Title: Packaging for fragile items
Abstract: One or more unique hinges are provided within panels of a fragility packaging article for use in retaining one or more fragile articles within a container (e.g., a corrugated box). The unique hinges provide predicted deformation paths that assist in protecting one or more fragile items stored in the container. One of the unique hinges is a diamond shaped hinge that provides at least two predicted deformation paths. Other unique hinges of the present invention includes a gusset hinge, a step hinge, and a v-hinge, each of which provides at least one predicted deformation path. The predicted deformation paths reduce permanent deformation and provide for improved overall cushioning, thereby increasing protection of fragile items and significantly reducing damage that may occur to the fragile items. The unique hinges of the present invention also improve the cosmetic appearance of a fragility packing article because a majority of crushing occurs along the unique hinges, preventing random unsightly crush points from occurring throughout the packaging article.
Patent Number: 6,840,381 Issued on 01/11/2005 to Stephens
| Inventors:
|
Stephens; Thomas (Los Gatos, CA)
|
| Assignee:
|
RSVP Operations, LLC (Campbell, CA)
|
| Appl. No.:
|
210408 |
| Filed:
|
July 31, 2002 |
| Current U.S. Class: |
206/589; 206/592 |
| Intern'l Class: |
B65D 081/02 |
| Field of Search: |
206/521,587,588,589,591,592,593,594,425,449,454
|
References Cited [Referenced By]
U.S. Patent Documents
| 4515272 | May., 1985 | Newhouse | 206/592.
|
| 5131543 | Jul., 1992 | Stephens.
| |
| 5226543 | Jul., 1993 | Foos et al.
| |
| 5249685 | Oct., 1993 | Stephens.
| |
| 5385232 | Jan., 1995 | Foos et al.
| |
| 5445292 | Aug., 1995 | Slomski et al.
| |
| 5515976 | May., 1996 | Moren et al.
| |
| 5545370 | Aug., 1996 | Moren et al.
| |
| 5586677 | Dec., 1996 | Foos.
| |
| 5634559 | Jun., 1997 | Foos et al.
| |
| 5788105 | Aug., 1998 | Foos.
| |
| 6010007 | Jan., 2000 | Moren et al.
| |
| 6123200 | Sep., 2000 | Stephens et al.
| |
| 6142304 | Nov., 2000 | Moren et al.
| |
| RE37253 | Jul., 2001 | Moren et al.
| |
| 6520337 | Feb., 2003 | Smith | 206/592.
|
Primary Examiner: Luong; Shian T.
Attorney, Agent or Firm: Fliesler Meyer LLP
Claims
What is claimed is:
1. A fragility packaging article panel for use in retaining and protecting
at least one fragile item within a container, the panel comprising:
a base having a peripheral edge including generally parallel front and rear
edges and generally parallel first and second side edges, said base for
resting on or against an inner surface of the container;
a platform for supporting at least a portion of the at least one item, said
platform including generally parallel front and rear edges and generally
parallel first and second side edges;
a front wall rising from said front edge of said base to said front edge of
said platform;
a rear wall rising from said rear edge of said base to said rear edge of
said platform;
a first side wall rising from said first side edge of said base to said
first side edge of said platform;
a second side wall rising from said second side edge of said base to said
second side edge of said platform;
said front wall, said rear wall, said first side wall and said second side
wall defining a skirt that suspends said platform above said base so that
a shock absorbing air cushioning space is defined between the inner
surface of the container and said platform; and
a diamond hinge located in a corner area where said platform, one of said
front and rear walls and one of said side walls all meet, said diamond
binge being defined by four substantially planer and substantially
triangular surfaces that meet at a point located below said platform, said
diamond hinge providing at least two predicted paths for deformation.
2. The panel according to claim 1, further comprising a plurality of ribs
projecting from said platform to define at least one item-supporting cell,
each said cell configured to receive one fragile item.
3. The panel according to claim 1, wherein an outer edge of said diamond
hinge has a generally diamond shape, said diamond shape being divided into
said four triangular surfaces by a pair of cross-hairs.
4. The panel according to claim 3, wherein:
a first of said cross-hairs defines a line along which a first pair of said
triangular surfaces bend toward a second pair of said triangular surfaces
during a first predicted deformation path; and
a second of said cross-hairs defines a line along which a third pair of
said triangular surfaces bend toward a fourth pair of said triangular
surfaces during a second predicted deformation path.
5. The panel according to claim 4, wherein a base of one or more of said
triangular surfaces is curved, each said base being an edge of one of said
triangular surfaces opposite said point where said triangular surfaces
meet, said bases of said four triangular surfaces collectively defining
said outer edge of said diamond hinge.
6. The panel according to claim 1, wherein said panel includes at least a
pair of said diamond hinges; a first said diamond hinge located in a
corner area where said platform, said front and said first side wall all
meet; a second said diamond hinge located in a corner area where said
platform, said rear wall and said first side wall all meet.
7. A fragility packaging article panel for use in retaining and protecting
at least one fragile item within a container, the panel comprising:
a base having a peripheral edge including generally parallel front and rear
edges and generally parallel first and second side edges, said base for
resting on or against a panel of the container;
a platform for supporting at least a portion of the at least one fragile
item, said platform including generally parallel front and rear edges and
generally parallel first and second side edges;
a front wall rising from said front edge of said base to said front edge of
said platform;
a rear wall rising from said rear edge of said base to said rear edge of
said platform;
a first side wall rising from said first side edge of said base to said
first side edge of said platform;
a second side wall rising from said second side edge of said base to said
second side edge of said platform;
said front wall, said rear wall, said first side wall and said second side
wall defining a skirt that suspends said platform above said base so that
a shock absorbing air cushioning space is defined between the inner
surface of the container and said platform; and
a v-hinge extending into said front wall and into said platform, said
v-hinge including:
a first v-shaped end in said front wall with a tip pointing generally
toward said front edge of said base;
a second v-shaped end in said platform with a tip pointing generally away
from said front edge of said base;
generally parallel edges that extend between said first v-shaped end and
said second v-shaped end; and
first and second walls extending down from said edges and meeting at a
trough to thereby form a v-shaped channel.
8. The panel according to claim 7, further comprising a plurality of ribs
projecting from said platform to define at least one item-supporting cell,
each said cell configured to receive one fragile item.
9. The panel according to claim 7, wherein said v-hinge provides a
predicted path for deformation, wherein during deformation said first and
second walls of said v-hinge bend toward one another along said trough.
10. The panel according to claim 9, further comprising a second v-hinge
extending into said rear wall and into said platform, said second v-hinge
including:
a first v-shaped end in said rear wall with a tip pointing generally toward
said rear edge of said base;
a second v-shaped end in said platform with a tip pointing generally away
from said rear edge of said base;
generally parallel edges that extend between said first v-shaped end and
said second v-shaped end; and
first and second walls extending down from said edges and meeting at a
trough to thereby form a v-shaped channel.
11. A fragility packaging article panel for use in retaining and protecting
at least one fragile item within a container, the panel comprising:
a base having a peripheral edge including generally parallel front and rear
edges and generally parallel first and second side edges, said base for
resting on or against a panel of the container;
a platform for supporting at least a portion of the at least one fragile
item, said platform including generally parallel front and rear edges and
generally parallel first and second side edges;
a front wall rising from said front edge of said base to said front edge of
said platform;
a rear wall rising from said rear edge of said base to said rear edge of
said platform;
a first side wall rising from said first side edge of said base to said
first side edge of said platform;
a second side wall rising from said second side edge of said base to said
second side edge of said platform;
said front wall, said rear wall, said first side wall and said second side
wall defining a skirt that suspends said platform above said base so that
a shock absorbing air cushioning space is defined between the inner
surface of the container and said platform; and
a v-hinge extending into said front wall, into and across and entire width
of said platform, and into said rear wall, said v-hinge including:
a first v-shaped end in said front wall with a tip pointing generally
toward said front edge of said base;
a second v-shaped end in said rear wall with a tip pointing generally
toward said rear edge of said base;
generally parallel edges that extend between said first v-shaped end and
said second v-shaped end; and
first and second walls extending down from said edges and meeting at a
trough to thereby form a v-shaped channel.
12. The panel according to claim 11, wherein said v-hinge provides a
predicted path for deformation, wherein during deformation said first and
second walls of said v-hinge bend toward one another along said trough.
13. A fragility packaging article panel for use in retaining and protecting
at least one fragile item within a container, the panel comprising:
a base having a peripheral edge including generally parallel front and rear
edges and generally parallel first and second side edges, said base for
resting on or against a panel of the container;
a platform for supporting at least a portion of the at least one fragile
item, said platform including generally parallel front and rear edges and
generally parallel first and second side edges;
a front wall rising from said front edge of said base to said front edge of
said platform;
a rear wall rising from said rear edge of said base to said rear edge of
said platform;
a first side wall rising from said first side edge of said base to said
first side edge of said platform;
a second side wall rising from said second side edge of said base to said
second side edge of said platform;
said front wall, said rear wall, said first side wall and said second side
wall defining a skirt that suspends said platform above said base so that
a shock absorbing air cushioning space is defined between the inner
surface of the container and said platform;
a plurality of ribs projecting from said platform to define at least one
item-supporting cell, each said cell configured to receive one fragile
item, at least one of said ribs including a gusset portion projecting from
one of said front and rear walls to provide additional strength to said at
least one of said ribs and to said one of said front and rear walls; and
a gusset hinge located in said gusset portion for providing a path of
deformation for said gusset.
14. The panel according to claim 13, wherein said gusset hinge comprises a
notch in an outer peripheral wall of said gusset portion.
15. The panel according to claim 14, wherein said notch includes a ledge
and a face meeting at a corner, and wherein said ledge and said face bend
toward one another along said corner during deformation.
16. The packing article as define in claim 15, wherein said ledge is
substantially parallel to said platform.
17. A fragility packaging article panel for use in retaining and protecting
at least one fragile item within a container, the panel comprising:
a base having a peripheral edge including generally parallel front and rear
edges and generally parallel first and second side edges, said base for
resting on or against an inner surface of the container;
a platform for supporting at least a portion of the at least one fragile
item, said platform including generally parallel front and rear edges and
generally parallel first and second side edges;
a front wall rising from said front edge of said base to said front edge of
said platform;
a rear wall rising from said rear edge of said base to said rear edge of
said platform;
a first side wall rising from said first side edge of said base to said
first side edge of said platform;
a second side wall rising from said second side edge of said base to said
second side edge of said platform;
said front wall, said rear wall, said first side wall and said second side
wall defining a skirt that suspends said platform above said base so that
a shock absorbing air cushioning space is defined between the inner
surface of the container and said platform; and
a step hinge within said front wall and extending at least a portion of a
length of said front wall, said step hinge including a ledge and a face
meeting at a corner, and wherein said ledge and said face bend toward one
another along said corner during deformation.
18. The packing article as define in claim 17, wherein said ledge is
substantially parallel to said platform.
19. The panel according to claim 17, further comprising a plurality of ribs
projecting from said platform to define at least one item-supporting cell,
each said cell configured to receive one fragile item.
20. The panel according to claim 19, wherein at least one of said ribs
including a gusset portion projecting from said front wall to provide
additional strength to said at least one of said ribs and to said front
wall.
21. The panel according to claim 20, wherein each said gusset portion
splits said step hinge into separate sections.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to packaging for fragile items such as
computer components, electronic devices and the like.
2. Description of the Related Art
Fragility packaging as used in the present context refers to a type of
packaging employing plastic structures (e.g., thermoformed plastic
structures) which provide both structural support and shock absorption to
the fragile items they are designed to carry. Such packages are typically
used in combination with conventional corrugated cartons, and define shock
absorbing air spaces between the packaged item and the inner surfaces of
corresponding panels of the carton. Such packages can also be plastic
totes that are used as material handling devices. Among the many
advantages of thermoformed fragility packages are that they are
recyclable, provide cushioning against repeated shock loading, are compact
to ship and store in bulk. Examples of fragility packages are described in
commonly assigned U.S. Pat. Nos. 5,226,543; 5,385,232; 5,515,976;
6,010,007; and 6,142,304, all of which are incorporated herein by
reference.
One embodiment of the above-described fragility packaging is used for
shipping computer components such as disk drives in bulk from
manufacturing to assembly points. The distance such packages are designed
to travel may vary from one end of a factory to another, to one end of the
world to another. Conventional bulk disk drive fragility packages provide
a main platform divided into cells for locating and separating each drive
relative to the adjacent drive. Generally parallel side edges of the main
platform are provided with integrally formed hinged flaps. Preferably,
these flaps are also divided into cells which are in registry with the
main platform cells, and once placed in a carton, the flaps provide
protection to the sides of the drives in each cell. Examples of such
packages are manufactured and sold by R.S.V.P., Inc., Soquel, Calif. under
the trademark U-PAD.
Often, U-PAD packages will be provided with a lid, which is typically a
thermoformed, generally planar panel also provided with cells in registry
with the other cells. When the lid is placed over the packaged disks in
the U-PAD already in the carton, the tops of the disk drives will also be
separated from adjacent disk drives, and the lid will also separate the
disk drives from the corresponding top panel or panels of the carton.
U-PAD packages may vary in configuration depending on the size and type of
items (e.g., disk drives) being packaged. In some cases, a single row of
items will be packaged in separated fashion with a carton, while in
others, two rows of items are placed in parallel relationship to each
other. In the latter situation, the main platform is provided with an
integrally formed, centrally located, vertically projecting sidewall
structure. This sidewall structure is also divided into cells to engage
the inner sides of each disk drive in each of the two rows of packaged
items. In the case of dual row packages, the corresponding lid is also
provided with separated, parallel rows of cells to be in registry with the
cells of the so-called DOUBLE U-PAD package.
With the increasing popularity of U-PAD packaging, and the corresponding
trend in the computer industry to out source components, a wider variety
of components and other packaged items are being shipped in this type of
package. Also, each manufacturer has its own specifications for the
properties which the packaging must have to provide satisfactory
protection. Thus, depending on the packaged item and the manufacturer,
various regions and/or portions of the fragility package need to have a
range of flexibility, rigidity and/or shock absorptive properties. For
example, packages designed to be carried by hand from one end of a factory
to another, or to be shipped by themselves, must be designed to withstand
a greater drop height than packages designed to be loaded onto a shipping
pallet for transport on a truck.
Another packaging design requirement of component manufacturers is that the
packaging be easily installed in the carton or tote and loaded with
fragile items by relatively unskilled workers, or even by machine, in as
rapid a fashion as possible while still taking into account the inherent
fragility of the items.
The packaging manufacturer is then forced to develop many designs of
fragility packaging to satisfy customers shipping relatively similar
fragile items. As such, to make the most efficient use of resources, the
goal of the packaging manufacturer is to provide packaging with a maximum
range of properties using as few distinctive package designs as possible.
One of the ways a thermoformed packaging structure protects fragile items
is by flexing and thereby absorbing forces that are applied to a carton
within which the thermoformed structure (and fragile items) are placed.
Such forces may result, for example, from the carton being dropped or
knocked over, or from further cartons being placed on top of the carton or
pushed against the carton. A problem with conventional thermoformed
packaging structures is that they often crush or deform at unpredictable
points (e.g., when applied forces overcomes the flexibility of the
structure). A result of unpredictable crush points is that the fragile
items may be damaged. A further result of such unpredictable crush points
is that the integrity of the packaging structure may be ruined, and thus
fragile items may be damaged by the force causing the unpredicted crush
point and/or later applied forces. Additionally, such unpredicted crush
points are unsightly and may cause a customer unpacking the fragile items
to question whether the producer and/or shipper took proper care of the
fragile items. This may strain otherwise good relations between parties.
Accordingly, there is a desire to overcome the problems caused by such
unpredictable crushing or deformation of packaging structures.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to improved fragility packaging articles
for use in retaining and protecting at least one fragile item within a
container. Each fragility packaging article is made up of one or more
panels. For example, a fragility packaging article may include a bottom
panel and a pair of side panels that together form a U-shaped packaging
article (often referred to as a U-PAD.TM.) that can be placed within the
container. Each panel is similar in that each includes a base for resting
on or against an inner surface (e.g., a bottom or a side) of the
container. Each panel also includes a platform, located a distance or
cushioning space from the base, for supporting at least a portion of a
fragile item. A front wall rises from a front edge of the base to a front
edge of the platform. Similarly, a rear wall rises from a rear edge of the
base to a rear edge of the platform. Additionally, a first side wall rises
from a first side edge of the base to a first side edge of the platform. A
second sidewall similarly rises from a second side edge of the base to a
second side edge of the platform. The front wall, rear wall, first side
wall and second side wall define a skirt that suspends the platform above
the base so that a shock absorbing air cushioning space is defined between
an inner surface of the container and the platform. Typically, a plurality
of ribs project from the platform to define at least one item-supporting
cell that is configured to receive one fragile item.
Embodiments of the present invention are directed to unique hinges that are
incorporated into the above described panels (or other similar panels) to
provide for, among other things, improved cushioning of fragile items. The
unique hinges of the present invention provide for predicted deformation
paths thereby reducing and hopefully preventing random crush zones or
points from occurring within a panel. Such predicted deformation paths
provide many advantages. For example, a packaging articles that
incorporate some or all of the unique hinges may be used to ship fragile
items having a broad weight range. The predicted deformation paths reduces
permanent deformation of the packaging article and provides for improved
overall cushioning, thereby increasing protection of fragile items and
significantly reducing damage that may occur to the fragile items. The
unique hinges of the present invention also improve the cosmetic
appearance of a fragility packing article because a majority of crushing
occurs along the unique hinges, preventing random unsightly crush points
from occurring throughout the article.
One of the unique hinges of the present invention, referred to as a diamond
hinge, is typically formed in a corner area of a panel, where the
platform, one of the front and rear walls and one of the side walls all
meet. The diamond hinge is defined by four substantially planer and
substantially triangular surfaces that meet at a point located below the
platform. A unique feature of the diamond hinge is that it provides at
least two predicted paths for deformation.
Another unique hinge of the present invention, referred to as a v-hinge,
typically extends into the front wall (and/or rear wall) and into the
platform of a panel. In accordance with an embodiment of the present
invention, the v-hinge includes a first v-shaped end in the front wall
with a tip pointing generally toward the front edge of the base of the
panel. A second v-shaped end in the platform has a tip pointing generally
away from the front edge of the base. Generally parallel edges extend
between the first v-shaped end and the second v-shaped end, with first and
second walls extending down from the edges and meeting at a trough to
thereby form a v-shaped channel. The v-hinge provides a predicted path for
deformation and also provides for vertical and horizontal movement. More
specifically, during deformation the first and second walls of the v-hinge
bend toward one another along the trough.
As mentioned above, typically, a plurality of ribs project from the
platform to define at least one item-supporting cell that is configured to
receive one fragile item. One or more of these ribs may include a gusset
portion projecting from one of the front and rear walls to provide
additional strength to the rib and to the one of the front and rear walls.
A further unique hinge of the present invention, referred to as a gusset
hinge, is located in the gusset to provide a path of deformation for the
gusset. The gusset hinge comprises a notch in an outer peripheral wall of
the gusset. The notch includes a ledge and a face meeting at a corner
(which is typically a curved or rounded corner, but maybe a sharper
corner). During deformation, the ledge and the face bend toward one
another along the corner.
Still another unique hinge of the present invention is a step hinge. The
step hinge is similar to a gusset hinge in that it includes a ledge and a
face that meet at a corner. During deformation, the ledge and the face
bend toward one another along the corner. The difference between the step
hinge and the gusset hinge is that the step hinge is included within one
of the walls (e.g., the front wall) of the panel, rather than in a gusset
projecting from the wall.
Further features and advantages of the present invention may be more
readily understood by reference to the following description taken in
conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
FIG. 1A a top view of three panel packaging article, according to an
embodiment of the present invention;
FIG. 1B is a perspective view of the packing article of FIG. 1,
appropriately folded to fit within a shipping container;
FIG. 1C is a perspective view of the packaging article of FIGS. 1A and 1B
placed into a shipping container (one of the walls is removed from the
shipping container so that the packaging article can be seen);
FIG. 2A a top view of six panel packaging article, according to an
embodiment of the present invention;
FIG. 2B is a perspective view of the packing article of FIG. 2A,
appropriately folded to fit within a shipping container;
FIG. 2C is a perspective view of the packaging article of FIGS. 2A and 2B
placed into a shipping container (one of the walls is removed from the
shipping container so that the packaging article can be seen);
FIG. 3A is a perspective view of an exemplary bottom panel of a packaging
article, where the panel includes a plurality of unique hinges in
accordance with embodiments of the present invention;
FIG. 3B is a top view of the panel shown in FIG. 3A;
FIG. 3C is a cut-away view of the panel shown in FIGS. 3A and 3B, cut along
line C--C;
FIG. 3D is a cut-away view of the panel shown in FIGS. 3A and 3B, cut along
line D--D;
FIG. 3E is a cut-away view of the panel shown in FIGS. 3A and 3B, cut along
line E--E;
FIG. 3F is a cut-away view of the panel shown in FIGS. 3A and 3B, cut along
line F--F;
FIG. 4 is a top view of a portion of a panel including an alternative
embodiment of a v-hinge;
FIG. 5A is a perspective view of an exemplary side panel of a packaging
article, that includes a step hinge according to an embodiment of the
present invention;
FIG. 5B is a top view of the panel shown in FIG. 5A; and
FIG. 5C is a cut-away view of the panel shown in FIGS. 5A and 5B, cut along
line C--C.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A shows a fragility package article 100, according to an embodiment
of the present invention, that includes a bottom panel 104 and a pair of
side panels 102 and 106. Article 100 is preferably formed from a single
sheet of plastic by thermoforming, injection molding, blow molding, or an
equivalent technology. The plastic can be a high density polyethylene
(HDPE), however other polymeric materials may be substituted depending on
the application, including the provision of additives for reducing static
electricity. HDPE works well due to its combination of stiffness,
flexibility and memory (i.e., its tendency to return to its original shape
after shock loading). Sheets of plastic used to produce article 100 should
typically have a thickness of about 10 to 90 gauge (mils), however other
thicknesses can be used, depending on the application.
Each side panel 102 and 106 is respectively coupled to bottom panel 104 by
integrally formed "living" hinges 103 and 105 that enable the panels to be
hinged or bent with respect to one another. More specifically, integrally
formed "living" hinge 103 allows side panel 102 to flap or bend toward
bottom panel 104 so that the panels are substantially perpendicular to one
another, as shown in FIG. 1B. Similarly, integrally formed "living" hinge
105 allows side panel 106 to bend or flap toward bottom panel 104, such
that side panels 104 and 106 are substantially parallel to one another, as
shown in FIG. 1B. In this configuration, article 100 can be placed in a
shipping container 120 (e.g., a corrugated cardboard box or tote) such
that a base of bottom panel 104 rests on a bottom of container 120, and
side panels 102 and 106 each rest against side walls of container 120, as
shown in FIG. 1C. One or more fragile items 110 can then be placed in
cells formed by article 100, as will be described below.
A lid 101 can be placed over the fragile items 110 to form a cushioning
distance between the top(s) of fragile item(s) 110 and the top or cover of
shipping container 120 (e.g., carton flaps that are folded over to close
the container). Lid 101 is a generally planar panel and is provided with
cells in registry with the other cells formed by fragility packaging
article 100. When lid 101 is placed over the packaged fragile items
already in the container, the tops of the fragile items will also be
separated from adjacent items, and lid 101 will also separate the fragile
items from the corresponding top panel or panels of the container (e.g., a
carton). Lid 101 can be formed (e.g., thermoformed) separately from
article 100, as shown in 1C. Alternatively, lid 101 can be integrally
formed with article 100 such that an integrally formed "living" hinge
(similar to hinges 103 and 105) exists between one of side panels 102 or
106 and lid 101, enabling lid 101 to bend (along the hinge) such that it
is perpendicular to side panels 102 and 106 and parallel to bottom panel
104. In an embodiment where the lid is integrally formed with panels 102,
104 and 106, the lid or top panel can be substantially identical to bottom
panel 104.
As can be appreciated from FIGS. 1B and 1C, article 100 resembles a letter
"U" when folded in the above described manner, and thus, may be referred
to as a U-PAD.TM.. However, embodiments of the present invention are not
limited to this configuration. For example, the U-PAD.TM. can be rotated
90 degrees to resemble a letter "C", and thus article 100 may be referred
to as a C-PAD. In the C-PAD arrangement, bottom panel 104 acts as a side
panel (and rests against a side of a shipping container), and side panels
102 and 104 act as top and bottom panels (and rest against top and bottom
surfaces of the shipping contain). In this arrangement, what was referred
to above as a top panel (e.g., lid 101) is now a side panel which is
placed over the sides of the fragile items 110 after they are loaded into
the C-PAD.
FIG. 2A shows a fragility package article 200, according to an alternative
embodiment of the present invention, that includes a pair of bottom panels
204 and 210 (each substantially the same as bottom panel 104), a pair of
side panels 202 and 212 (substantially the same as side panels 202 and
206), and a pair of middle panels 206 and 208. Each panel is coupled to
its adjacent panel or panels by integrally formed "living" hinges (203,
205, 207, 209, 211) that enable the panels to be hinged or bent with
respect to one another. For example, integrally formed "living" hinge 203
allows side panel 202 to flap toward bottom panel 204 so that the panels
are substantially perpendicular to one another, as shown in FIG. 2B. Hinge
207 allows middle panels 206 and 208 to be bent 180 degrees with respect
to one another such that the panels are back-to-back, as shown in FIG. 2B.
Once bent into the configuration shown in FIG. 2B, article 200 can be
placed in a shipping container 220 (e.g., a corrugated cardboard box) such
that bases of bottom panels 204 and 210 rests on a bottom of container
220, and bases of side panels 202 and 212 each rest against side walls of
container 220, as shown in FIG. 2C. One or more fragile items 230 can then
be placed in cells formed by article 200, as will be described below. As
can be appreciated from FIGS. 2B and 2C, fragility packaging article 200
provides two parallel rows of item storing cells (as apposed to the one
row provided by article 100). A lid 201 can be placed over the fragile
items 230 to form a cushioning distance between the top(s) of fragile
item(s) 110 and the top or cover of shipping container 220 (e.g., carton
flaps that are folded over to close the container). As can be appreciated
from FIGS. 2B and 2C, article 200 resembles a pair of "U"s placed next to
one another, when folded in the above described manner, and thus may be
referred to as a DOUBLE U-PAD.TM.. Fragility packaging articles can also
be made to include three or more rows of items storing cells (e.g., a
triple U-PAD, etc.).
Each of the above mentioned panels is similar in that each includes a base
for resting on or against an inner surface (e.g., a bottom or a side) of a
container. Each panel also includes a platform, located a distance or
cushioning space from the base, for supporting at least a portion of a
fragile item. A front wall rises from a front edge of the base to a front
edge of the platform. Similarly, a rear wall rises from a rear edge of the
base to a rear edge of the platform. Additionally, a first side wall rises
from a first side edge of the base to a first side edge of the platform. A
second side wall similarly rises from a second side edge of the base to a
second side edge of the platform. The front wall, rear wall, first side
wall and second side wall define a skirt that suspends the platform above
the base so that a shock absorbing air cushioning space is defined between
an inner surface of the container and the platform. For example, referring
to FIGS. 3A and 3B, an exemplary bottom panel 304 of a fragility packaging
article includes a base 318 having a peripheral edge including generally
parallel front and rear edges 312,314 and generally parallel side edges
316,317. Panel 304 also includes a platform 320 for supporting at least a
portion of a fragile item. A front wall 322 rises from front edge 312 of
base 318 to a corresponding front edge of platform 320. A rear wall 324
rises from rear edge 314 of base 318 to a corresponding rear edge of
platform 320. A first side wall 340 rises from first side edge 316 of base
318 to a first side edge of platform 320. A second side wall 342 rises
from second side edge 317 of the base 318 to a second side edge of
platform 320. Front wall 322, rear wall 324, first side wall 340 and
second side wall 342 define a skirt that suspends platform 320 above base
318 so that a shock absorbing air cushioning space is defined between
platform 320 and an inner surface (e.g., a bottom) of a container (e.g., a
corrugated box).
In the embodiments shown in the figures, front wall 322 rises from front
edge 312 of base 318 at substantially constant angle from base 318 to
platform 320. Similarly, rear wall 324 rises from rear edge 314 of base
318 to platform at a substantially constant angle. Sidewalls 340 and 342
are each shown as extending up from base 318 and curving to meet platform
220. These angles at which front wall 322 and rearwall 324 rise to
platform 322, and the radius of the curve between sidewalls 342 and 344
and platform 320, in part define the overall flexibility and cushioning of
panel 304. For example, the steeper the angle the stiffer (i.e., less
flexible) the panel.
A plurality of ribs typically project from the platform of each panel to
divide each platform into one or more of item-supporting and
item-separating cells, where each cell is configured to receive one
fragile item. For example, a plurality of ribs 330 project from platform
320 of exemplary bottom panel 304 to divide platform 320 into a plurality
of item-supporting cells, as shown in FIGS. 3A and 3B. A fragile item can
be placed between opposing walls of each pair of adjacent ribs 330 such
that a portion of the fragile item rests between the pair of ribs 330 and
against platform 320.
In the exemplary panels shown in FIGS. 1A-1C, eleven ribs project from each
panel to thereby define ten cells. Accordingly, packaging article 100
shown in FIGS. 1A-1C may be referred to as a "10-pack" in that it is used
to retain ten fragile items. Exemplary bottom panel 304, shown in FIGS. 3A
and 3B, similarly includes eleven ribs. Packaging article 200 shown in
FIGS. 2A-2C may be referred to as a "20-pack" since two rows of tens cells
are provided. It is noted, however, that features of present invention are
not limited to use with the specific embodiments shown in the figures. For
example, features of the present invention can be used with a packaging
article designed to store a single fragile item (e.g., a video monitor),
or any other number of items.
Referring to FIG. 3E, which is a cutaway side view of panel 304 along line
E--E, each rib 330 is typically configured to have a slight draft angle
.mu. selected to balance the design requirement of sufficient product
contact for support purposes on the one hand, and ease of withdrawing the
article (e.g., article 100 or 200) from a forming tool and withdrawing the
fragile item from a cell on the other hand. It has also been found that
the greater the draft angle, the more flexible rib 330, and the less
resistant it is to shock loading. The draft angle of rib 330 is most
likely within a range of about 3 to 45 degrees, with a preferred range of
about 3 to 15 degrees.
Typically, each fragile item (e.g., item 110 or 230) packaged using
embodiments of the present invention is generally rectangular in shape and
in some cases may be provided in its own further wrapping or packaging,
depending on the application. Examples of fragile items include, but are
not limited to, disk storage drives, printed circuit boards, flat screen
displays, already assembled lap top computers, set top boxes and computer
processing units (CPUs).
As will be appreciated from the following description, embodiments of the
present invention are directed to unique hinges that are incorporated into
the above described panels (or other similar panels) to provide for, among
other things, improved cushioning of fragile items. More specifically, the
unique hinges of the present invention provide for predicted deformation
paths thereby reducing and hopefully preventing random permanent crush
zones or points from occurring within a panel. Such predicted deformation
paths provide many advantages. For example, the unique hinges of the
present invention provide a more efficient packaging article (e.g.,
article 100 or 200) in that a packaging articles that incorporate some or
all of the unique hinges can handle (i.e., be used to ship) fragile items
(e.g., items 110 or 230) having a broad weight range. The predicted
deformation paths also provide for improved overall cushioning thereby
increasing protection of fragile items and thereby significantly reducing
damage that may occur to the fragile items. The unique hinges of the
present invention also improve the cosmetic appearance of a fragility
packing article because a majority of crushing occurs along the unique
hinges, preventing random unsightly crush points from occurring throughout
the article.
One or all of the different unique hinges of the present invention can be
incorporated into an a single panel of a fragility packaging article.
Further, one or more of each unique hinge (i.e., of a specific type of
unique hinge) can be incorporated into a single panel. Each of the unique
hinges shall now be discussed individually, mainly with reference to FIGS.
3A-3F. As mentioned above, panel 304 shown in FIGS. 3A-3F is an exemplary
bottom panel of a fragility packing article that most likely also includes
at least a pair of side panels (e.g., similar to side panels 102 and 106).
As will be appreciated from the following description, one or more of the
unique hinges of the present invention can be, and likely are, also
incorporated into the side panels (and middle panels, when used).
Gusset Hinge
In accordance with an embodiment of the present invention, hinges are
placed within gussets that are used to strengthen front and rear walls and
of a panel. For example, referring to FIGS. 3A and 3B, the fifth, seventh
and ninth ribs 330 (from the left) are shown as each including gussets 332
projecting up from front and rearwalls 322 and 324 of panel 304. A gusset
hinge 334 is located in each gusset 332 for providing a path of
deformation for the gusset 332. Referring to FIG. 3C, which is a cut-away
view along line C--C, gusset hinge 334 is a notch in gusset 332 and is
somewhat "L" shaped in that it includes a ledge 338 and a face 336
extending up from ledge 338. A corner 337, defined between ledge 338 and
face 336, is where the predicted deformation path begins, when a
sufficient force is applied. Such a force typically originates outside of
the shipping container (e.g., container 120 or 230). During deformation,
ledge 338 and face 336 will bend toward one another about corner 337. Such
deformation assists in absorbing the force, thereby preventing the force
from damaging the fragile items that are stored between ribs 330. When the
force is no longer applied, ledge 338 and face 336 will substantially
return to their original positions.
Gusset hinges 334 provides a movement path at a chosen bearing point that
is variable and can be altered indefinitely to provide more or less
resistance. An exemplary bearing point is even with the level of platform
320 (i.e., at the same height from base 318 as platform 320, as can best
be seen in FIG. 3C). Below or above that level will change resistance and
either add or subtract stiffness. The size of gusset hinges 334 and the
draft angles of its surface (i.e., ledges 338 and faces 336) can be
altered to create more or less stiffness.
Gusset hinges 334 are useful for absorbing forces that are applied from any
direction except from a direction substantially perpendicular to side wall
342 or side wall 344. Other hinges of the present invention, discussed
below, are useful for absorbing forces applied from the direction
substantially perpendicular to side wall 342 or side wall 344.
Diamond Hinge
Another unique hinge of the present invention shall be referred to as a
diamond hinge because of its generally diamond shape. Referring to FIGS.
3A and 3B, a diamond hinge 360 is located in a corner area where platform
320, front wall 322, and side wall 342 all meet. A further diamond hinge
360 is located in a corner area where platform 320, rear wall 324 and side
wall 342 all meet. Each diamond hinge 360 is defined by four substantially
planer and substantially triangular surfaces 362, 364, 366 and 368 that
meet at a point 370 located below platform 320 (i.e., when base 318 of
panel 304 rests against a surface of a shipping container, point 370 is
closer to that surface than platform 320).
Referring to the top view of panel 304 in FIG. 3B, diamond hinge 360
resembles a diamond through which a pair of cross-hairs 372 and 374 are
drawn, with cross-hairs 372 and 374 crossing one another at point 370.
These cross-hairs 372 and 374 divide the diamond shape into the four
triangular surfaces 362, 364, 366 and 368. The bases of triangular
surfaces 362, 364, 366 and 368 (i.e., the sides of the triangular surfaces
opposite point 370) form the generally diamond shape of diamond hinge 360.
These bases, as shown in the figures, may be curved (i.e., not straight)
due to the shapes of the walls through which the triangular surfaces
intersect. For example, a base of triangular surface 364 is curved because
it intersects with side wall 342, which as described above curves to meet
platform 320. Similarly, a base of triangular surface 366 is curved
because it also intersects side wall 342.
The lengths of the above described cross-hairs can be varied, thereby
altering the overall shape and size of diamond hinge 360 (as well as the
shapes and sizes of triangular surfaces 362, 364, 366 and 368). The
precise shape and size of diamond hinge 360 is dependent on the
application. For example, a larger diamond hinge will provide a longer and
generally more flexible (i.e., less stiff) deformation path than a smaller
diamond hinge. Also, as is the case for all the unique hinges of the
present invention, the thickness of the plastic making up the hinge will
affect the stiffness of the hinge. Generally, the thinner the plastic
making up the hinge, the more flexible (and weaker) the hinge. The
converse is also generally true. The thicker the plastic making up the
hinge, the stiffer (and stronger) the hinge. The plastic thickness
selected for a particular application should have the right balance of
flexibility and stiffness taking into account, among other things, the
size and weight of the fragile items being packaged.
In the embodiment shown in FIGS. 3A and 3B, cross-hairs 372 and 374 are
substantially perpendicular to one another. Accordingly, in this exemplary
embodiment, each of the triangular surfaces 362, 364, 366 and 368 includes
a substantially right (i.e., 90 degree) angle.
Each diamond hinge 360 provides at least two predicted deformation paths.
Cross-hair 372 defines where one of the predicted deformation paths begin.
During deformation, triangular surfaces 366 and 364 will bend toward
triangular surfaces 368 and 362 along cross-hair 372 when, for example, a
sufficient force is applied in a direction perpendicular to one of side
walls 342 and 340 (e.g., a force applied in the direction of arrow 380).
Such deformation assists in absorbing the force, thereby preventing the
force from damaging the fragile items that are stored between ribs 330.
When the force is no longer applied, the triangular surfaces will
substantially return to their original positions.
Cross-hair 374 defines where a second predicted deformation path begins.
During deformation, triangular surfaces 362 and 364 will bend toward
triangular surfaces 368 and 366 along cross-hair 377 when, for example, a
sufficient force is applied in a direction toward front wall 342 or rear
wall 340 (e.g., a force applied in the direction of arrow 382). Such
deformation assists in absorbing the force, thereby preventing the force
from damaging the fragile items that are stored between ribs 330. When the
force is no longer applied, the triangular surfaces will substantially
return to their original positions.
Diamond hinge 360 may hinge in accordance with mainly one of the above
described deformations paths, or simultaneously in accordance with both of
the above described deformation paths, depending upon where a force is
applied. For example, if a force is applied in a direction of arrow 384
shown in FIG. 3A (e.g., toward an upper corner of a container within which
bottom panel 304 is sitting), it is likely that diamond hinge 360 will
hinge along both of the above described paths. Because of its shape and
its location, diamond hinge 360 may tweak or twist while absorbing such a
force. However, once the force is no longer applied diamond hinge 360 will
substantially return to its original shape.
V-Hinge
A further unique hinge of the present invention shall be referred to as a
v-hinge because of its generally "V" like shape. Referring to FIGS. 3A and
3B, a V-hinge 386 extends into front wall 322 close to where front wall
322 meets with side wall 340. v-hinge 386 includes a first v-shaped end
388 in front wall 324 with a tip pointing generally toward front edge 312
of base 318. A second v-shaped end 390 is located in platform 320 with a
tip pointing generally away from front edge 312 of base 318. Generally
parallel edges 392 and 394 extend between first v-shaped end 388 and
second v-shaped end 390. First and second walls 396 and 398 extend down,
respectively, from edges 392 and 394 and meet at a trough 399, thereby
forming a v-shaped channel. Similarly, a further v-hinge 386 extends into
rear wall 324 and platform 320 close to where rear wall 324 meets with
side wall 340.
As can be seen in FIG. 3D, which is a cut-away view along line D--D shown
in FIGS. 3A and 3B, edge 394, wall 396 and trough 399 (as well as edge 392
and wall 396) of v-hinge 386 curve or bend in a similar manner as does
front wall 322 (and rear wall 324) as it meets platform 320. This is
because the v-shaped channel of v-hinge 386 extends into both front wall
322 and platform 320. As can also be seen in FIG. 3D, a width of wall 398
is substantially constant along its length, except near first v-shaped end
388 and second v-shaped end 390, where the width of wall 398 tapers to a
point. The same is true for wall 396, which has substantially the same
shape as wall 398.
V-hinges 386 are useful for absorbing forces that are applied from a
direction substantially perpendicular or parallel to side wall 342 or side
wall 344 (e.g., a force along arrow 380). Trough 399 is where the
predicted deformation path begins, when a sufficient force is applied.
During deformation, first and second walls 396 and 398 will bend toward
one another about trough 399. As walls 396 and 398 bend toward one
another, an angle .theta. between each v-shape end 390 and 388 gets
smaller. Also, as walls 396 and 398 bend toward one another, an angle
.OMEGA. defined between walls 396 and 398 gets smaller (best seen in FIG.
3F, which is a cross-section view along line F--F shown in FIGS. 3A and
3B). Such deformation assists in absorbing the force, thereby preventing
the force from damaging the fragile items that are stored between ribs
330. When the force is no longer applied, first and second walls 396 and
398 will substantially return to their original positions, and angle
.theta. and angle .OMEGA. will each substantially return to their original
angles.
In exemplary panel 304, one v-hinge 386 extends into front wall 322 and
platform 320 close to where front wall 322 and platform 320 meet with side
wall 340, and the other v-hinge 386 extends into rear wall 324 and
platform 320 close to where rear wall 322 and platform 320 meet with side
wall 340. It is beneficial to have the v-hinges 286 located close a side
wall (e.g., side wall 340 or 342) so that the predicted deformation path
in front wall 322, rear wall 324 and platform 320 occurs outside the area
where fragile items are stored (i.e., outside of the region made up of
cells 352 between ribs 330). The same is true for diamond hinges 360
discussed above. However, v-hinges 386 can alternatively (or additionally)
be placed at other locations along front wall 322 and/or rear wall 324.
That is, the v-hinge need not be located near a side wall (i.e., near side
wall 340 or 342). For example, a v-hinge 386 can extend into front wall
322 at a location between the forth and fifth ribs 330 (from the left) and
another v-hinge 386 can extend into rear wall 324 between the same forth
and fifth ribs 330. V-hinges may even extend into sidewalls 340 and/or
342.
Preferably, v-hinges 386 are used as pairs of hinges so that substantially
equal deformation occurs in each of the front wall 322 and rear wall 324.
In another embodiment, rather than using a pair of v-hinges 386, a single
elongated v-hinges 386' extends into front wall 322, into and across the
entire width of platform 320, and into rear wall 324, as shown in FIG. 4.
Such an elongated v-hinge 386' is more flexible than a pair of v-hinges
386, because there is no flat portion of platform 320 between v-shaped
ends 390 of the pair of v-hinges 386 to resist flexing.
Observing FIGS. 3A and 3B, exemplary bottom panel 304 is shown as including
a total of six gusset hinges 332, two diamond hinges 360 and tw
