U.S. patent application number 11/080766 was filed with the patent office on 2006-09-21 for packaging system for a component including a compressive and shock-absorbent packing insert.
This patent application is currently assigned to International Business Machines Corporation. Invention is credited to Paul Cance, William Jason-Oliver Green, Jeffrey Wood Johnson, Jeffrey Jay Miller.
Application Number | 20060207914 11/080766 |
Document ID | / |
Family ID | 37009191 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060207914 |
Kind Code |
A1 |
Cance; Paul ; et
al. |
September 21, 2006 |
Packaging system for a component including a compressive and
shock-absorbent packing insert
Abstract
A packaging system for a component is disclosed. The packaging
system includes a compressible and shock-absorbent packing insert,
wherein the packing insert includes deformable "cushion elements"
that accommodate components of varying sizes and shapes in a
protective manner.
Inventors: |
Cance; Paul; (Durham,
NC) ; Green; William Jason-Oliver; (Cary, NC)
; Johnson; Jeffrey Wood; (Raleigh, NC) ; Miller;
Jeffrey Jay; (Cary, NC) |
Correspondence
Address: |
IBM CORPORATION (SYL-RPS)
C/O SYNNESTVEDT & LECHNER LLP
1101 MARKET STREET, SUITE 2600
PHILADELPHIA
PA
19107
US
|
Assignee: |
International Business Machines
Corporation
Armonk
NY
|
Family ID: |
37009191 |
Appl. No.: |
11/080766 |
Filed: |
March 15, 2005 |
Current U.S.
Class: |
206/588 ;
206/523; 206/586 |
Current CPC
Class: |
B65D 5/509 20130101;
B65D 81/1075 20130101 |
Class at
Publication: |
206/588 ;
206/523; 206/586 |
International
Class: |
B65D 81/02 20060101
B65D081/02; B65D 85/30 20060101 B65D085/30 |
Claims
1. A packaging system for components, the packaging system
comprising: a first frame, said first frame defining a first inner
area in which to nest one or more of said components and having at
least one compressible and shock-absorbent cushion element
positioned in said first inner area, said cushion element exerting
a compressive force on a component nested in said first inner
area.
2. The packaging system of claim 1, wherein said first frame
includes a plurality of said cushion elements positioned in said
first inner area, said plurality of cushion elements including one
or more cushion arches.
3. The packaging system of claim 1, wherein said first frame
includes a plurality of said cushion elements positioned in said
inner area, said plurality of cushion elements including one or
more cushion nubs.
4. The packaging system of claim 2, wherein said plurality of
cushion elements further includes one or more cushion nubs.
5. The packaging system of claim 4, wherein said first frame is
compressible and shock-absorbent.
6. The packaging system of claim 5, wherein said first frame and
said cushion elements comprise a unitary piece of the same
material.
7. The packaging system of claim 6, wherein: said first inner area
has four sides, and wherein said cushion arches are situated along
two of said sides, and said cushion nubs are situated along one of
said sides.
8. The packaging system of claim 7, wherein said cushion arches are
situated along two abutting sides.
9. The packaging system of claim 8, further comprising: a box; and
a compressible and shock-absorbing bottom cushion; wherein said
bottom cushion is placed in said box, said first frame being
situated atop said bottom cushion, and said one or more components
are nested within said inner area of said first frame.
10. The packaging system of claim 9, further comprising a
compressible and shock-absorbing top cushion, situated atop said
first frame.
11. The packaging system of claim 10, wherein said bottom cushion
comprises a second frame defining a second inner area that is
smaller than said first inner area.
12. The packaging system of claim 10, wherein said top cushion
comprises a third frame defining a third inner area that is smaller
than said first inner area.
13. A packaging element for components, comprising: a frame, said
frame defining an inner area in which to nest one or more of said
components and having at least one compressible and shock-absorbent
cushion element positioned in said inner area, said cushion element
exerting a compressive force on a component nested in said inner
area.
14. The packaging element of claim 13, wherein said frame includes
a plurality of said cushion elements positioned in said inner area,
said plurality of cushion elements including one or more cushion
arches.
15. The packaging element of claim 13, wherein said frame includes
a plurality of said cushion elements positioned in said inner area,
said plurality of cushion elements including one or more cushion
nubs.
16. The packaging element of claim 14, wherein said plurality of
cushion elements further includes one or more cushion nubs.
17. The packaging element of claim 16, wherein said frame is
compressible and shock-absorbent.
18. The packaging element of claim 17, wherein said frame and said
cushion elements comprise a unitary piece of the same material.
19. The packaging system of claim 18, wherein: said inner area has
four sides, and wherein said cushion arches are situated along two
of said sides, and said cushion nubs are situated along one of said
sides.
20. The packaging system of claim 19, wherein said cushion arches
are situated along two abutting sides.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to packaging systems
and more specifically to a packing insert for use in a packaging
system for fragile components.
[0003] 2. Description of the Related Art
[0004] Previous approaches to shipping fragile components (i.e.,
notebook computers, hard drives, etc.) have typically utilized
substances such as resilient foam, as well as adhesives and other
non-recyclable materials when packaging such components. Typically
in the case of notebook computers, the maximum force that can be
applied to all axes in a conventional hard drive is approximately
70 Gs.
[0005] FIG. 1 is an exploded view of a typical packaging system 100
for a notebook computer. The system includes a polyurethane bottom
cushion 112, a polyurethane middle cushion 114, a polyurethane top
cushion 116 and a corrugated tray 118, all of which fit into a
corrugated carton 110. Utilizing this approach, the notebook
computer to be shipped (not shown) is inserted between the
polyurethane top cushion 116 and the polyurethane bottom cushion
112, through the polyurethane middle cushion 114.
[0006] The middle cushion 114 defines an opening 120 in which the
component to be shipped is placed. The size of the opening will
vary, depending upon the dimensions of the component. In the case
of original packing (i.e., when the product is shipped from the
manufacturer to the consumer), the manufacturer is able to select
the size of the polyurethane middle cushion 114 to fit the size of
the component being shipped. For example, IBM's ThinkPad.RTM. line
of notebook computers have similar generic characteristics, but
from one model to the next, the overall dimensions, particularly
the length and width, can vary by several inches. The manufacturer
can have available one size of middle cushion for a first model, a
second size of middle cushion for a second model, etc. The
manufacturer simply selects the appropriate sized cushion and packs
the device into the box.
[0007] This requires that the manufacturer keep on hand middle
cushions of various sizes. Further, when a consumer wishes to ship
a device, e.g., a notebook computer, back to the manufacturer for
repair, the standard practice has been to send the consumer a box
and shipping materials to be used in shipping the device back for
repair. To simplify the process, rather than asking the consumer
which specific device is being shipped and confirming the
dimensions of the device to be shipped, and then sending a middle
cushion that will fit the device, the practice has been to send a
"one-size-fits-all" package to the consumer, and then have the
consumer conform the packing material to the particular item being
shipped. This packaging comprises a middle cushion 114 having a
cavity that has "tear outs" that can be removed for different sized
products. The larger the product, the more tear-outs have to be
removed to accommodate its larger size. Once the tear-outs are
removed, they are not replaceable, and the pieces that are removed
need to be thrown away.
[0008] While providing a convenient solution, the tear-out solution
it is not without its drawbacks. For example, once the tear-out
inserts are removed, the middle cushion can only be reused with the
same sized or larger products. If for some reason a smaller product
is substituted for the larger one (e.g., a replacement is shipped
to the consumer on receipt of the returned item), a new middle
cushion must be used. Second, removed tear-outs typically cannot be
recycled in non-industrial environments (such as at the consumer
location) and thus must be thrown away, increasing the quantity of
non-biodegradable materials in landfills. Further, it relies on the
customer to make the right choice on the number of tear-outs to be
removed. If too many are taken out, the product will be loose
inside the carton, subjecting it to increased risk of damage.
[0009] Additionally, the prior art method of using a complete top
and bottom cushion, with or without the tear-outs, results in very
high G values on "top drops" (the dropping of an object onto the
top of the packaging containing an item). This is because, as is
known from basic packaging dynamics, the more cushioning material
there is in contact with the product, the less the cushioning
material can flex, thus increasing the shock force applied to the
product. The G value can be lowered by thicker top and bottom
cushions, but this increases both packaging and shipping costs.
[0010] Accordingly, what is needed is a packaging system and method
which provides flexibility in terms of the size of the components
being shipped, utilizes environmentally safe and recyclable
materials, can accommodate multiple-sized components while still
being reusable, and yet safely protects fragile components from
potential damage that can be caused during the shipping process.
The present invention addresses such needs.
SUMMARY OF THE INVENTION
[0011] A packaging system for a component is disclosed. The
packaging system includes a compressible and shock-absorbent
packing insert, wherein the packing insert includes deformable
"cushion arches" that accommodate components of varying sizes and
shapes in a protective manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded view of a conventional packaging
system for fragile components;
[0013] FIGS. 2-5 illustrate a middle cushion of the prior art
tear-away system in varying states of use;
[0014] FIG. 6 illustrates a first embodiment of the present
invention, wherein "cushion arches" and "cushion nubs" are used
instead of tear-outs to enable the accommodation of different sized
products, and hold them in place;
[0015] FIG. 7 shows the insertion of component 630 into the opening
of middle cushion 614;
[0016] FIG. 8 illustrates an example of such deformation, in
connection with the insertion of component 632 into the same area
occupied by component 630 in FIG. 7; and
[0017] FIG. 9 illustrates top and bottom cushions used in
connection with the middle cushion of FIGS. 6-8, according to the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] To better understand the present invention, it is helpful to
understand the deficiencies of the prior art. The prior art is
described below with reference to FIGS. 2-5. FIGS. 2-5 illustrate
the middle cushion of the prior art tear-away system described
above, in varying states of use. Referring first to FIG. 2, the
middle cushion 214 includes a cut-out portion 220 and a plurality
of tear-away elements 222A-222N. A single rectangular piece of foam
material, e.g., polyethylene foam, polyurethane foam, or
polypropylene foam, having a length and width equal to middle
cushion 214, is subjected to a first cut that completely removes a
portion of the foam equal in size to the cut-out portion 220. To
create the tear-away elements, a second cutting process is utilized
that makes only a partial cut defining the tear-away elements
222A-222N, i.e., the cut does not go all the way through the
thickness of the polyurethane foam, and/or perforating cuts are
made along the lengths and widths of the tear-away elements
222A-222N, so that they are not separated from the middle cushion
214, but are easily torn away from the middle cushion as desired.
As is well known, perforating cuts can be a series of holes or
slits along the length of the tear-away element making it easy to
tear the tear-away elements away on a selective basis.
[0019] Shown next to the middle cushion 214 are two components 230
and 232 representing two rectangular components of different sizes,
each of which are capable of being packed in a package using the
middle cushion 214 of FIG. 2. Components 230 and 232 can represent
notebook computers, hard drives, and the like. In the example of
FIG. 2, both of the components 230 and 232 are larger than the
opening 220 and thus neither of them will fit into the middle
cushion 214 without the removal of one or more of the tear-away
elements 222A-222N.
[0020] FIG. 3 illustrates the middle cushion 214 of FIG. 2 with
certain of the tear-away elements removed. Specifically, if a
person wishes to insert component 230 into middle cushion 214, they
can place the component 230 on top of the middle cushion 214 so
that the particular tear-away elements that need to be removed to
allow the middle cushion 214 to accommodate the component 230 can
be estimated. In this example, tear-away elements 222C, F, I, J, K,
L, and M have been removed (shown in their removed state below
middle cushion 214), thereby expanding the size of opening 220.
[0021] FIG. 4 shows component 230 inserted into opening 220. As can
be seen, the remaining (those that have not been torn away)
tear-away elements 222A, B, D, E, G, H, and N remain in place and
provide a limitation on the movement of component 230. It is noted
that the removed tear-away elements can no longer be used and are
thus discarded.
[0022] FIG. 5 illustrates the use of the same middle cushion 214
for use in connection with the shipping of component 232. As shown
in FIG. 5, removal of all of the tear-away elements 222A-222N
allows component 232 to fit in the opening 220. Once removed, all
of the tear-away elements 222A-222N are discarded. Further, the
middle cushion is no longer useable to safely ship component 230,
since all of the tear-away elements have been removed.
[0023] FIG. 6 illustrates a first embodiment of the present
invention, wherein compressible and shock-absorbent cushion
elements, e.g., "cushion arches" and "cushion nubs," are used to
enable the accommodation of different sized products, and hold them
in place. Referring to FIG. 6, a series of arches 634, 636, 638,
640, and 642 are formed as part of frame-shaped middle cushion 614,
with the arches extending inward into the inner area formed by
opening 620. The arches can be formed using any known method, e.g.,
cutting or molding polyethylene, polyurethane, polypropylene, or
any known cushioning material having resilient properties.
[0024] In FIG. 6, Nubs 644 and 646 are formed on one interior side
of middle cushion 614, extending into the inner area formed by
opening 620 as shown. Nubs 644 and 646 comprise, in this example,
semi-circular protrusions formed by cutting and/or molding. The
bottom side of opening 620 in this example has neither arches nor
nubs extending therein; however, it is understood that any
combination of arches and/or nubs can be formed on one, two, three,
or all four interior sides extending into opening 620 and still
fall within the scope of the present invention. In the preferred
embodiment illustrated in FIG. 6, two sides are provided without
arches to make it easier to insert a product into the opening 620.
The arches and/or nubs exert a compressive force on products placed
within the inner area formed by opening 620. Compressing arches on
all four sides, or even on three sides, is more difficult than
having to compress arches on only two sides as shown. With arches
on only two sides, pressure need be exerted against the arches in
only one direction (diagonally) to load the product instead of
multiple directions. The nubs make the product fit better and
allows for some variability in larger products.
[0025] Although not limited to such dimensions, applicant currently
contemplates two configurations differing only by dimension and
selected based on practicality of use and not based on performance
characteristics, i.e., the differences in dimensions are based on
maximizing the ability to use the packaging material with the
widest variety of products, and the dimensional differences do not
affect the performance of the packaging materials. In one design,
the outside dimensions of the middle cushion are
15''.times.14.75'', with an opening of 12.625''.times.10.625''. In
another design, the outside dimensions are 16.5''.times.15.5'',
with an opening of 13.625''.times.11.625''. The arches, in the
preferred embodiment, range from 4.5'' wide.times.1.1'' high (i.e.,
extension into the opening) to 6'' wide.times.1.5'' high. Arches of
this size give 0.75'' to 1.25'' in dimensional variability (length
and width) for products to be used with the packaging. In a
preferred embodiment, the material used is extruded polyethylene
foam having a thickness of 1.5 inches and a cushion density of 1.7
PCF; it is understood, however, that the present invention is not
limited to this material, nor to these dimensional or density
characterisics.
[0026] FIG. 7 shows the insertion of component 630 into the opening
of middle cushion 614. Since component 630 is the smaller of the
two components 630 and 632, it deforms the cushion arches and nubs
little, if any at all, yet the arches and nubs hold the component
630 in place to limit movement during shipping. In this example the
area defined by the arches and cushions in their undeformed state
is approximately equal to the are defined by the component 630.
However, it is understood that the arches could extend further into
the opening 620 that is shown in FIG. 7 and still be able to
accommodate component 630, since the arches and nubs are made of
deformable material and have room to deform when pressure is
exerted thereon.
[0027] FIG. 8 illustrates an example of such deformation, in
connection with the insertion of component 632 into the same area
occupied by component 630 in FIG. 7. Referring to FIG. 8, the
cushion arches 634-642 are shown deformed such that they have
essentially no curvature and are thus fully compressed against the
cushion 614 and component 632. Nubs 644 and 646 are almost
obstructed form view, as they too are fully compressed by the
component 632. In this arrangement, the component 632 is held in
place so that it can move very little, if at all, during shipment.
However, in contrast to the prior art, when the component 632 is
removed from the middle cushion 614, the arches and nubs reform
back to their original shape as shown in FIG. 6. This allows them
to be reused with a smaller component, unlike the tear-away system
of the prior art.
[0028] The arches and nubs provide effective cushioning for the
product, against drops and vibration damage. The design
accommodates a variety of shapes and sizes, and the configuration
can be varied to accommodate almost any size and shape of
component. The design also reduces the amount of waste material,
since there are no pieces that are removed and discarded by the
consumer. Further, there is no judgment required of the consumer,
thereby eliminating the possibility that the consumer will render
the shipping materials useless for their intended purpose. In
addition, the arched shape and the flexed arches (when the size of
the component depresses the arches) leads to added protection
against damage due to vibration, dropping, etc.
[0029] In a preferred embodiment, the middle cushion 614 of the
present invention is utilized with a bottom cushion 912 and a top
cushion 916, which can then be placed in a box or other shipping
container in a well-known manner. As shown in FIG. 9, in accordance
with the present invention, the bottom cushion 912 is frame-shaped,
defining an inner area (opening) 913, i.e., the center portion of
bottom cushion 912 is removed. Similarly, top cushion 916 is
frame-shaped, defining an inner area (opening) 917. In addition to
reducing the weight of the overall shipping package, the removal of
the center portion of the bottom and top cushions 912 and 916
reduces the bearing area (the portions of the cushioning contacting
the product) of the top and bottom cushions, which lowers the
resultant G's after drops in accordance with well-known packaging
dynamics principles. This results in a smaller package with
increased protection for the product. The amount of cushioning
removed can vary and can be optimized by taking into consideration
the size and weight of the product(s) being shipped. In a preferred
embodiment the size of the inner areas 913 and 917 is smaller in
length and width than the size of the product nested in middle
cushion 214. It is understood that only a top cushion or bottom
cushion can be used if desired, and that using both top and bottom
cushions provides the most protection for the component being
shipped.
[0030] The arches bend/compress with the larger systems, and thus
do not generate additional scrap by the user, therefore reducing
the amount of materials discarded into landfills. Any scrap
materials associated with the packaging of the present invention
will be generated at the supplier site, and can be reused and/or
recycled through industrial channels, not available to the typical
consumer.
[0031] The arches compress and extend for various sized products,
so the package can be reused for multiple sized products in
multiple shipments. This reduces waste in packaging, as well as
reduces the cost of using packaging for each shipment. Also,
because the arches compress and extend, they provide additional
protection to the product, which results in more protection for
less space. This can result in significant size reductions, as much
as 33% reductions in some cases. The size, thickness, and number of
arches can be adjusted to accommodate larger/smaller, as well as
heavier/lighter products.
[0032] Although the present invention has been described with
respect to a specific preferred embodiment thereof, various changes
and modifications may be suggested to one skilled in the art and it
is intended that the present invention encompass such changes and
modifications as fall within the scope of the appended claims.
* * * * *