U.S. patent application number 10/851301 was filed with the patent office on 2005-08-18 for universal computer packaging cushion.
This patent application is currently assigned to Sony Corporation. Invention is credited to Sotto, Ryan.
Application Number | 20050178690 10/851301 |
Document ID | / |
Family ID | 34841188 |
Filed Date | 2005-08-18 |
United States Patent
Application |
20050178690 |
Kind Code |
A1 |
Sotto, Ryan |
August 18, 2005 |
UNIVERSAL COMPUTER PACKAGING CUSHION
Abstract
A computer cushion has a foam frame defining a window through
which a computer can be placed to rest on supports that are glued
to the frame and that span the window. Hinged flaps are provided on
the inside of each side of the frame, and the flaps are biased
against the frame inside the window to reduce its size for smaller
computers. When a larger computer is pushed through the window, it
can pivot one or more of the flaps outwardly from the window so the
computer will fit into the now-larger window.
Inventors: |
Sotto, Ryan; (Escondido,
CA) |
Correspondence
Address: |
Sony Electronics Inc.
MZ 7190
16450 West Bernardo Drive
San Diego
CA
92127-1898
US
|
Assignee: |
Sony Corporation
Sony Electronics Inc.
|
Family ID: |
34841188 |
Appl. No.: |
10/851301 |
Filed: |
May 21, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60544634 |
Feb 13, 2004 |
|
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Current U.S.
Class: |
206/523 ;
206/320; 206/591 |
Current CPC
Class: |
B65D 81/107 20130101;
B65D 2585/6835 20130101 |
Class at
Publication: |
206/523 ;
206/320; 206/591 |
International
Class: |
B65D 085/30 |
Claims
I claim:
1. A computer packaging cushion for holding at least one computer
component, comprising: a parallelepiped-shaped frame defining a
window substantially in the center thereof; at least one U-shaped
support engaged with the frame and spanning the window, and at
least one flap hingedly engaged with the frame and biased to a
first configuration, wherein the flap is substantially flush
against an inner wall of the frame to partially block the window,
the flap being movable to a second configuration, wherein the flap
is folded outwardly away from the window a provided, one for each
side of the frame.
2. (canceled)
3. The cushion of claim 1, wherein the flap is attached to the
frame by a hinge, the hinge being defined by a lamination
material.
4. The cushion of claim 1, wherein the flap is moved to the second
configuration automatically when a computer component is pushed
against the flap while advancing the component through the
window.
5. The cushion of claim 1, comprising two supports spanning the
window.
6. The cushion of claim 1, wherein the frame is made of foam.
7. (canceled)
8. A cushion for packaging, comprising: at least one support in
which a component can be cushionably supported; and at least one
frame engaged with the support and defining a window structure
through which the component can be disposed to rest on the support,
wherein the window structure is biased to a first configuration in
which the window structure defines a relatively smaller window
area, the window structure being movable to a second configuration
when a sufficiently large objects advanced therethrough to define a
relatively larger window area, wherein the frame defines a window
and the window structure includes four flaps hingedly engaged with
respective sides of the frame, each flap being biased to a recessed
configuration, wherein the flap is substantially flush against an
inner wall of the frame, each flap being movable to an extended
configuration, wherein the flap is folded outwardly away from the
window.
9. (canceled)
10. The cushion of claim 8, wherein the flap is attached to the
frame by a hinge, the hinge being defined by a lamination
material.
11. The cushion of claim 8, wherein the flap is moved to the second
configuration automatically when a computer component is pushed
against the flap while advancing the component through the
window.
12. The cushion of claim 8, comprising supports spanning the
window.
13. The cushion of claim 8, wherein the frame is made of foam.
14-16. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional
application Ser. No. 60/544,634, filed Feb. 13, 2004.
I. FIELD OF THE INVENTION
[0002] The present invention relates generally to shipping
containers for computer systems.
II. BACKGROUND OF THE INVENTION
[0003] A computer production area is normally filled with palates
of products, packaging cushions for he products, and shipping
cartons. A computer can be shipped to a consumer with many
accessories. For example, some computer peripherals include a
mouse, a battery charger, a power cord, and a keyboard. These
peripherals are not connected to the computer but are still shipped
with the computer and generally require separate packaging.
[0004] As understood herein, a computer production area can require
a great deal of space for manufacturing, testing, and shipping the
computer. Also, space is required for loading software onto
computers prior to shipment to a consumer. Unfortunately, valuable
space is consumed by the shipping materials, which can decrease
production throughput. The present invention recognizes that one
source of this problem is the fact that different sizes of
computers require different sizes of packaging cushions to snugly
hold the computers within the shipping boxes, so that a plethora of
differently-sized cushions must be stored in the production area,
consuming excessive space. Having made this critical observation,
the invention herein has been provided.
SUMMARY OF THE INVENTION
[0005] A computer packaging cushion for holding a computer
component includes a parallelepiped-shaped frame that defines a
window which is substantially in the center of the frame. At least
one U-shaped support is engaged with the frame and spans the
window. Also, one or more flaps are hingedly engaged with the frame
and are biased to a first configuration, wherein the flaps are
substantially flush against respective inner walls of the frame to
partially block the window. The flaps are movable to a second
configuration, wherein the flaps are folded outwardly away from the
window.
[0006] In one embodiment four flaps are provided, one for each side
of the frame. Each flap may be attached to the frame by a hinge
that can be defined by a lamination material. A flap can be moved
to the second configuration automatically when a computer component
is pushed against the flap while advancing the component through
the window. The frame may be made of foam.
[0007] In another aspect, a cushion for packaging includes at least
one support in which a component can be cushionably supported, and
at least one frame engaged with the support and defining a window
structure through which the component can be disposed to rest on
the support. The window structure is biased to a first
configuration in which the window structure defines a relatively
smaller window area. Also, the window structure is movable to a
second configuration when a sufficiently large object is advanced
therethrough to define a relatively larger window area.
[0008] In still another aspect, a method of making a packaging
cushion includes providing lamination on a foam structure, and
cutting the foam structure to form a window centrally therein
without cutting completely through all of the lamination. With this
method, sufficient lamination remains to establish a hinge between
a frame defined during the cutting act and at least one flap that
is also defined during the cutting act.
[0009] The details of the present invention, both as to its
structure and operation, can best be understood in reference to the
accompanying drawings, in which like reference numerals refer to
like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of the computer packaging
cushion, with the upper and lower flaps folded out and the side
flaps folded in;
[0011] FIG. 2 is a perspective view of the computer packaging
cushion, with the upper and lower flaps folded in and the side
flaps folded out;
[0012] FIG. 3 is a perspective view of the computer packaging
cushion, with all four flaps folded out, showing a computer
component in an exploded relationship with the cushion; and
[0013] FIG. 4 is a flow chart of the method for making the
cushion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring initially to FIGS. 1-3, a packaging cushion is
shown, generally designated 10, for holding, in a box, a computer
component (such as a personal computer shown in FIG. 3 below). In
accordance with present principles, the packaging cushion 10 may
include a hollow parallelepiped-shaped unitary foam frame 12
defining a central rectangular window 14.
[0015] For illustration purposes terms of orientation (such as
"upper", "lower", "left", "right", etc.) will be used in the
discussion below, it being understood that the terms of orientation
are relative only and non-limiting. For instance, the "upper" part
of the packaging cushion 10 may actually be placed against what
might be termed a "bottom" of a box, etc.
[0016] As shown in FIGS. 1-3, at least one and preferably two
U-shaped supports 16 are connected to the frame 12 by, e.g.,
solvent bonding. Specifically, each support 16 is connected to the
front surfaces 18 of opposite parallel left and right sides 20 of
the frame 12 such that a cross-bar 22 of each support 16 spans the
window 14.
[0017] In accordance with the present invention, the cushion 10
includes at least one and preferably four flaps that are hingedly
coupled to the frame. In the embodiment shown, the cushion 10
includes upper and lower flaps 24, 26 that are respectively hinged
to upper and lower segments 28, 30 of the frame 12. Also, the
cushion 10 includes left and right flaps 32, 34 that are
respectively hinged to the left and right sides 20 of the frame 12.
In one non-limiting embodiment, a lamination material 36
establishes the hinge between each flap and its respective frame
side. In one embodiment, the frame 12 may be made of conventional
packaging foam and the lamination material is made of thicker and
stronger foam material than the frame 12. In the non-limiting
embodiment shown in FIG. 1, the upper and lower flaps 24, 26 may be
long enough to extend substantially the entire width of the window
14, whereas if desired the side flaps 32, 34 may be only so long as
to extend only part of the way of the length of the window 14 as
shown, although the side flaps 32, 34 may alternatively extend for
substantially the entire length of the window 14.
[0018] Owing to the hinge structure described above, the flaps 24,
26, 32, 34 are materially biased by the respective hinges 36 to a
recessed configuration, wherein the flap is substantially flush
against the inner wall of its respective side of the frame 12. In
FIG. 1, the side flaps 32, 34 are shown in the recessed
configuration, and in FIG. 2 the upper and lower flaps 24, 26 are
shown in the recessed configuration. Also, each flap 24, 26, 32, 34
can be moved to an extended configuration, wherein the flap is
folded outwardly away from the window 14 such that the face of the
flap that is against the inner wall of the frame when the flap in
the recessed configuration is substantially coplanar with and
adjacent to the inner wall when in the extended configuration. In
FIG. 1, the upper and lower flaps 24, 26 are shown in the extended
configuration, while in FIG. 2 the side flaps 32, 34 are in the
extended configuration. In FIG. 3, all four flaps are in the
extended configuration. It readily will be appreciated that a flap
in the recessed configuration partially blocks the window 14, and
when a flap is in the extended configuration it does not block the
window. In addition to the particular combinations of flap
configurations shown in FIGS. 1-3, all four flaps may be recessed,
or only one flap extended, or some other combination, may be
possible with the cushion 10.
[0019] Referring specifically to FIG. 3, because the flaps are
hinged to the frame, when a component such as a computer 38 is
pushed against a flap while advancing the component through the
window 14, the flap being pushed pivots from the recessed
configuration to the extended configuration automatically. The flap
is held in the extended configuration by the component, which
extends through the window 14 to rest on the supports 16. Then,
when the component is removed from the cushion 10, any flap in the
extended configuration pivots back to the recessed configuration,
owing to the material bias provided by the non-limiting hinge. The
frame 12 accordingly can be thought of as having a window structure
through which the component 38 can be disposed to rest on the
supports 16, with the window structure being biased to a recessed
configuration in which the window structure defines a relatively
smaller window area and with the window structure being movable to
an extended configuration when a sufficiently large object is
advanced therethrough to define a relatively larger window
area.
[0020] With this structure, it may now be appreciated that the
frame 12 with flaps 24, 26, 32, 34 can be configured and sized such
that a computer or other component with a relatively smaller form
factor will fit snugly within window 14 when all four flaps are in
the recessed configuration. It may be further appreciated that a
component with a relatively larger form factor can be pushed
through the window 14 to pivot one or more of the flaps 24, 26, 32,
34 as necessary to provide clearance for the component to rest
partially within the window 14 and partially against the supports
16, again snugly held on all four sides by the frame 12 with
flaps.
[0021] Now referring to FIG. 4, a non-limiting method for making
the cushion 10 can be seen. A blank piece of foam stock is provided
at block 40 and a laminate material disposed on it by means known
in the art. The foam stock may be a solid parallelepiped-shaped
piece of material. Then, at block 42 the stock is cut (e.g., by
stamping) to form the window 14. During the cutting process, the
portions of the laminate that are to form the hinges 36 are not
cut. Also during the cutting process, the flaps 24, 26, 32, 34 are
formed by cutting away foam material around them to shape them
into, e.g., parallelepiped-shaped flaps as shown. At block 44 the
U-shaped supports can be glued onto the frame 12.
[0022] While the particular UNIVERSAL COMPUTER PACKAGING CUSHION as
herein shown and described in detail is fully capable of attaining
the above-described objects of the invention, it is to be
understood that it is the presently preferred embodiment of the
present invention and is thus representative of the subject matter
which is broadly contemplated by the present invention, that the
scope of the present invention fully encompasses other embodiments
which may become obvious to those skilled in the art, and that the
scope of the present invention is accordingly to be limited by
nothing other than the appended claims, in which reference to an
element in the singular is not intended to mean "one and only one"
unless explicitly so stated, but rather "one or more". It is not
necessary for a device or method to address each and every problem
sought to be solved by the present invention, for it to be
encompassed by the present claims. Furthermore, no element,
component, or method step in the present disclosure is intended to
be dedicated to the public regardless of whether the element,
component, or method step is explicitly recited in the claims.
Absent express definitions herein, claim terms are to be given all
ordinary and accustomed meanings that are not irreconcilable with
the present specification and file history.
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