Patent ID: 7891494

Claim:
A unitary product cushioning device for supporting shock sensitive products during transport in an exterior container, comprising: a product support region having a platform and a flap on either side of the product support region; a plurality of ribs on each of the flaps and on the product support region, the ribs defining product-supporting cavities therebetween for receiving and supporting the products; for each flap, at least two fold stops between the flap and the product support region to keep the flap spaced from the product support region when the cushioning device is flat, the fold stops defining a fold stop hinge to permit each flap to fold upwards and towards the product support region, the fold stops being angled to facilitate folding of each flap towards the product support region to form a generally “U” shape in the exterior container, wherein the fold stops are constructed and arranged to maintain the shape of the unitary product cushioning device; and wherein the at least two fold stops collectively are of a length less than the length of the flap to define a cutout between the at least two fold stops on either side of the product support region, wherein the cutouts serve to reduce the overall material of the unitary product cushioning device; and wherein the device is made of a flexible, thermoformed material.