U.S. patent application number 12/462030 was filed with the patent office on 2011-02-03 for suspension / retention packaging.
This patent application is currently assigned to Columbia Corrugated Box. Invention is credited to Stephen M. Tanner.
Application Number | 20110024324 12/462030 |
Document ID | / |
Family ID | 43525994 |
Filed Date | 2011-02-03 |
United States Patent
Application |
20110024324 |
Kind Code |
A1 |
Tanner; Stephen M. |
February 3, 2011 |
Suspension / retention packaging
Abstract
An improved suspension package system in which one or more
suspension frames are used to suspend an article within a shipping
container, wherein the suspension frame includes a suspension
mechanism formed by a plurality of generally concentric cuts
forming a plurality of suspension channel members, each cut being
interrupted by one or more nicks. The nicks conjoin adjacent
channel members, and conjoin an innermost channel member to an
optional article platform, and conjoin an outermost channel member
to an optional perimeter portion. Sidewalls give the suspension
frame a 3-D shape and provide suspension clearance. The article can
be sandwiched between two opposing suspension frames. The
suspension frame can be formed as a monolithic piece of corrugated
containerboard. Forming the suspension of corrugated containerboard
improves the recyclability of the product, and reduces its
manufacturing cost by eliminating the need for purchasing and
assembling a plastic suspension sheet. The frame can also be
configured as a retention frame.
Inventors: |
Tanner; Stephen M.; (Oregon
City, OR) |
Correspondence
Address: |
Attn Roggy Pflug;Columbia Corrugated Box
12777 SW Tualatin-Sherwood Road
Tualatin
OR
97062
US
|
Assignee: |
Columbia Corrugated Box
|
Family ID: |
43525994 |
Appl. No.: |
12/462030 |
Filed: |
July 28, 2009 |
Current U.S.
Class: |
206/588 |
Current CPC
Class: |
Y02W 30/80 20150501;
B65D 81/075 20130101; Y02W 30/807 20150501 |
Class at
Publication: |
206/588 |
International
Class: |
B65D 81/02 20060101
B65D081/02 |
Claims
1. An apparatus comprising: a first suspension frame including, an
article platform portion, a perimeter portion, a sidewall portion
coupled to the perimeter portion to provide suspension clearance,
and a suspension portion coupling the article platform portion to
the perimeter portion, wherein the suspension portion includes a
plurality of channels separated by a plurality of cuts, the cuts
being interrupted by nicks.
2. The apparatus of claim 1 wherein: the suspension frame is
constructed as a monolithic whole.
3. The apparatus of claim 2 wherein: the suspension frame is
constructed of corrugated containerboard.
4. The apparatus of claim 1 further comprising: a box; and a second
suspension frame; wherein the first and second suspension frames
are disposed within the box so as to have their perimeter portions
substantially abutting one another.
5. A suspension frame for suspending an article within a shipping
container, the suspension frame comprising: a suspension portion
including a plurality of channels separated by a plurality of cuts,
each cut being interrupted by a plurality of nicks, wherein the
cuts enable the suspension portion to flex in a first direction;
and a sidewall portion coupled to the suspension portion and having
a dimension in the first direction providing clearance for movement
of the suspension portion.
6. The suspension frame of claim 5 further comprising: a perimeter
portion coupling the suspension portion to the sidewall
portion.
7. The suspension frame of claim 5 wherein: the sidewall portion
comprises four sidewalls arranged in a generally rectilinear
configuration about the suspension portion.
8. The suspension frame of claim 5 further comprising: an article
platform portion disposed substantially at a center of the
suspension portion.
9. The suspension frame of claim 8 wherein the article platform
portion comprises: a void providing a perimeter for engaging the
article.
10. The suspension frame of claim 8 wherein: the plurality of nicks
are arranged in a regular pattern.
11. A product produced by the process comprising: cutting a
suspension frame from a sheet of material; providing the suspension
frame with a suspension portion having a plurality of cuts disposed
about a location, each cut being interrupted by at least one nick,
such that a plurality of suspension channels are formed, with
adjacent suspension channels being conjoined by at least one nick;
and providing the suspension frame with means for facilitating
subsequently folding the suspension frame into a 3-D
configuration.
12. The product by process of claim 11 wherein the process further
comprises: folding the suspension frame into the 3-D
configuration.
13. The product by process of claim 11 wherein providing the means
for facilitating subsequently folding comprises: providing the
suspension frame with a perimeter portion adjacent to and conjoined
with an outer perimeter of the suspension portion; and providing
the suspension frame with a plurality of sidewall portions adjacent
to and conjoined with the perimeter portion.
14. The product by process of claim 13 wherein the process further
comprises: providing the suspension frame with an article platform
portion disposed within the suspension portion.
15. The product by process of claim 13 wherein the process further
comprises: folding the suspension frame into the 3-D configuration
by folding the sidewall portions to angles between 40 degrees and
140 degrees of perpendicular to the perimeter portion.
16. An apparatus comprising: a corrugated containerboard box; and,
disposed within the corrugated containerboard box, a first
suspension frame adjacent a bottom inner surface of the corrugated
containerboard box; and a second suspension frame adjacent a top
inner surface of the corrugated containerboard box; wherein each
suspension frame comprises, a plurality of sidewalls having a
vertical height providing suspension clearance, a suspension
portion coupled to the sidewalls so as to be dimensionally removed
from the corrugated containerboard box by the vertical height of
the sidewalls; wherein the suspension portions of the first and
second suspension frames provide suspension for an article placed
therebetween.
17. The apparatus of claim 16 comprising: the article placed
between the suspension portions of the first and second suspension
frames.
18. The apparatus of claim 16 further comprising: a plurality of
additional suspension frames disposed within the corrugated
containerboard box.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] This invention relates generally to shipment packaging, and
more specifically to packaging formed of corrugated containerboard,
folding carton stock, paperboard, or the like, having an improved
means of suspending or retaining articles packaged therein.
[0003] 2. Background Art
[0004] U.S. Pat. No. 5,388,701 "Suspension Packaging" by Devin C.
Ridgeway and assigned to Sealed Air Corp. teaches a suspension
packaging system in which two suspension frames are disposed within
a corrugated containerboard box. Each suspension frame includes a
corrugated containerboard frame to which is affixed a resilient
member formed of a sheet of plastic. The suspension frames are
placed one atop the other, with their plastic sheets adjacent each
other, and the packaged article is suspended between the plastic
sheets. The resiliency of the plastic sheets provides the
suspension characteristic of the packaging, and allows the packaged
article to move or bounce within the package. The depth of the
corrugated containerboard frames provides clearance so the article
does not strike the enclosing corrugated containerboard box. This
packaging system has been widely adopted. Unfortunately, it
requires the use of plastic sheeting, which is less ecologically
friendly than the corrugated containerboard. And unfortunately, the
use of the plastic sheeting raises manufacturing costs not only in
materials but also in assembly.
[0005] U.S. Pat. Nos. 7,296,681 and 6,675,973, both entitled
"Suspension Packaging Assembly" and both by McDonald et al., teach
a packaging system in which a sheet of polyethylene film is
stretched over an article to retain it against the corrugated
cardboard suspension pieces. These suffer the same flaws as the
Ridgeway invention.
[0006] What is needed is an improved suspension packaging system
having improved recyclability and lower manufacturing cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows one embodiment of the corrugated containerboard
suspension frame of this invention, in a flat configuration as
manufactured before folding into a 3-D configuration.
[0008] FIG. 2 shows the folded, 3-D configuration of the suspension
frame of FIG. 1.
[0009] FIG. 3 shows the suspension frame in cross-section view,
illustrating the movement of the suspension features.
[0010] FIG. 4 shows the assembly of the suspension package system,
including a corrugated containerboard box and two opposed
suspension frames, in an exploded view.
[0011] FIG. 5 shows the suspension package system in use suspending
an article to be shipped, in cross-section view.
[0012] FIG. 6 shows another embodiment of a suspension frame.
[0013] FIG. 7 shows yet another embodiment of a suspension
frame.
[0014] FIG. 8 shows another embodiment of a suspension package
system, employing suspension frames on multiple sides of an article
to be shipped.
[0015] FIG. 9 shows an embodiment of a retention frame, in a flat
configuration as manufactured before folding into a 3-D
configuration.
DETAILED DESCRIPTION
[0016] The invention will be understood more fully from the
detailed description given below and from the accompanying drawings
of embodiments of the invention which, however, should not be taken
to limit the invention to the specific embodiments described, but
are for explanation and understanding only.
[0017] FIG. 1 with detail view IA illustrates one embodiment of a
suspension frame 10 which may be used in practicing the principles
of this invention. The suspension frame may advantageously be
formed from a single sheet of corrugated containerboard, with its
features being formed by die cutting. The suspension frame includes
an article platform portion 12 which may in some embodiments be
located generally in a center of the suspension frame. The
suspension frame also includes a perimeter portion 14 which will
define a mating face of the suspension frame, and sidewall portions
16 which will be folded during the assembly process to give the
suspension frame a 3-D shape providing depth for suspension
clearance.
[0018] The article platform is coupled to the perimeter portion by
a suspension portion 18 having a plurality of cuts 20 which extend
through the corrugated containerboard and define between them a
plurality of suspension channels 22. In one embodiment, the cuts
are arranged in a generally concentric, evenly-spaced manner. Any
given cut is interrupted by a plurality of nicks 24. Each nick
conjoins two adjacent channels, maintaining structural integrity of
the suspension frame.
[0019] In some applications, or with some manufacturing equipment,
it may be desirable to form the cuts as simple slices, in which no
material is removed. In other applications, or with other
manufacturing equipment, it may be desirable to form the cuts by
removing material from the suspension frame.
[0020] The relative geometries of the number and width (if any) of
the cuts, the number and length of the nicks, the width of the
channels, the thickness and stiffness of the suspension frame
material, and so forth, should all be determined according to the
dictates of the application at hand, taking into account the size,
mass, shape, and fragileness of the article to be shipped.
[0021] In the embodiment shown, the nicks are arranged in a regular
pattern in which each cut is interrupted by six nicks, and every
second cut is angularly offset from its neighbors by half, such
that there are twelve "spokes" of nicks. The outermost cut has two
pairs of nicks 26 which conjoin the outermost channel to the
perimeter portion of the frame at respective, opposing sides of the
suspension frame, and two individual nicks 28 which conjoin the
outermost channel to the perimeter portion of the frame at the
other opposite sides.
[0022] Other nick patterns are certainly conceivable and useable
within the teachings of this invention.
[0023] Optionally, the perimeter portion of the suspension frame
may include one or more voids 30 which provide containment and/or
display of the articles enclosed.
[0024] FIG. 2 illustrates the suspension frame 10 after folding
during assembly. In this embodiment, the sidewall portions 16 have
been folded and their tabs engaged with the slots 32 at the outer
edges of the perimeter portion 14, to lock the suspension frame
into shape. A variety of other mechanisms could be used to
accomplish this. The platform portion 12 is raised by the height of
the folded sidewall portions, to provide suspension clearance as
will be shown below.
[0025] FIG. 3 illustrates the suspension frame 10 in cross-section
view, more particularly illustrating the suspension
characteristics. The platform portion 12 is offset (downward in
this view) from the perimeter portion 14, such as if there were an
article pressing against it. The sidewall portions 16 should be
sized appropriately, to provide adequate suspension movement
clearance such that the article does not "bottom".
[0026] FIG. 4 illustrates the assembly of the overall suspension
packaging system 40, in an exploded view. The packaging system
includes e.g. a corrugated containerboard box 42, a lower
suspension frame 10L and an upper suspension frame 10U. The box's
inner dimensions may advantageously match the suspension frames'
outer dimensions, such that the suspension frames are held securely
in place when disposed within the box. The upper suspension frame
is upside-down with respect to the lower suspension frame, such
that their perimeter portions and, more importantly, their article
platform portions, are directly adjacent each other.
[0027] FIG. 5 illustrates the suspension packaging system 40 in
use. An article 44 is trapped between the opposing faces of the
platform portions (and perhaps part of the suspension portions) of
the lower and upper suspension frames 10L and 10U, and the
suspension frames are enclosed within the corrugated containerboard
box 42 (which will, of course, be closed before shipment). The
suspension of the lower suspension frame is distended downward, and
the suspension of the upper suspension frame is distended upward,
entrapping the article for shipment. Optionally but advantageously,
the sidewall portions of the suspension frames provide additional
clearance, such that when the box is dropped or jostled, the
article does not strike the inner surfaces of the box (or does so
with reduced force, at least).
[0028] FIG. 6 illustrates an alternative embodiment of a suspension
frame 50 which may be used in practicing this invention. Whereas in
the previous figures the suspension cuts were illustrated as being
a series of concentric, nick-interrupted circles, in this
embodiment the cuts take a more rectangular shape.
[0029] The suspension frame includes an article platform portion
52, a perimeter portion 54, and sidewall portions 56. It further
includes a plurality of generally concentric cuts 58 interrupted by
nicks 60. In one embodiment, the cuts could have a strict
rectangular shape. However, in the embodiment shown, the cuts have
a "rounded rectangle" shape such that the portion 62 of the
channels at the corners provides a rounded, smooth transition.
Avoiding abrupt, sharp angles in the cuts may improve the strength
and durability of the channels, by preventing tearing.
[0030] FIG. 7 illustrates yet another embodiment of a suspension
frame 70, in which the article platform portion 72 is interrupted
by a central void 74. This void may, in some applications, be
advantageous for engaging with the shape of a particular piece of
the article to be shipped (not shown), preventing lateral movement,
twisting, and the like.
[0031] FIG. 8 illustrates a packaging system 80 according to yet
another embodiment of this invention. Within a box 80, an article
to be shipped (not shown) is surrounded by multiple suspension
frames. For example, a first suspension frame 84 resides beneath
the article, and has a heavy suspension with extra clearance, to
support the weight of the article. Four suspension frames 86, 88,
90, 92 are disposed at four sides of the article, and a suspension
frame 94 is disposed above the article. It should be noted that,
not only can the suspension frames be of different construction,
strength, clearance, and so forth, they may have their platform
portions arranged in a variety of locations, not necessarily
symmetric with each other, as dictated by the shape and
characteristics of the article to be shipped.
[0032] FIG. 9 illustrates a retention frame 100 according to still
another embodiment of this invention. The frame includes an article
platform portion 112 which is connected to a perimeter portion 114
by a suspension portion 118. The article platform portion may
optionally include a hole 120 sized and shaped to engage or mate
with a portion of, or a perimeter of, the article to be packaged
(not shown). The frame includes a plurality of portions, tabs,
panels, etc. which can be folded to create the 3-D configuration of
the frame, as is known in the art.
[0033] The article platform portion, perimeter portion, and
suspension portion are parts of (and, ideally but optionally, are
of monolithic construction comprising) a first panel 122. When the
suspension package is assembled by folding into its 3-D
configuration, the article is sandwiched between the first panel
and an adjacent second panel 124. The first and second panels are
folded to be substantially parallel. A third panel 126 is folded at
right angles to the second panel, and defines the height of the
suspension package. A fourth panel 128 is folded parallel with the
first and second panels. A fifth panel 130 is folded parallel with
the third panel. At some point in the folding process, sixth and
seventh panels 132 are folded at right angles to the second panel.
The third, fifth, sixth, and seventh panels form the four "sides"
of the package, while the second panel forms the "bottom" and the
fourth panel forms the "top". Eighth and ninth panels 134 are
folded so as to be substantially flush with their respective
counterparts of the sixth and seventh panels, and serve to keep the
first panel in position so the suspension retains the article
against the second panel.
[0034] The assembled retention frame may optionally be included
within a shipping box (not shown). And, optionally, the box may be
equipped with a means for suspending the suspension package such
that the second panel is not in direct contact with an exterior
panel of the box, whereby the packaged article is provided with
clearance to reduce the chance of damage if the box is penetrated
or crushed.
CONCLUSION
[0035] When one component is said to be "adjacent" another
component, it should not be interpreted to mean that there is
absolutely nothing between the two components, only that they are
in the order indicated.
[0036] The various features illustrated in the figures may be
combined in many ways, and should not be interpreted as though
limited to the specific embodiments in which they were explained
and shown.
[0037] Those skilled in the art, having the benefit of this
disclosure, will appreciate that many other variations from the
foregoing description and drawings may be made within the scope of
the present invention. Indeed, the invention is not limited to the
details described above. Rather, it is the following claims
including any amendments thereto that define the scope of the
invention.
[0038] In some applications, it may be desirable to manufacture the
suspension frame of this invention from corrugated containerboard,
while in other applications, it may be desirable to use a different
material such as corrugated plastic, or metal sheeting, or what
have you. In the preferred embodiment, the suspension flame is
manufactured of corrugated containerboard, but the invention is not
limited to that particular material.
[0039] For convenience only, the suspension frame and packaging
system have been illustrated in square or rectangular shaped
embodiments. Although those are certainly the most common packaging
shapes in use, due to their manufacturability and effective packing
density when multiple packages are stacked next to each other, the
invention is not limited to those shapes. Other shapes of
suspension frames may utilize the principles of this invention,
such as round, oval, triangular, hexagonal, and so forth, as
determined by the dictates of the application at hand.
[0040] In some applications, it may be desirable to use different
suspension frames together in the same package. For example, a
heavy article may dictate a heavy, stiff lower suspension, but a
lighter, less stiff upper suspension.
[0041] Although, for convenience, the various suspension frames
have been illustrated as including both a perimeter portion and a
sidewall portion, in some applications either of those may be
omitted. For example, if the suspension portion extends all the way
to the edge of the frame and is conjoined directly with the
sidewall portion, then technically there is no perimeter portion.
Or, if the suspension clearance is to be provided by independent
legs, or standoffs within the box, or by the suspension frame being
stapled or glued to the box at a position somewhat removed from the
end of the box, there may not necessarily be a sidewall portion in
the sense suggested above. The salient feature of this invention is
the suspension portion. And furthermore, even the article platform
portion may be omitted, such as if the suspension cuts extend all
the way to the center or at least to a central void.
* * * * *