PATENT DOCUMENT

Publication Number: US-7866478-B2
Application Number: US-4753308-A
Country: US
Kind Code: B2

Title: Packaging for an article

Abstract:
Packaging for use with an article of manufacture, which includes a first member having a first interior cavity for receiving a first portion of the article, a second member having a second interior cavity for receiving a second portion of the article, and a molded hinge connecting the first member and the second member. The first member may be attached to an outer container for holding the article.

Claims:
1. A packaging assembly, comprising:
 an outer container; 
 an inner container disposed within said outer container, said inner container having at least one corner, the inner container adapted to hold an article; and 
 a corner protector separate from said outer container disposed about a corner of said inner container, the corner protector including:
 a first member having two sidewalls defining a first interior cavity therebetween receiving the corner of said inner container, and an angled shoulder extending between the two first member sidewalls, wherein a portion of said first member is attached to said outer container, 
 a second member having two sidewalls defining a second interior cavity therebetween for receiving the corner of said inner container, and an angled shoulder extending between the two second member sidewalls, and 
 a molded hinge connecting said first member and said second member, 
 
 wherein the angled shoulder of said first member abuts the angled shoulder of said second member aligning with the corner of said inner container, and 
 wherein said first member being attached to said outer container rotates relative to said second member about said molded hinge and said second member remains within said outer container when said outer container is opened to facilitate removal of said inner container from said outer container. 
 
     
     
       2. The packaging assembly of  claim 1 , further comprising means for attaching said first member to said outer container. 
     
     
       3. The packaging assembly of  claim 2 , wherein said means for attaching comprises adhesive. 
     
     
       4. The packaging assembly of  claim 1 , wherein said first member further comprises a flange for attaching said first member to said outer container. 
     
     
       5. The packaging assembly of  claim 1 , wherein said first member, said second member, and said molded hinge are molded as a unitary piece. 
     
     
       6. The packaging assembly of  claim 1 , wherein said first and second members are made by injection molding. 
     
     
       7. The packaging assembly of  claim 1 , wherein said first and second members are made by compression molding. 
     
     
       8. The packaging assembly of  claim 1 , wherein said first and second members comprise molded pulp. 
     
     
       9. The packaging assembly of  claim 1 , wherein said first and second members comprise a material selected from the group consisting of: pulp, rubber, polypropylene, PETE, and styrene. 
     
     
       10. The packaging assembly of  claim 1 , wherein said second member is not attached to said outer container. 
     
     
       11. A packaging assembly, comprising:
 an outer container having a flap; 
 an inner container disposed within said outer container, said inner container having at least two corners, the inner container adapted to hold an article; and 
 a plurality of corner protectors, each disposed about a corner of said inner container, the corner protector including:
 a first member having two sidewalls defining a first interior cavity therebetween for receiving a corner of said inner container, an angled shoulder extending between the two first member sidewalls, and a flange attached to the flap of said outer container, said flange disposed about the perimeter of said first member, 
 a second member having two sidewalls defining a second interior cavity therebetween for receiving the corner of said inner container, and an angled shoulder extending between the two second member sidewalls, wherein said second member is not attached to said outer container, and 
 a hinge connecting said first member and said second member, 
 
 wherein the angled shoulder of said first member cooperates with the angled shoulder of said second member to align with the corner of said inner container, and 
 wherein said first member being attached to the flap of said outer container rotates about said molded hinge and said second member remains within said outer container when said outer container is opened to facilitate removal of said inner container from said outer container. 
 
     
     
       12. The packaging assembly of  claim 11 , wherein each of said corner protectors is molded as a unitary piece. 
     
     
       13. The packaging assembly of  claim 11 , wherein said corner protectors are injected molded. 
     
     
       14. The packaging assembly of  claim 11 , wherein said corner protectors comprise molded pulp. 
     
     
       15. The packaging assembly of  claim 11 , wherein the second member sidewalls are disposed between said outer container and said inner container. 
     
     
       16. The packaging assembly of  claim 11 , wherein said outer container comprises a box. 
     
     
       17. The packaging assembly of  claim 11 , wherein said corner protectors are discrete from said outer container and said inner container. 
     
     
       18. The packaging assembly of  claim 11 , wherein said inner container comprises a rectangular box.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to packaging, and more particularly, to packaging for an article of manufacture. 
     2. Background Art 
     A main purpose of packaging is to protect a product during shipment and merchandising. It is desirable for packaging to be strong enough to prevent significant damage caused by compressive forces that may be encountered, while at the same time being relatively simple and affordable to mass produce. 
     Another purpose for packaging may be to generate consumer interest and to project a positive image and brand of the company who produces the product. Consumer products companies may want to leave purchasers with an environmentally-friendly impression of the company by providing recyclable and re-usable product packaging. In addition, packaging that has fewer pieces and is easier for the purchaser to disassemble may result in less waste, and may appeal to consumers. Branding can be particularly important in the highly competitive marketplace of consumer electronics, such as computers like the MacBook® Pro widescreen notebooks sold by Apple, Inc. of Cupertino, Calif. Consumers of such devices tend to be discriminating and savvy, and may expect product packaging to have the same unique qualities as the products themselves. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the present invention relate to packaging for use with an article, comprising: a first member having a first interior cavity for receiving a first portion of the article; a second member having a second interior cavity for receiving a second portion of the article; and a molded hinge connecting the first member and the second member. 
     Embodiments of the present invention also relate to a packaging assembly for use with an article of manufacture comprising a container for holding the article, the container having a flap; and a plurality of corner protectors, each corner protector comprising: a first member having a first interior space for receiving a first portion of the article; a second member having a second interior space for receiving a second portion of the article; and a molded hinge connecting the first member and the second member. The first member may be attached to the flap of the container such that when the flap is opened the first member rotates about the molded hinge. 
     Embodiments of the present invention further relate to packaging for protecting a corner of an article of manufacture disposed in an outer container, the packaging comprising: a first member having a first cavity formed therein for receiving a first side of the article and a flange attached to the outer container; a second member having a second cavity formed therein for receiving a second side of the article; and a hinge connecting the first member and the second member, wherein the packaging is integrally molded as a unitary piece. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which: 
         FIG. 1  is a perspective view of a corner protector for packaging according to an embodiment of the present invention; 
         FIG. 2  is a side view of the corner protector for packaging according to an embodiment of the present invention; 
         FIG. 3  is a perspective view of packaging according to an embodiment of the present invention; 
         FIG. 4  is a perspective view of packaging according to an embodiment of the present invention; 
         FIG. 5  is a cross-sectional front elevation view of packaging according to an embodiment of the present invention; and 
         FIG. 6  is a perspective view of a corner protector including strengthening ribs according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order not to unnecessarily obscure the present invention. 
     With reference to  FIGS. 1-5 , an embodiment of the present invention includes a corner protector  10  packaging component for protecting a corner of an article of manufacture during shipping and/or merchandising. As will be described in detail below, the corner protector  10  may be used in a packaging assembly  20  including an article of manufacture  40  and an outer container  30 , such as, for example, a box. The corner protector  10  may be disposed between a portion of the article of manufacture  40  (e.g., a corner) and the outer container  30 . In this manner, the corner protector  10  may provide an air gap between the article  40  and the outer container  30  in order to protect the article from damage caused by crushing. The outer container  30  may be made of, for example, paper, cardboard, metal, or any other material suitable for packaging. 
     As shown in  FIG. 1 , the corner protector  10  comprises a first member  12  and a second member  14  connected by a hinge  16 . The first member  12  and the second member  14  are adapted to rotate about the hinge  16  between an open position (as shown in  FIG. 1 ) and a closed position about the article  40  ( FIG. 2 ). Each of the first member  12  and the second member  14  includes two sidewalls  13  which define a cavity  11  intermediate the two sidewalls. Each cavity  11  may be adapted to receive a portion of the article of manufacture  40 . For example, as shown in  FIG. 2 , the cavity  11  of the first member  12  and the cavity  11  of the second member  14  may define two planes so as to receive a corner (i.e., adjacent sides) of the article  40 . Thus, when the corner protector  10  is in the closed position, the shape of the inside of the corner protector  10  may correspond to the outer shape of the article  40 . 
     In one embodiment of the present invention, the first member  12  and the second member  14  further include a shoulder  15 . As shown in  FIG. 2 , the shoulders  15  may comprise angled surfaces such that the shoulder  15  of the first member  12  may be adapted to cooperate with the shoulder  15  of the second member  14  when the corner protector  10  is in a closed position about a portion of the article  40 . In this embodiment, the shoulders  15  come together to form a corner, and, thus, the first member  12  may be perpendicular to the second member  14 . 
     As best shown in  FIG. 3 , in one embodiment, a flange  17  may be formed on the first member  12  and/or the second member  14  (shown unattached to the outer container  30  in  FIG. 3  for illustrative purposes). The flange  17  may provide an attachment surface for attaching the first member  12  and/or the second member  14  to the outer container  30 . The flange  17  may be attached to a portion of the outer container  30 , such as, for example, a flap  31  of the container. As shown in  FIG. 4 , the flange  17  may be attached to the outer container  30  such that when the outer container  30  is opened, the first member  12  remains attached to the outer container  30  and is rotated about the hinge  16 . The first member  12  may be correspondingly pulled away from the article  40 , thereby exposing the article and facilitating its removal from the container. As a result, there may be less damage to the corner protector  10  during disassembly of the packaging assembly  20 , which may allow for the corner protector  10  to be re-used. Further, the flange  17  may formed so as to provide rigidity and strength to the corner protector  10 . 
     In one embodiment of the present invention, the first member  12  and the second member  14  further include a shoulder  15 . As shown in  FIG. 2 , the shoulders  15  may comprise angled surfaces such that the shoulder  15  of the first member  12  may be adapted to cooperate with or abut the shoulder  15  of the second member  14  when the corner protector  10  is in a closed position about a portion of the article  40 . In this embodiment, the shoulders  15  come together to form a corner, and, thus, the first member  12  may be perpendicular to the second member  14 . 
     In one embodiment, the flange  17  may be attached to the outer container  30  using an adhesive, such as glue. Other suitable means for attaching the flange  17  to the outer container  30 , including, but not limited to, double-sided tape and staples, may be used. 
     In one embodiment of the present invention, the flange  17  may comprise a continuous surface formed around the perimeter of the first member  12  and/or the second member  14 . In alternative embodiments, the flange  17  may comprise a segmented surface formed around one or more portions of the perimeter of the first member  12  and/or the second member  14 . For example, the flange  17  may comprise a tab on the sides of the first member  12  and/or the second member  14 . 
     The flange  17  may be sized such that there is sufficient surface area to attach to the outer container  30  properly. In some embodiments, the flange  17  may extend inwardly in order to create a larger attachment surface and may be sized to provide increased strength. In another embodiment, the flange  17  may extend across the entire width of the corresponding member. 
     The size and shape of the corner protector  10  may be widely varied to accommodate a wide variety of article shapes and sizes. With reference to  FIG. 2 , for example, in one embodiment the corner protector  10  may be adapted to receive a rectangular-shaped article such as a MacBook® Pro widescreen notebook produced by Apple, Inc. In other embodiments, the corner protector  10  may be adapted to be used with articles of manufacture having shapes that do not have a clearly defined corner, such as a cylindrical or round object, or other irregular shapes for packaging. 
     In one embodiment, the first member  12  and the second member  14  are substantially similar in size and shape. In alternative embodiments, it is contemplated that the first member  12  and the second member  14  may have different sizes and/or shapes. For example, the first member  12  may be longer or shorter than the second member  14 , and/or the cavity  11  formed in the first member  12  may be wider or more narrow than the cavity  11  formed in the second member  14 . 
     In one embodiment of the present invention, one or more of the sidewalls  13  may include a notch (not shown) formed within the sidewall for receiving a bump or edge of the article of manufacture at or near the corner of the article. Similarly, the cavity  11  of the first member  12  or the second member  14  may include such a notch. 
     In an embodiment of the present invention, the sidewalls  13  may define the cavity  11  such that the article of manufacture  40  fits snugly within the cavity  11 . Alternatively, the sidewalls may be formed such that the article  40  may move within the cavity  11 . 
     In an embodiment of the present invention, the corner protector  10  may be integrally molded as a unitary piece. As will be apparent to those of ordinary skill in the art, the corner protector  10  may be scored with, for example, a high pressure compression point to form the hinge  16 . In this embodiment, the first member  12  and the second member  14  are thus connected by the molded hinge (i.e., a living hinge)  16 . The corner protector  10  may be molded using known techniques such as, for example, injection molding, and compression molding. Alternatively, in some embodiments, other manufacturing techniques, including, but not limited to, vacuum forming, thermo forming, blister packaging, and/or casting, may be used to form the corner protector  10 . In one embodiment, the corner protector  10  and the outer container  30  may be molded as a unitary piece. 
     In an alternative embodiment, one or more portions of the corner protector  10  may be formed separately. For example, the first member  12  and the second member  14  may be molded separately and subsequently joined by a hinge  16 . In this embodiment, the hinge  16  may comprise, for example, tape or other material for creating a flexible seam and connecting the first member  12  and the second member  14 . 
     In one embodiment, the corner protector  10  may comprise a recyclable material, such as, for example, molded pulp, in order to address environmental concerns. As will be apparent to those of ordinary skill in the art, the molding process using pulp generally includes forming a slurry with water, recycled paper, and a binder material. The slurry is then formed into shapes by pressing the slurry through a screen and into a mold. As discussed above, the material may be molded into a variety of forms in order to match the shape of the article  40  and/or outer container  30 . Other suitable packaging materials, including, but not limited to, rubber, polypropylene, styrene, and/or poly(ethylene terephthalate) (PETE) and the like may be used. To further alleviate environmental concerns, it is contemplated that the corner protector  10  may be of sufficient strength to be re-usable throughout the supply chain. In this manner, a manufacturer, integrator, vendor, retailer, and/or ultimate user of the article, for example, may re-use the corner protector  10  and limit waste. In one embodiment, the corner protector  10  and the outer container comprise the same material. In one embodiment, the first  12  and second  14  members may be formed from the same material. In alternative embodiments, the first  12  and second  14  members, and/or the hinge  16  may be formed from different materials. For example, in an embodiment in which the first member  12  and the second member  14  may be molded separately and subsequently joined by a hinge  16 , the first and second members may be formed from different materials. 
     In one embodiment, the corner member  10  may be molded to form a hollow structure. In this embodiment, the corner protector  10  may provide a rigid but compressive form having spring-like characteristics by which it deforms under a load, but returns to form when the load is removed. For example, the walls of the corner protector  10  may resist forces but bend inwardly when a force is applied without substantially imparting the force onto the article  40 . In this manner, the corner member  10  may help reduce impacts and loads on the article  40 . The corner member  10  may be molded to have any desired wall thickness. In one embodiment, the corner member  10  has a uniform wall thickness. Alternatively, the corner member  10  may be molded such that one portion of the corner member has a thicker wall thickness to accommodate a more sensitive portion of the article. In alternative embodiments, the corner protector  10  may be molded such that it comprises a solid form. 
     With reference to  FIG. 6 , in one embodiment the corner protector  10  may be molded to include one or more ribs  18  formed on the first member  12  and/or the second member  14  for increased strength. In one embodiment, two ribs  18  may be formed on the first member  12  on either side of the article  40 . The size, shape, and location of the ribs  18  may be widely varied to provide the required strength characteristics. In one embodiment, the ribs  18  may comprise a lattice structure to further increase strength. 
     With reference to  FIGS. 2-5 , an exemplary use of a plurality of corner protectors  10  as part of a packaging assembly  20  will now be described. With particular reference to  FIG. 5 , a corner protector  10  may be disposed snugly about each corner of an article of manufacture  40 . The article may be placed in an outer container  30  such that each corner protector  10  is disposed between the corners of the article  40  and the outer container  30 , thereby holding the article  40  in its desired position within the outer container  30 . The shape of the inner surface(s) of each corner protector  10  may correspond to the shape of the outer surface(s) of the article  40 . Similarly, the shape of the outer surface(s) of each corner protector  10  may correspond to the shape of the inner surface(s) of the outer container  30 . As such, the shape of each corner protector  10  may permit the outer container  30  to close, while holding the article in its desired position within the container. 
     The corner protectors  10  may provide an air gap between the article  40  and the outer container  30  on each side of the article. For example, in embodiments where the article  40  and the outer container  30  are rectangular in shape, the corner protectors  10  may provide an air gap between the article and the container on the six sides of the article. When the outer container  30  is subjected to forces, one or more corner protectors  10  may compress under stress without substantially imparting the force onto the article, thereby reducing or preventing damage to the article. 
     One or more of the corner protectors  10  may be attached to the outer container  30  as discussed above. As shown in  FIG. 4 , when a flap  31  of the outer container  30  is opened, the first member  12  attached to that flap remains attached to the outer container  30  and is rotated about the hinge  16 . The first member  12  is correspondingly pulled away from the article  40 , thereby exposing the article and facilitating its removal from the container. 
     While the invention has been described in terms of several embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. For example, the packaging can be used for items other than electronic devices, and may be used with items not in packaging, or in packaging made of material other than paper or cardboard. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall with the true spirit and scope of the present invention.

Metadata:
Filing Date: 20080313
Publication Date: 20110111
Grant Date: 20110111
Priority Date: 20080313
Inventors: ROHRBACH MATTHEW DEAN
MULTZ CARTER
Assignee: APPLE INC
CPC Classifications: [{"code": "B65D81/056", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D81/056", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 41061838