create the friction fit. The first retaining tab234aand the second retaining tab234bform a pair of retaining tabs. Another pair of retaining tabs234cand234dcan be positioned on an opposite side of the second sidewalls230to create another friction fit to retain the bottom cushion support structure112in the folded form.

The second sidewalls230can include two pair of sidewalls230supporting and extending between the second horizontal layer212and the third horizontal layer220. One pair of sidewalls230are located at opposite outer edges (e.g.,238a,238bshown inFIG.2A, respectively, of the second horizontal layer212. The other pair of sidewalls230are located approximately midway between the first pair of sidewalls230. This second pair of sidewalls230are adjacent to each other, when the bottom cushion support structure112is in a folded configuration, and can include retaining tabs234a-234d.

The second pair of sidewalls230can include the pair of retaining tabs234cand234dpreviously described. The pair of retaining tabs234cand234dare positioned on an opposite side of the second sidewalls230from the sidewalls230to create another friction fit to retain the bottom cushion support structure112in the folded form.

In some cases, each sidewall230of both the first pair and the second pair of sidewalls230include at least one of support tabs236extending between the second horizontal layer212and the first horizontal layer206.

Bottom cushion support structure112includes support tabs236. In some examples, the support tabs236are coupled to and extend from one of the pair of second regions218awhich make up the second horizontal layer212. The support tabs236are coupled to and extend from the other of the pair of second regions218bwhich make up the second horizontal layer212. In some examples, the support tabs236are coupled to and extend from the sidewall regions (e.g.,230a-230dshown inFIG.2A) that form the second sidewalls230. In either example, the support tabs236extend between the second horizontal layer212and the first horizontal layer206. The support tabs236support and space the first horizontal layer206from the second horizontal layer212. The height of at least one of the support tabs236, which is the same as height216, can be substantially the same as a distance by which the second horizontal layer212is spaced apart from the first horizontal layer206.

Each of the portions of the bottom cushion support structure112(the first horizontal layer206, the first sidewalls228, the pair of the third regions226aand226b, the second sidewalls230, the pair of second regions218aand218b, and the second pair of sidewalls230) have two common edges246aand246b. Referring toFIG.2A, each of the regions of the bottom cushion support structure112are separated from each other by perforations244. The regions of the unfolded bottom cushion support structure112are folded along the perforations244to form the folded bottom cushion support structure112. The perforations244extend from the common edge246ato the common edge246b.

Referring toFIG.1, the shipping assembly100includes the top cushion support structure114. The top cushion support structure114retains the one or more shipping objects110a-110fin a spaced-apart arrangement within the shipping container102. The top cushion support structure114is generally similar to the bottom cushion support structure112previously described.

FIG.3Ais a top view an example unfolded top cushion support structure114ofFIG.1andFIG.3Bis a side view an example folded top cushion support structure114ofFIG.1. The unfolded top cushion support structure114is a paperboard sheet200which can be folded to form a folded top cushion support structure114(e.g., as shown inFIGS.3C-3G). The paperboard sheet200can be a corrugated board sheet. The sheet200is formed into multiple regions304,322a,322b,320a,320b,322c, and322deach separated by perforations326. The regions, when folded at the perforations326, form multiple layers (e.g., fourth or bottom layer304, and fifth or top layer312) and sidewalls. The center region forms the fourth or bottom layer304of the top cushion support structure114. The bottom layer304includes multiple apertures306. A pair of sidewall regions322a,322bborder the center region (e.g., layer304) on opposite sides. When folded, the sidewall regions322a,322bwill form outer sidewalls318of the top cushion support structure114. A pair of second regions320a,320bborder each of the two sidewall regions322a,322b. When folded, the second regions320a,320bwill form the top layer312of the top cushion support structure114. A second pair of sidewall regions322c,322dborder the second regions320a,320b. When folded, the second pair of sidewall regions322c,322dwill from a second set of sidewalls318that support the top layer312and separate the top layer312from the bottom layer304.

In some implementations, the second pair of sidewall regions322c,322dcan include interlocking tabs324a-324d. The interlocking tabs324a-324dcan be used to retain the top cushion support structure114in the folded configuration, e.g., as shown inFIGS.3B and3G.

FIGS.3C-3Gillustrate the steps of folding the top cushion support structure ofFIG.1. As explained in reference toFIG.3Aabove, the top cushion support structure114includes a second paperboard sheet200folded to form a second set of layers302(shown inFIGS.3D-3G) to retain the one or more shipping objects110a-110fin a spaced-apart arrangement within the shipping container102.

Referring toFIGS.3C-3G, the second set of layers302includes a fourth horizontal layer304. The fourth horizontal layer304includes multiple second apertures306. The second aperture306is sized to retain a second end308aof the first shipping object110a. Likewise, each of the second apertures306are sized to retain second ends308b-308fof each of the objects110b-110f, respectively. Each of the second apertures306are arranged to align with one of the first apertures208of the bottom cushion support structure112when the bottom cushion support structure112the top cushion support structure114are positioned in the shipping container102.

Each of the second apertures306can be the shape of a circle (as shown inFIGS.3A-3G), a square, or a rectangle. Each of the second apertures306can be the same shape. Alternatively, one or more of second apertures306can be different shapes. Each of the second apertures306are sized to form a friction fit with the respective second ends308a-308fof the shipping objects110a-110f.

In some cases, the first apertures208and the second apertures306are the same shape. For example, as shown inFIGS.2G and3G, the shipping object is a circular glass bottle and both the first apertures208and the second apertures306are round. In other cases, the first apertures208and the second apertures306are the different shapes. For example, the first ends210a-210fof the shipping objects110a-110fcan be square (not shown), while the respective second ends308a-308fof the shipping objects110a-110fare circular, such as shown inFIG.3Gwith a cap310acovering an opening (not shown) of the shipping object110afor pouring the contents out of the shipping object110a.

In some cases, the second apertures306are smaller than the first apertures208. For example, a diameter308(shown inFIG.3A) of the second aperture306can be smaller than a diameter242(shown inFIG.2A) of the first aperture208a. Sometimes, the second apertures306are larger than the first apertures208. For example, a diameter308(shown inFIG.3A) of the second aperture306can be larger than the diameter242(shown inFIG.2A) of the first aperture208. Still in other examples, the second apertures306are the same size as the first apertures208. For example, a diameter308(shown inFIG.3A) of the second aperture306is the same as the diameter242(shown inFIG.2A) of the first aperture208.

As shown inFIGS.3D-3G, the second set of layers302includes a fifth horizontal layer312. The fifth horizontal layer312is above fourth horizontal layer304. The fifth horizontal layer312is spaced apart from the fourth horizontal layer304by a height316(shown inFIGS.3E and3G). In some cases, the fifth horizontal layer312includes two separate regions320aand320b.

The top cushion support structure114includes third sidewalls318. The third sidewalls318couple the fourth horizontal layer304to the fifth horizontal layer312. The third sidewalls318are sized to maintain the fourth horizontal layer304spaced apart from the fifth horizontal layer312. In some implementations, the third sidewalls comprise at least four sidewalls. In some cases, all of the third sidewalls318(e.g., sidewall regions322a-322d) are all of substantially equal height.

The top cushion support structure114includes a retaining tab324a. The retaining tab324ais mechanically coupled to the third sidewall318. The retaining tab324acreates a friction fit with the third sidewalls318. When the retaining tab324ais engaged to the middle two sidewalls218, the retaining tab324aretains the top cushion support structure114in a folded form. The top cushion support structure114includes retraining tabs324b-324d, substantially similar to retaining tab324a. Referring toFIGS.3D-3E and3G, retaining tabs324aand324bengage to retain the top cushion support structure114in a folded form. Likewise, retaining tabs324cand324dengage to retain the top cushion support structure114in a folded form.

As shown inFIG.1, a width116and a length118of the bottom cushion support structure112substantially match inner dimensions of the shipping container102. A width120and a length122of the top cushion support structure114substantially match the inner dimensions of the shipping container102.

Each of the portions of the top cushion support structure114(the fourth horizontal layer304, the sidewall portions322a-322dof the third sidewall318, and the two regions320aand320bof the fifth horizontal layer312) have two common edges328aand328b. Referring toFIG.3A, each of the regions of the top cushion support structure114are separated from each other by perforations326. The regions of the unfolded top cushion support structure114are folded along the perforations326to form the folded top cushion support structure114. The perforations326extend from the common edge328ato the common edge328b.

FIGS.2C-2Gillustrate a method of folding the unfolded paperboard sheet bottom cushion support structure112(shown inFIG.2A) into the folded paperboard sheet bottom cushion support structure112(shown inFIG.2G).FIGS.2B-2Dprogressively show the second pair of sidewalls230folded over the pair of second regions218aand218b, which then continue to fold over the second sidewalls230to contact the pair of the third regions226aand226band fully expose the support tabs236. The folding continues until the support tabs236contact the first horizontal layer206and the first sidewalls228contact. Finally, the retaining tab234ais engaged to the retaining tab234band the retaining tab234cis engaged to the retaining tab234dto retain the bottom cushion support structure112in a folded form.

FIGS.3C-3Gillustrate a method of folding the unfolded paperboard sheet top cushion support structure114(shown inFIG.3A) into the folded paperboard sheet top cushion support structure114(shown inFIG.3F).FIGS.3B-3Dprogressively show the first portion322cand a second portion322d(the third sidewall318) folded inward over two separate regions320aand320bof the fifth horizontal layer312, respectively. These are then folded over the third sidewalls318aand318buntil the sidewall region322cand the sidewall region322dcontact (shown inFIGS.3D and3E). Finally, inFIGS.3F and3G, the retaining tab324ais engaged to the retaining tab324band the retaining tab324cis engaged to the retaining tab324dto retain the top cushion support structure114in a folded form.

FIGS.4A-4Iillustrate steps of a method of assembling the shipping assembly ofFIG.1.FIGS.4A-4Iprogressively show the shipping objects110a-110fbeing coupled to the folded bottom cushion support structure112and the folded top cushion support structure114without a shipping container102for illustrative purposes. Referring toFIG.4A, the folded bottom cushion support structure112and the folded top cushion support structure114are shown. The first apertures208are visible on the first horizontal layer206. The second horizontal layer212is visible through the first apertures208.

Referring toFIG.4B, the shipping objects110a-110fare placed in the first apertures208. The shipping objects110a-110fare pressed through the first apertures208until the shipping objects110a-110fcontact the second horizontal layer212.

Referring toFIGS.4C and4D, the second apertures306are placed over the shipping objects110a-110fand couple to the shipping objects110a-110f.

FIG.4Eshows the second ends308eand308fof two shipping objects110eand110finside the top cushion support structure114.FIG.4Fshow the first ends210eand210fof two shipping objects110eand110finside the bottom cushion support structure112.

FIGS.4G-4Jprogressively show the shipping objects110a-110fbeing coupled to the folded bottom cushion support structure112and the folded top cushion support structure114into the shipping container102.FIG.4Gshows the folded bottom cushion support structure112, the folded top cushion support structure114, and the shipping container102prepared for loading the shipping objects110a-110f.FIG.4Hshows the folded bottom cushion support structure112placed inside the shipping container102.FIG.4Ishows the shipping objects110a-110fplaced into the folded bottom cushion support structure112inside the shipping container102.FIG.4Jshows the folded top cushion support structure114placed onto the shipping objects110a-110f(no longer seen) inside the shipping container102.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any invention or on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations of particular inventions. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub combination or variation of a sub-combination.

While this document contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations or embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub combination or variation of a sub combination.