U.S. patent application number 12/104434 was filed with the patent office on 2009-10-01 for retention packaging having film with pleated portion.
This patent application is currently assigned to KPC-MASTER'S CRAFT INTERNATIONAL, INC.. Invention is credited to Richard ANDERSON, Stephen A. KEIGER.
Application Number | 20090242448 12/104434 |
Document ID | / |
Family ID | 41115503 |
Filed Date | 2009-10-01 |
United States Patent
Application |
20090242448 |
Kind Code |
A1 |
KEIGER; Stephen A. ; et
al. |
October 1, 2009 |
RETENTION PACKAGING HAVING FILM WITH PLEATED PORTION
Abstract
A retention packaging includes a support member having first and
second sections each defining a support surface for receiving an
object thereon for shipping, and a film disposed in covering
relation to the support surfaces of the support member and retained
to the support member at the first and second sections. The first
and second sections are pivotably connected to one another along a
fold line that transects the support member. The film includes
opposite ends each enclosing a respective opposite end of the
support member and defining overlapping areas of the film that are
permanently joined together, and a pleated portion that is located
between the opposite ends of the film and that includes at least
one fold in the film. The film is removably secured to itself so as
to removably secure the at least one fold of the pleated
portion.
Inventors: |
KEIGER; Stephen A.; (Copley,
OH) ; ANDERSON; Richard; (Massillon, OH) |
Correspondence
Address: |
TILLMAN WRIGHT, PLLC
PO BOX 473909
CHARLOTTE
NC
28247
US
|
Assignee: |
KPC-MASTER'S CRAFT INTERNATIONAL,
INC.
Massillon
OH
|
Family ID: |
41115503 |
Appl. No.: |
12/104434 |
Filed: |
April 17, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61041569 |
Apr 1, 2008 |
|
|
|
Current U.S.
Class: |
206/478 ;
206/594 |
Current CPC
Class: |
B65D 5/5028 20130101;
B65D 75/305 20130101 |
Class at
Publication: |
206/478 ;
206/594 |
International
Class: |
B65D 73/00 20060101
B65D073/00; B65D 81/02 20060101 B65D081/02 |
Claims
1. A retention packaging, comprising: (a) a support member having
first and second sections each defining a support surface for
receiving an object thereon for shipping, the first and second
sections being pivotably connected to one another along a fold line
that transects the support member; and (b) a film disposed in
covering relation to the support surfaces of the support member and
retained to the support member at the first and second sections,
the film including opposite ends each enclosing a respective
opposite end of the support member and defining overlapping areas
of the film that are permanently joined together, with the first
section of the support member extending between the overlapping
areas of one of the opposite ends of the film, and with the second
section of the support member extending between the overlapping
areas of the other of the opposite ends of the film; (c) wherein,
(i) each opposite end of the support member includes a respective
opposite end edge of the support member, the opposite end edges of
the support member being spaced a distance apart when the first and
second sections are coplanar, and (ii) the film further comprises a
pleated portion that is located between the opposite ends of the
film and that includes at least one fold in the film, the film
being removably secured to itself so as to removably secure the at
least one fold of the pleated portion, whereby an unfolded length
of the film may exceed the distance between the opposite end edges
of the support member without compromising the retention of the
film to the support member.
2. The retention packaging of claim 1, wherein the fold line
generally bisects the support member.
3. The retention packaging of claim 1, wherein the film is retained
to the support member only by extension of the first and second
sections of the support member between the overlapping areas of the
film.
4. The retention packaging of claim 1, wherein the film further
comprises a plurality of tabs located along a side edge of the film
and spaced to substantially coincide with one another by virtue of
the at least one fold in the film, wherein the tabs are removably
attached to one another to removably secure the at least one fold
of the pleated portion.
5. The retention packaging of claim 4, wherein the plurality of
tabs are adhered together to removably secure the at least one fold
of the pleated portion.
6. The retention packaging of claim 4, wherein the plurality of
tabs are sealed together to removably secure the at least one fold
of the pleated portion.
7. The retention packaging of claim 1, wherein the first and second
sections of the support member are approximately equal in length
and width.
8. The retention packaging of claim 1, wherein the first and second
sections of the support member have approximately equal surface
area.
9. The retention packaging of claim 1, wherein the overlapping
areas of the film that are permanently joined together are heat
sealed, adhered, or welded together.
10. The retention packaging of claim 1, wherein the film comprises
a stretchable material.
11. The retention packaging of claim 1, wherein the film comprises
a heat shrinkable material.
12. The retention packaging of claim 1, wherein the support member
is scored along the fold line.
13. The retention packaging of claim 1, wherein the support member
comprises a rigid material.
14. A shipping apparatus, comprising: (a) a shipping container
having an interior cargo space defined by a length, a height, and a
width; and (b) a retention packaging contained within the shipping
container, the retention packaging comprising: (i) a support member
having first and second sections each defining a support surface
for receiving an object thereon for shipping, the first and second
sections being pivotably connected to one another along a fold line
that transects the support member; and (ii) a film disposed in
covering relation to the support surfaces of the support member and
retained to the support member at the first and second sections,
the film including opposite ends each enclosing a respective
opposite end of the support member and defining overlapping areas
of the film that are permanently joined together, with the first
section of the support member extending between the overlapping
areas of one of the opposite ends of the film, and with the second
section of the support member extending between the overlapping
areas of the other of the opposite ends of the film; (iii) wherein,
(A) each opposite end of the support member includes a respective
opposite end edge of the support member, the opposite end edges of
the support member being spaced a distance apart when the first and
second sections are coplanar, (B) the film further comprises a
pleated portion that is located between the opposite ends of the
film and that includes at least one fold in the film, the film
being removably secured to itself so as to removably secure the at
least one fold of the pleated portion, and (C) the film further
comprises a plurality of tabs located along a side edge of the film
and spaced to substantially coincide with one another by virtue of
the at least one fold in the film, wherein the tabs are removably
attached to one another to removably secure the at least one fold
of the pleated portion, whereby an unfolded length of the film may
exceed the distance between the opposite end edges of the support
member without compromising the retention of the film to the
support member.
15. The shipping apparatus of claim 14, wherein: (a) the fold line
generally bisects the support member; (b) the first and second
sections of the support member are approximately equal in length
and width; and (c) the equal lengths and widths of the first and
second sections of the support member are generally the same as the
length and width of the interior cargo space of the shipping
container.
16. The shipping apparatus of claim 15, wherein the film with the
pleated portion is retained to the support member only by extension
of the first and second sections of the support member between the
overlapping areas of the film.
17. The shipping apparatus of claim 15, wherein the overlapping
areas of the film that are permanently joined together are heat
sealed, adhered, or welded together.
18. The shipping apparatus of claim 15, wherein the film comprises
a stretchable material.
19. The shipping apparatus of claim 15, wherein the film comprises
a heat shrinkable material.
20. A retention packaging, comprising: (a) a support member having
first and second sections each defining a support surface for
receiving an object thereon for shipping, the first and second
sections being pivotably connected to one another along a fold line
that transects the support member; and (b) a film comprised of a
stretchable material and disposed in covering relation to the
support surfaces of the support member and retained to the support
member at the first and second sections, the film including
opposite ends each enclosing a respective opposite end of the
support member and defining overlapping areas of the film that are
permanently joined together, with the first section of the support
member extending between the overlapping areas of one of the
opposite ends of the film, and with the second section of the
support member extending between the overlapping areas of the other
of the opposite ends of the film; (c) wherein, (i) each opposite
end of the support member includes a respective opposite end edge
of the support member, the opposite end edges of the support member
being spaced a distance apart when the first and second sections
are coplanar, (ii) the film further comprises a pleated portion
that is located between the opposite ends of the film and that
includes at least one fold in the film, the film being removably
secured to itself so as to removably secure the at least one fold
of the pleated portion, whereby an unfolded length of the film may
exceed the distance between the opposite end edges of the support
member without compromising the retention of the film to the
support member, and (iii) the first and second sections of the
support member are approximately equal in length and width.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a U.S. nonprovisional patent
application of, and claims priority under 35 U.S.C. .sctn.119(e)
to, U.S. Provisional Patent Application No. 61/041,569, filed Apr.
1, 2008, which provisional patent application is incorporated
herein by reference.
INCORPORATION BY REFERENCE
[0002] The present application further incorporates herein by
reference the following: [0003] a) Keiger, U.S. patent application
Ser. No. 11/941,061, filed Nov. 15, 2007, and Keiger, U.S. Patent
Application Publication No. ______, which represents the
publication of the '061 application to Keiger; [0004] b) Anderson,
et al., U.S. patent application Ser. No. 11/941,067, filed Nov. 15,
2007, and Anderson et al., U.S. Patent Application Publication No.
______, which represents the publication of the '067 application to
Anderson et al.; and [0005] c) Keiger, U.S. Provisional Patent
Application No. 60/865,847, filed Nov. 15, 2006.
COPYRIGHT STATEMENT
[0006] All of the material in this patent document is subject to
copyright protection under the copyright laws of the United States
and other countries. The copyright owner has no objection to the
facsimile reproduction by anyone of the patent document or the
patent disclosure, as it appears in official governmental records
but, otherwise, all other copyright rights whatsoever are
reserved.
BACKGROUND OF THE INVENTION
[0007] The present invention generally relates to packaging
materials, and particularly to a retention packaging for securely
holding an object to be packaged against a backing.
[0008] Retention packaging designs are well known. A typical
retention packaging includes a rigid platform or backing against
which an object is held and a pliable film that covers the object
and that is tensioned in order to securely hold the object against
the backing. Known retention packaging designs are disclosed, for
example, in U.S. Pat. No. 6,675,973 to McDonald et al. ("McDonald")
and U.S. Pat. No. 6,010,003 to Wilkinson ("Wilkinson"), each of
which is hereby incorporated herein by reference.
[0009] In this respect, McDonald discloses a retention packaging
that includes a backing having end flaps and a middle portion. An
object is supported on the middle portion of the backing and a
pliable film is extended over the object. The film furthermore
includes pockets at opposite ends thereof that surround and enclose
the end flaps of the backing. When the end flaps are folded down in
a direction away from the object, the film is tensioned and
stretched over the object and, thereby, retains the object against
the middle portion of the backing. A stated benefit of the
retention packaging of McDonald is that the film and the backing
may be separately manufactured at different facilities
geographically distant from one another and then shipped to and
assembled at a common location by simply inserting the end flaps of
the backing into the pockets formed in the ends of the film.
[0010] In contrast to McDonald, Wilkinson discloses a retention
packaging that includes a backing and a pliable film that extends
between opposite ends of the backing. The film is folded over and
affixed to the rear of each of the opposite ends of the backing.
When the backing is folded, the film is stretched over an object
placed between the backing and the film, and the object is thereby
suspended on the backing by the tensioned film.
[0011] While the retention packaging of McDonald and the retention
packaging of Wilkinson are fit for their intended purposes, an
improved retention packaging and method of manufacture nevertheless
are desirable. In particular, a need exists for a retention
packaging that is capable of securely holding tall, large, or bulky
objects in a sturdy manner so as to protect such objects during
shipping or transportation. Furthermore, a need exists for a simple
and reliable method of manufacturing such a retention packaging.
These, and other needs, are addressed by one or more aspects of the
present invention.
SUMMARY OF THE INVENTION
[0012] The present invention includes many aspects and features.
Moreover, while many aspects and features relate to, and are
described in, the context of a retention packaging, the present
invention is not limited to use only in connection with a retention
packaging, as will become apparent from the following summaries and
detailed descriptions of aspects, features, and one or more
embodiments of the present invention.
[0013] Accordingly, one aspect of the present invention relates to
a retention packaging. An exemplary such retention packaging
includes a support member having first and second sections each
defining a support surface for receiving an object thereon for
shipping, and a film disposed in covering relation to the support
surfaces of the support member and retained to the support member
at the first and second sections. Furthermore, in this aspect of
the invention, the first and second sections are pivotably
connected to one another along a fold line that transects the
support member. The file includes opposite ends each enclosing a
respective opposite end of the support member and defining
overlapping areas of the film that are permanently joined together,
with the first section of the support member extending between the
overlapping areas of one of the opposite ends of the film, and with
the second section of the support member extending between the
overlapping areas of the other of the opposite ends of the film.
Still yet in this aspect, each opposite end of the support member
includes a respective opposite end edge of the support member. The
opposite end edges of the support member are spaced a distance
apart when the first and second sections are coplanar. The film
further includes a pleated portion that is located between the
opposite ends of the film and that includes at least one fold in
the film. The film is removably secured to itself so as to
removably secure the at least one fold of the pleated portion. An
unfolded length of the film may exceed the distance between the
opposite end edges of the support member without compromising the
retention of the film to the support member.
[0014] In variations of this aspect, the fold line may generally
bisect the support member; the film may be retained to the support
member only by extension of the first and second sections of the
support member between the overlapping areas of the film; the first
and second sections of the support member may be approximately
equal in length and width; the first and second sections of the
support member may have approximately equal surface area; the
overlapping areas of the film that are permanently joined together
may be heat sealed, adhered, or welded together; the film may
include a stretchable material; the film may include a heat
shrinkable material; the support member may be scored along the
fold line; and the support member may include a rigid material.
[0015] In a feature of this aspect of the invention, the film
further may include a plurality of tabs located along a side edge
of the film and spaced to substantially coincide with one another
by virtue of the at least one fold in the film. In accordance with
this aspect, the tabs may be removably attached to one another to
removably secure the at least one fold of the pleated portion.
Furthermore, the plurality of tabs may be adhered together to
removably secure the at least one fold of the pleated portion.
Alternatively, the plurality of tabs may be sealed together to
removably secure the at least one fold of the pleated portion.
[0016] Another aspect of the invention relates to a shipping
apparatus. An exemplary such shipping apparatus includes a shipping
container having an interior cargo space defined by a length, a
height, and a width; and a retention packaging contained within the
shipping container. The retention packaging includes a support
member having first and second sections each defining a support
surface for receiving an object thereon for shipping, and a film
disposed in covering relation to the support surfaces of the
support member and retained to the support member at the first and
second sections. The first and second sections are pivotably
connected to one another along a fold line that transects the
support member. The film includes opposite ends each enclosing a
respective opposite end of the support member and defining
overlapping areas of the film that are permanently joined together,
with the first section of the support member extending between the
overlapping areas of one of the opposite ends of the film, and with
the second section of the support member extending between the
overlapping areas of the other of the opposite ends of the film.
Furthermore, in this aspect of the invention, each opposite end of
the support member includes a respective opposite end edge of the
support member. The opposite end edges of the support member are
spaced a distance apart when the first and second sections are
coplanar. The film further includes a pleated portion that is
located between the opposite ends of the film and that includes at
least one fold in the film. The film is removably secured to itself
so as to removably secure the at least one fold of the pleated
portion. The film further includes a plurality of tabs located
along a side edge of the film and spaced to substantially coincide
with one another by virtue of the at least one fold in the film.
The tabs are removably attached to one another to removably secure
the at least one fold of the pleated portion. Still yet in this
aspect, an unfolded length of the film may exceed the distance
between the opposite end edges of the support member without
compromising the retention of the film to the support member.
[0017] In variations of this aspect, the fold line may generally
bisect the support member, the first and second sections of the
support member may be approximately equal in length and width, and
the equal lengths and widths of the first and second sections of
the support member may be generally the same as the length and
width of the interior cargo space of the shipping container.
Furthermore, in accordance with this aspect, the film with the
pleated portion may be retained to the support member only by
extension of the first and second sections of the support member
between the overlapping areas of the film; the overlapping areas of
the film that are permanently joined together may be heat sealed,
adhered, or welded together; and the film may include a stretchable
material.
[0018] Another aspect of the invention relates to a method of
preparing a shipping container. An exemplary such method includes
providing a retention packaging that includes a support member
having first and second sections each defining a support surface
for receiving an object thereon for shipping, and a film disposed
in covering relation to the support surfaces of the support member
and retained to the support member at the first and second
sections. The first and second sections are pivotably connected to
one another along a fold line that transects the support member.
The film includes opposite ends each enclosing a respective
opposite end of the support member and defining overlapping areas
of the film that are permanently joined together, with the first
section of the support member extending between the overlapping
areas of one of the opposite ends of the film, and with the second
section of the support member extending between the overlapping
areas of the other of the opposite ends of the film. Each opposite
end of the support member includes a respective opposite end edge
of the support member. The opposite end edges of the support member
are spaced a distance apart when the first and second sections are
coplanar. The film further includes a pleated portion that is
located between the opposite ends of the film and that includes at
least one fold in the film. The film is removably secured to itself
so as to removably secure the at least one fold of the pleated
portion. The film further includes a plurality of tabs located
along a side edge of the film and spaced to substantially coincide
with one another by virtue of the at least one fold in the film.
The tabs are removably attached to one another to removably secure
the at least one fold of the pleated portion.
[0019] In accordance with this aspect, the method further includes
separating the tabs from one another so as to unsecure the at least
one fold and thereby open the pleated portion of the film; placing
an object on the support surface of a selected one of the first and
second sections of the support member such that the film extends
over the object; pivoting one of the sections relative to the other
section about the fold line so that the first and second sections
of the support member are disposed in substantially overlapping,
abutting relation to one another such that the film tensions the
object in abutment with the selected support surface; and placing
the retention packaging into an interior cargo space of the
shipping container.
[0020] In variations of this aspect, a height of the object from
the selected support surface may exceed both a length and a width
of the selected support surface. Additionally, the height of the
object from the selected support surface may exceed twice the
length and twice the width of the selected support surface.
[0021] Another aspect of the invention relates to a method of
making a retention packaging. An exemplary such method includes
positioning both a film and a support member such that the film
extends, in covering relation to a surface of the support member,
beyond a first side edge of the support member, beyond a second
side edge of the support member, and beyond opposite end edges of
the support member; folding opposite end edges of the film such
that the film forms first overlapping areas beyond and proximate
the first side edge of the support member at the opposite end edges
of the support member, and forms second overlapping areas beyond
and proximate the second side edge of the support member at the
opposite end edges of the support member; and permanently joining
the first overlapping areas of the film together and permanently
joining the second overlapping areas of the film together. The
method further includes creating at least one fold in the film
between the opposite end edges of the film and removably securing
the film to itself so as to removably secure the at least one fold
in the film, thereby defining a pleated portion of the film. An
unfolded length of the film may exceed a distance between the
opposite end edges of the support member. Furthermore, in this
aspect of the invention, the film with the pleated portion is
retained to the support member by the opposite end edges of the
film that are folded over the opposite end edges of the support
member and the permanently joined overlapping areas of the film
that are beyond and proximate the first and second side edges of
the support member.
[0022] In variations of this aspect, the method may further include
cutting the film proximate the first overlapping areas and
proximate the second overlapping areas.
[0023] Still another aspect of the invention relates to a method of
making first and second retention packagings via an assembly line.
An exemplary such method includes, for each of the first and second
retention packagings, positioning both a film and a support member
such that the film extends, in covering relation to a surface of
the support member, beyond a leading edge of the support member,
beyond a trailing edge of the support member, and beyond opposite
side edges of the support member; folding opposite side edges of
the film such that the film forms first overlapping areas proximate
and beyond the leading edge of the support member; permanently
joining the first overlapping areas of the film together; cutting
the film proximate the first overlapping areas; folding opposite
side edges of the film such that the film forms second overlapping
areas proximate and beyond the trailing edge of the support member;
permanently joining the second overlapping areas of the film
together; and cutting the film proximate the second overlapping
areas.
[0024] Furthermore, in this aspect of the invention, the film is
retained to the support member by opposite side edges of the film
that are folded over the opposite side edges of the support member
and the permanently joined overlapping areas of the film that are
proximate and beyond the leading and trailing edges of the support
member. Still yet in this aspect, the step of cutting the film at
the second overlapping areas with regard to the first retention
packaging is performed concurrently with the step of cutting the
film at the first overlapping areas with regard to the second
retention packaging. The method further includes forming a pleated
portion in the film of each of the first and second retention
packagings by creating at least one fold in the film between
opposite side edges of the support member and removably securing
the film to itself so as to removably secure the at least one fold
in the film.
[0025] In addition to the aforementioned aspects and features of
the present invention, it should be noted that the present
invention further encompasses the various possible combinations of
such aspects and features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] One or more preferred embodiments of the present invention
now will be described in detail with reference to the accompanying
drawings, wherein the same elements are referred to with the same
reference numerals, and wherein,
[0027] FIG. 1 is a perspective view of a shipping container
including a box containing a retention packaging in accordance with
a preferred embodiment of the present invention, wherein the
retention packaging retains an object for shipment;
[0028] FIG. 2 is a side cross-sectional view of the box and
retention packaging of FIG. 1 taken along the line 2-2;
[0029] FIG. 3A is a bottom plan view of the retention packaging of
FIG. 1, shown before the object has been loaded therein;
[0030] FIG. 3B is a top plan view of the retention packaging of
FIG. 1, shown before the object has been loaded therein;
[0031] FIG. 4 is a side plan view of the retention packaging of
FIG. 1, shown before the object has been loaded therein;
[0032] FIG. 5A is a side plan view of the retention packaging of
FIG. 1, with an object placed therein and the support member
partially folded about the fold line;
[0033] FIG. 5B is a side plan view of the retention packaging and
object of FIG. 1 in a shipping configuration;
[0034] FIG. 6 is a schematic illustration, from a side point of
view, representing a method and system of manufacturing preferred
retention packaging of the present invention; and
[0035] FIG. 7 is a schematic illustration, from a top point of
view, representing a portion of the manufacturing method and system
of FIG. 6.
DETAILED DESCRIPTION
[0036] As a preliminary matter, it will readily be understood by
one having ordinary skill in the relevant art ("Ordinary Artisan")
that the present invention has broad utility and application.
Furthermore, any embodiment discussed and identified as being
"preferred" is considered to be part of a best mode contemplated
for carrying out the present invention. Other embodiments also may
be discussed for additional illustrative purposes in providing a
full and enabling disclosure of the present invention. Moreover,
many embodiments, such as adaptations, variations, modifications,
and equivalent arrangements, will be implicitly disclosed by the
embodiments described herein and fall within the scope of the
present invention.
[0037] Accordingly, while the present invention is described herein
in detail in relation to one or more embodiments, it is to be
understood that this disclosure is illustrative and exemplary of
the present invention, and is made merely for the purposes of
providing a full and enabling disclosure of the present invention.
The detailed disclosure herein of one or more embodiments is not
intended, nor is to be construed, to limit the scope of patent
protection afforded the present invention, which scope is to be
defined by the claims and the equivalents thereof. It is not
intended that the scope of patent protection afforded the present
invention be defined by reading into any claim a limitation found
herein that does not explicitly appear in the claim itself.
[0038] Thus, for example, any sequence(s) and/or temporal order of
steps of various processes or methods that are described herein are
illustrative and not restrictive. Accordingly, it should be
understood that, although steps of various processes or methods may
be shown and described as being in a sequence or temporal order,
the steps of any such processes or methods are not limited to being
carried out in any particular sequence or order, absent an
indication otherwise. Indeed, the steps in such processes or
methods generally may be carried out in various different sequences
and orders while still falling within the scope of the present
invention. Accordingly, it is intended that the scope of patent
protection afforded the present invention is to be defined by the
appended claims rather than the description set forth herein.
[0039] Additionally, it is important to note that each term used
herein refers to that which the Ordinary Artisan would understand
such term to mean based on the contextual use of such term herein.
To the extent that the meaning of a term used herein-as understood
by the Ordinary Artisan based on the contextual use of such
term-differs in any way from any particular dictionary definition
of such term, it is intended that the meaning of the term as
understood by the Ordinary Artisan should prevail.
[0040] Furthermore, it is important to note that, as used herein,
"a" and "an" each generally denotes "at least one," but does not
exclude a plurality unless the contextual use dictates otherwise.
Thus, reference to "a picnic basket having an apple" describes "a
picnic basket having at least one apple" as well as "a picnic
basket having apples." In contrast, reference to "a picnic basket
having a single apple" describes "a picnic basket having only one
apple."
[0041] When used herein to join a list of items, "or" denotes "at
least one of the items," but does not exclude a plurality of items
of the list. Thus, reference to "a picnic basket having cheese or
crackers" describes "a picnic basket having cheese without
crackers", "a picnic basket having crackers without cheese", and "a
picnic basket having both cheese and crackers." Finally, when used
herein to join a list of items, "and" denotes "all of the items of
the list." Thus, reference to "a picnic basket having cheese and
crackers" describes "a picnic basket having cheese, wherein the
picnic basket further has crackers," as well as describes "a picnic
basket having crackers, wherein the picnic basket further has
cheese."
[0042] Referring now to the drawings, one or more preferred
embodiments of the present invention are next described. The
following description of one or more preferred embodiments is
merely exemplary in nature and is in no way intended to limit the
invention, its implementations, or uses.
[0043] FIGS. 1 and 2 illustrate a retention packaging 10 disposed
in a shipping container for transport. For purposes of
illustration, the shipping container is illustrated in the form
factor of a box 16. The retention packaging 10 retains an object 18
having a tall, large, or bulky shape from movement within the box
16 during transport in order to avoid jostling of, and possible
damage to, the object 16. More particularly, FIG. 1 is a
perspective view of a box 16 containing a retention packaging 10 in
accordance with a first preferred embodiment of the present
invention. FIG. 2 is a side, cross-sectional view of the box 16 and
retention packaging 10 taken along the line 2-2 of FIG. 1.
[0044] The retention packaging 10 includes a support member 12 and
a film 14. As shown in FIGS. 1 and 2, the retention packaging 10 is
disposed in a shipping configuration, which is described in greater
detail below. However, it will be noted that, when in the shipping
configuration, the film 14 of the retention packaging 10 is
stretched over the object 18 and is tensioned so as to inhibit
movement of the object 18 during transport of the box 16. The
Ordinary Artisan will understand that the film 14 may be formed
from any suitable plastic film material. Examples include
polypropylene, PVC, linear low density polyethylene, or hybrid
biaxially oriented shrink film. Further, the film 14 may have a
memory characteristic such that when the object 18 is removed from
the retention packaging 10, the film 14 will retain an impression
therein of the object 18 so that the object 18--or an object having
a similar shape-may then be placed in the retention packaging 10
for subsequent transport, with the film 14 corresponding to the
shape of the object for a shape-conforming fit of the object.
[0045] It also is contemplated that the film 14 further may be heat
shrunk over the object 18 prior to the retention packaging 10 being
placed into the box 16 (provided the film is heat shrinkable). The
heating shrinking would be performed according to conventional heat
shrinking methods and, therefore, a detailed description of such
heat shrinking is not included herein.
[0046] Typically, once a tall, large, or bulky object 18 to be
shipped has been placed in the retention packaging 10 and the
retention packaging 10 has been arranged in the shipping
configuration, the retention packaging 10 is placed in the box 16,
with the support member 12 resting against a base 20 of the box 16.
The film 14 of the retention packaging 10 holds the object 18
against the support member 12 and suspends the object 18 away from
walls 22 of the box 16 so that the object 18 does not collide with
the walls 22 of the box 16 during transport. The support member 12
of the retention packaging 10 also provides a buffer between the
object 18 and the base 20 of the box 16. An additional buffer (not
shown) also may be provided on top of the retention packaging 10 to
secure the retention packaging 10 in its abutment with the base 20
of the box 16.
[0047] FIG. 3A and FIG. 3B are a bottom plan view and a top plan
view, respectively, of the retention packaging 10 of FIG. 1 before
the object 18 has been loaded therein. FIG. 4 is a side plan view
of the retention packaging 10 of FIG. 1 before the object 18 has
been loaded therein. As shown in FIGS. 3A, 3B, and 4, the support
member 12 of the retention packaging 10 includes a quadrilateral
perimeter having opposite ends 24 and sides 26. A fold line 40
transects the support member 12 and defines a first section 28 and
a second section 30. Each section 28,30 has, respectively, a top
surface 32,34 and a bottom surface 36,37. The film 14 is disposed
in covering relation to the top surfaces 32,34 of the first and
second sections 28,30 of the support member 14, with the opposite
ends 24 of the support member 12 extending within the receiving
areas 46 of the film 14.
[0048] Described in more detail, the fold line 40 demarcates the
first and second sections 28,30 from each other and provides an
axis of rotation for the first and second sections 28,30 relative
to one another. Preferably, the fold line 40 bisects the support
member 12 such that the surface areas of the first section 28 and
the second section 30 are approximately equal. The film 14 includes
opposite ends 42 and sides 44. The film 14 is disposed in covering
relation to the support member 12. More particularly, the film 14
extends in covering relation to the top surfaces 32,34 of the first
and second sections 28,30 of the support member 12. The film 14
further extends beyond the ends 24 of the support member 12, and
ends 42 of the film 14 respectively wrap around the ends 24 of the
support member 12 and partially cover portions of the bottom
surfaces 36,37. The opposite ends 42 of the film 14 also are folded
around the corresponding opposite ends 24 of the support member 12
such that folded portions of the film 14 define receiving areas 46
within which opposite ends 24 of the support member 12 are received
and at least are partially enclosed. For each receiving area 46,
overlapping areas comprising coinciding edges 48 of the portion of
the film 14 forming the receiving area 46 are permanently jointed
together to maintain the fold forming the receiving area 46.
Various methods are available for permanently joining the edges 48
together. Examples include heat sealing, ultrasonic sealing, and
use of various adhesives, such as glue. Furthermore, a discrete
point or discrete points along the edges 48 may be permanently
joined together or, alternatively, the entire edges 48 of the
portions of the film 14 forming the receiving areas 46 may be
permanently joined together.
[0049] As is further shown in FIGS. 3A, 3B, and 4, the film 14 has
a pleated portion 70 located between the opposite ends 42 of the
film 14. The pleated portion 70 includes at least one fold 74
whereby the film 14 is folded back upon itself. To form the pleat
in the pleated portion 70, the portion of the film 14 that forms
the fold 74 is secured to the remaining portion of the film 14 at
tabs 72 located along side edges of the film 14. The tabs 72 may be
spaced along side edges of the film 14 so as to substantially
coincide with one another when the film 14 is folded back upon
itself to form the fold 74 of the pleated portion 70. Tabs from
each respective side of the film 14 may then be attached to one
another to form the pleated portion 70. With the inclusion of the
pleated portion 70 in the film 14, an unfolded length of the film
14 may exceed the distance between the outer edges of the ends 24
of the support member 12 without compromising the retention of the
film 14 to the support member 12.
[0050] Preferably, tabs 72 are attached together in a removable
manner so as to permit the pleat of the pleated portion 70 to be
opened and the retention packaging 10 to be prepared for shipping.
Upon opening the pleated portion 70, a large retaining space 50 is
thereby defined between the film 14 and the support member 12
wherein a tall, large, or bulky object to be transported or shipped
may be placed. The tabs 72 may be removably attached together by
any means that might be preferred so as to permit the pleated
portion 70 to be opened with relative ease when the retention
packaging 10 is prepared for shipping. For instance, the tabs 72
may be attached together with an adhesive, or the tabs 72 may be
sealed to one another. In particular, the tabs 72 may be sealed
together with a tack seal.
[0051] Separating the tabs 72 and opening the pleated portion 70
provides a retaining space 50 between the film 14 and the support
member 12 wherein a large, tall, or bulky object 18 to be
transported or shipped may be placed. Horizontal planes of the
first and second sections 28,30 of the support member 12 are
generally aligned when the retention packaging 10 is in this
configuration, which results in relaxation of the film 14 compared
to the shipping configuration. An object may be placed on either of
the top surfaces 32,34. Once an object 18 to be shipped is inserted
into the retaining space 50 and placed on the top surface of one of
the two sections 28,30 of the support member 12, the section of the
support member 12 that is not supporting the object 18 is rotated
away from the object 18. Consequently, it is preferred that the
object 18 not overlap a perimeter 52 of the section of the support
member 12 on which it is placed.
[0052] In loading a large, tall, or bulky object 18 in the
retention packaging 10, the tabs 72 on either side of the pleated
portion 70 are separated from one another to open the pleated
portion. Opening of the pleated portion 70 prior to loading permits
the film 14 to be particularly loose in order to accommodate the
greater size or bulk associated with larger objects. One of the
sections 28,30 is pivoted upwardly about fold line 40 relative to
the other section, thereby further loosening the film 14 and
forming an insertion pocket for easy loading of the object 18 onto
one of the top surfaces 32,34. In pivoting one of the sections
28,30 upwardly, the first and second sections 28,30 may tend to
form an "L" or "V" shaped configuration. Once the object 18 is
loaded onto a top surface of one of the sections 28,30, the other
section is then pivoted downwardly about fold line 40 relative to
the section supporting the object 18, which begins to tension and
tighten the film 14 about the object 18.
[0053] FIGS. 5A and 5B illustrate the tensioning of the film as
this pivoting action transitions the retention packaging 10 to the
shipping configuration. In particular, FIG. 5A is a side plan view
of the retention packaging 10, with the large, tall, or bulky
object 18 placed therein during transitioning to the shipping
configuration. For exemplary purposes, the object 18 is shown in
FIG. 5A as having been placed upon-and is being supported by-the
first section 28. Accordingly, with continuing reference to FIG.
5A, the second section 30 is rotated about the fold line 40
downwardly and away from the object 18 and the support surface of
the first section 28. As the second section 30 is folded away from
the object 18, the film 14 is tensioned and stretched over the
object 18. With the unfolded length of the film 14 exceeding the
distance between the outer edges of the ends 24 of the support
member 12, the film 14 is more ably suited to accommodate and
secure the large, tall, or bulky object 18. In particular, the film
14 may accommodate an object 18 having a height exceeding a length
and/or a width of the top surface 32 of the section 28 upon which
the object 18 is loaded. In some instances, the film 14 may
accommodate an object having a height exceeding twice a length
and/or twice a width of the top surface 32 of the section 28 upon
which the object 18 is loaded. The further the second section 30 is
rotated, the tighter the film 14 is stretched across the object 18,
and the stretched and tensioned film 14 extending over the object
18 prevents the object from sliding or shifting in the box 16
during transport. The second section 30 is folded until the bottom
surface 37 of the second section 30 is disposed adjacent--and
preferably in complete overlying abutment with-the bottom surface
36 of the first section 28 as shown in FIG. 5B. In this
arrangement, the retention packaging 10 is disposed in the shipping
configuration.
[0054] Furthermore, it should be noted that for the illustrated
embodiment, wherein the first section 28 and the second section 30
are the same size, the receiving areas 46 of the film 14 and
opposite ends 24 of the support member 12 are aligned when the
retention packaging 10 is disposed in this shipping configuration.
As such, the support member 12 provides a double layer of support
for the object 18 placed thereon. Accordingly, the retention
packaging 10 is able to accommodate relatively heavy objects for
shipping and transport. Further, the torque applied to the film 14
when the retention packaging 10 is transitioned to the shipping
configuration is a product of a lever arm that equals the length of
the second section 30 and is approximately half the length of the
support member 12.
[0055] It also is contemplated that the film 14 of the retention
packaging 10 may further be heat shrunk prior to the retention
packaging 10 being placed into the box 16 for shipment (provided
that the film that is used is heat shrinkable). In this regard, the
retention packaging 10 may be heat shrunk via a conventional heat
shrinking tunnel or other conventional heat shrinking means.
[0056] To remove the large, tall, or bulky object 18 from the
retention packaging 10, a person receiving the shipment merely
removes the retention packing 10 and object 18 from the box 16 and
then rotates the second section 30 away from its overlapping
abutment with the first section 28. This relaxes and loosens the
film 14, thereby permitting access to the retaining space 50
wherein the object 18 is held. The person then merely reaches into
the retaining space 50, takes hold of the object 18, and removes it
from the retention packaging 10.
[0057] The retention packaging 10 does not have to be damaged or
torn in order to retrieve the object 18 therefrom. One merely
pivots a support section about fold line 40 relative to the other
support section to relax and loosen the film in order to remove the
object 18 that was shipped therein. Further, the retention
packaging 10 thereafter may be used again for shipment of a
similarly shaped object. For reuse, either the original object 18
or an object having the same general shape and size as the original
object 18 is placed in the retaining space 50 of the retention
packaging 10. Then the retention packaging 10 is returned to the
shipping configuration with the film 14 again conforming to the
shape of the object, and the retention packaging 10 with the object
retained therein is then placed in a box (possibly even the same
box 16) for shipment. Furthermore, to the extent that the film 14
is initially stretched so as to retain a shape or memory of the
original object 18, the object with which the retention packaging
10 is reused is positioned in the same orientation so as to
correspond with and conform to such stretched area of the film
14.
[0058] FIGS. 6 and 7 illustrate the manufacturing method and system
set forth in FIGS. 8 and 9 of U.S. patent application Ser. No.
11/941,061, which is referenced above and incorporated by reference
herein. In particular, FIGS. 6 and 7 illustrate a preferred method
and system 54 of manufacturing retention packaging 10. More
particularly, FIG. 6 is a schematic illustration from a side point
of view of the manufacturing method and system 54, and FIG. 7 is a
schematic illustration from a top point of view of a portion of the
manufacturing method and system 54.
[0059] In general, the manufacturing system 54 includes: a film
supply roll 56; an endless conveyor belt 58 for conveying and
supporting uncut film 60 as it is removed from the supply roll 56;
an apparatus (not shown) both for folding opposite side edges of
the film 60 around opposite side edges of the support members 12,
and for folding opposite side edges of the film such that the film
forms overlapping areas; and an apparatus 64 for sealing and
cutting the film 60 to form permanent overlapping areas of the film
14. Furthermore, the cutting and sealing apparatus 64 may be one
apparatus as shown or may be two separate apparatus. The
manufacturing system 54 also includes a support member supply 68
that feeds pre-cut support members 12 onto the belt 58 supporting
the film 60.
[0060] The manufacturing system 54 is arranged such that a pre-cut
support member 12 is placed onto the film 60 as the film 60 is
unrolled. A series of support members 12 are arranged along the
conveyor belt on top of the film 60 with some incremental,
predetermined space between each of the support members 12. The
folding apparatus provides a folding surface that encourages
opposite side edges of the film 60 to fold over on itself This
results in the opposite side edges of the film 60 folding around
opposite side edges of the support member 12 as well as folding
over on itself to form overlapping areas of the film in the spacing
between the support member 12. Then, while the folded side edges of
the film 60 are maintained in said position, the cutting and
sealing apparatus 64 seals and cuts the film 60 in between the
support member 12 at adjacent leading and trailing edges of the
support members 12. A retention packaging 10 is thereby formed
after the overlapping areas of the film 14 have been sealed and cut
on both the leading edge and then the trailing edge of a support
member 12. The completed retention packaging 10 then continues on
the conveyor belt 58 and is received in a supply container.
[0061] It further is noted that, during manufacturing, the film 14
is disposed below the support member 12 relative to the ground.
Subsequently, for use, the finished retention packaging 10 is
turned upside down such that the support member 12 is disposed
below the film 14, in relation to the ground, for then receiving an
object for shipment.
[0062] In addition to the above outlined steps in connection with
the manufacturing method and system of the '061 application, a
manufacturing method and system in accordance with the present
invention may also include creating at least one fold in the film
between the opposite end edges of the film and removably securing
the film to itself so as to removably secure the at least one fold
in the film. A pleated portion of the film is thereby defined,
whereby an unfolded length of the film may exceed a distance
between the opposite end edges of the support member. In
particular, the folding step, whereby at least one fold is created
in the film, may occur prior to the cutting and sealing step
discussed above. More particularly, the folding step to create at
least one fold of the pleated portion may occur simultaneously with
the folding step discussed above in connection with folding side
edges of the film over to form overlapping areas of the film.
Additionally, at the cutting and sealing step, the cutting and
sealing apparatus that cuts and seals the film may have a void area
or a specially configured blade that permits the formation of
integral tabs extending at either side of the cut film. As the
apparatus cuts and seals the film, the apparatus may simultaneously
seal the tabs together with a tack seal so as to removably secure
the film to itself and thereby form the pleated portion.
[0063] FIG. 7 provides a more detailed view of the folding,
cutting, and sealing process of the manufacturing system 54.
[0064] As is illustrated in FIG. 7, the support member 12 is
positioned on the film 60 such that the film 60 extends beyond a
leading edge of the support member 12, beyond a trailing edge of
the support member 12, and beyond opposite side edges of the
support member 12. As the belt 58 moves, opposite side edges of the
film 60 are folded such that: the film 60 forms first overlapping
areas beyond and proximate the leading edge of the support member
12; the opposite side edges of the film 60 are folded around the
opposite side edges of the support member 12; and the film 60 forms
second overlapping areas beyond and proximate the trailing edge of
the support member 12. Such folding takes place for successive
support members 12 as they progress along the conveyor belt 58.
[0065] After at least the first overlapping area is folded, the
first overlapping area of the film 60 may be permanently joined
together. The film 60 may also then be cut proximate the first
overlapping area. Similarly, the second overlapping area of the
film 60 may be permanently joined and then the film 60 may be cut
proximate the second overlapping area. Typically, such sealing and
cutting will occur between successive support members 12 so that
sealing and cutting is occurring for a trailing edge of one support
member 12 while simultaneously occurring for a leading edge of a
following support member 12. After the film 14 is sealed and cut,
it is retained to the support member 12 by the opposite side edges
of the film 14 that are folded over opposite side edges of the
support member 12 and the permanently joined overlapping areas of
the film 14 that are beyond and proximate the leading and trailing
edges of the support member 12.
[0066] In addition to the above outlined steps, the manufacturing
process may also include scoring the support member 12 between
opposite side edges of the support member 12 such that a score line
40 transects the support member 12 and defines first and second
sections of the support member 12 that are pivotably connected to
one another along the score line 40.
[0067] In addition to the above outlined steps in connection with
the manufacturing method and system of the '061 application, a
method of making first and second retention packagings via an
assembly line in accordance with the present invention may also
include forming a pleated portion in the film of each of the first
and second retention packagings by creating at least one fold in
the film between opposite side edges of the support member and
removably securing the film to itself so as to removably secure the
at least one fold in the film. In particular, the folding step,
whereby at least one fold is created in the film, may occur prior
to the cutting and sealing step discussed above.
[0068] More particularly, the folding step to create at least one
fold of the pleated portion may occur simultaneously with the
folding step discussed above in connection with folding side edges
of the film over to form overlapping areas of the film for
successive support members. Additionally, at the cutting and
sealing step, the cutting and sealing apparatus that cuts and seals
the film may have a void area or a specially configured blade that
permits the formation of integral tabs extending at either side of
the cut film. As the apparatus cuts and seals the film, the
apparatus may simultaneously seal the tabs together with a tack
seal so as to removably secure the film to itself and thereby form
the pleated portion. Tabs may be formed and sealed together
simultaneously at a trailing edge of one support member while
simultaneously being formed and sealed together at a leading edge
of a following support member.
[0069] Based on the foregoing description, it will be readily
understood by those persons skilled in the art that the present
invention is susceptible of broad utility and application. Many
embodiments and adaptations of the present invention other than
those specifically described herein, as well as many variations,
modifications, and equivalent arrangements, will be apparent from
or reasonably suggested by the present invention and the foregoing
descriptions thereof, without departing from the substance or scope
of the present invention. Accordingly, while the present invention
has been described herein in detail in relation to one or more
preferred embodiments, it is to be understood that this disclosure
is only illustrative and exemplary of the present invention and is
made merely for the purpose of providing a full and enabling
disclosure of the invention. The foregoing disclosure is not
intended to be construed to limit the present invention or
otherwise exclude any such other embodiments, adaptations,
variations, modifications or equivalent arrangements, the present
invention being limited only by the claims appended hereto and the
equivalents thereof
* * * * *