Shipping container and packaging cushion assembly

Patent metadata

Field	Value
Publication number	US-11820574-B2
Application number	US-202117346092-A
Country	US
Kind code	B2
Filing date	Jun 11, 2021
Priority date	Jun 11, 2021
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

A shipping assembly is described. The assembly includes a shipping container, a bottom structure, and a top structure. The bottom and top structures retain objects in a spaced-apart arrangement within the shipping container. A paperboard sheet is folded into three horizontal layers to form the bottom structure. A first layer has apertures to retain the objects. A second layer is below and spaced apart from the first layer with a substantially flat surface below the first apertures. A third layer is below and spaced apart from the second layer. Another paperboard sheet is folded into two horizontal layers to form the top structure. A fourth layer has another set of apertures to retain the objects. A fifth layer is above and spaced apart from the fourth layer. The apertures are align to position the objects in the shipping container.

First claim

The invention claimed is:

1. A shipping assembly comprising;
a shipping container; and
a bottom structure configured to retain a plurality of objects in a spaced-apart arrangement within the shipping container, the bottom structure comprising a first paperboard sheet folded to form a first set of layers, the first set of layers comprising:
a first horizontal layer comprising a plurality of first apertures, each first aperture sized to retain a first end of one of the objects;
a second horizontal layer below and spaced apart from the first horizontal layer, the second horizontal layer comprising a substantially flat surface below the plurality of first apertures;
a third horizontal layer below and spaced apart from the second horizontal layer;
first sidewalls coupling the first horizontal layer to the third horizontal layer; and
second sidewalls coupling the third horizontal layer to the second horizontal layer, wherein at least one of the second sidewalls comprises a retaining tab configured to create a friction fit with another one of the second sidewalls and retain the bottom structure in a folded form.

2. The shipping assembly of claim 1 ,
wherein a height of the first sidewalls is greater than a height of the second sidewalls.

3. The shipping assembly of claim 2 , wherein the first sidewalls are sized to maintain the first horizontal layer spaced apart from the third horizontal layer.

4. The shipping assembly of claim 2 , wherein the second sidewalls are sized to maintain the second horizontal layer spaced apart from the third horizontal layer.

5. The shipping assembly of claim 2 , wherein at least one of the second sidewalls comprises at least one support tab extending between the second horizontal layer and the first horizontal layer.

6. The shipping assembly of claim 5 , wherein a height of the at least one support tab is substantially the same as a distance by which the second horizontal layer is spaced apart from the first horizontal layer.

7. The shipping assembly of claim 2 , wherein the second sidewalls comprise a first pair of sidewalls and a second pair of sidewalls, the first pair located at opposite outer edges of the second horizontal layer and the second pair located approximately midway between the first pair.

8. The shipping assembly of claim 7 , wherein the second pair of sidewalls comprise retaining tabs configured to create a friction fit between the second pair of sidewalls and retain the bottom structure in a folded form.

9. The shipping assembly of claim 7 , wherein each sidewall of both the first pair and the second pair of sidewalls comprise at least one support tab extending between the second horizontal layer and the first horizontal layer.

10. The shipping assembly of claim 1 , further comprising a top structure configured to retain the plurality of objects in a spaced-apart arrangement within the shipping container, the top structure comprising a second paperboard sheet folded to form a second set of layers, the second set of layers comprising:
a fourth horizontal layer comprising a plurality of second apertures, each second aperture sized to retain a second end of one of the objects, and each second aperture arranged to align with one of the first apertures of the bottom structure when the bottom structure and the top structure are positioned in the shipping container; and
a fifth horizontal layer above and spaced apart from the fourth horizontal layer.

11. The shipping assembly of claim 10 , wherein the top structure comprises third sidewalls coupling the fourth horizontal layer to the fifth horizontal layer, and wherein the third sidewalls are sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer.

12. The shipping assembly of claim 11 , wherein the third sidewalls comprise at least four sidewalls of substantially equal height, and wherein at least one of the third sidewalls comprises a retaining tab configured to create a friction fit with another one of the third sidewalls and retain the top structure in a folded form.

13. The shipping assembly of claim 10 , wherein the first apertures are sized to form a friction fit with the first end of the objects, and wherein the second apertures are sized to form a friction fit with the second end of the objects.

14. The shipping assembly of claim 10 , wherein a width and a length of the bottom structure substantially match inner dimensions of the shipping container, and wherein a width and a length of the top structure substantially match the inner dimensions of the shipping container.

15. A shipping assembly comprising;
a shipping container; and
a bottom structure configured to retain a plurality of objects in a spaced-apart arrangement within the shipping container, the bottom structure comprising a first paperboard sheet folded to form a first set of layers, the first set of layers comprising:
a first horizontal layer comprising a plurality of first apertures arranged in at least two parallel rows, each first aperture sized to retain a first end of one of the objects;
a second horizontal layer below and spaced apart from the first horizontal layer, the second horizontal layer comprising a substantially flat surface below the plurality of first apertures, and at least one support tab extending between the second horizontal layer and the first horizontal layer and aligned with a region of the first horizontal layer that is between two rows of the first apertures;
a third horizontal layer below and spaced apart from the second horizontal layer;
first sidewalls coupling the first horizontal layer to the third horizontal layer, the first sidewalls being sized to maintain the first horizontal layer spaced apart from the third horizontal layer;
second sidewalls coupling the third horizontal layer to the second horizontal layer.

16. The shipping assembly of claim 15 , further comprising a top structure configured to retain the plurality of objects in a spaced-apart arrangement within the shipping container, the top structure comprising a second paperboard sheet folded to form a second set of layers, the second set of layers comprising:
a fourth horizontal layer comprising a plurality of second apertures, each second aperture sized to retain a second end of one of the objects, and each second aperture arranged to align with one of the first apertures of the bottom structure when the bottom structure and the top structure are positioned in the shipping container;
a fifth horizontal layer above and spaced apart from the fourth horizontal layer; and
third sidewalls coupling the fourth horizontal layer to the fifth horizontal layer, and wherein the third sidewalls are sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer.

17. A shipping assembly comprising;
a shipping container; and
a bottom structure configured to retain a plurality of objects in a spaced-apart arrangement within the shipping container, the bottom structure comprising a first paperboard sheet folded to form a first set of layers, the first set of layers comprising:
a first horizontal layer comprising a plurality of first apertures, each first aperture sized to retain a first end of one of the objects;
a second horizontal layer below and spaced apart from the first horizontal layer, the second horizontal layer comprising a substantially flat surface below the plurality of first apertures;
a third horizontal layer below and spaced apart from the second horizontal layer;
first sidewalls coupling the first horizontal layer to the third horizontal la

Assignees

• Federal Express Corp

Inventors

• Zhou Yongquan

Classifications

• B65D81/133 Primary

  of a shape specially adapted to accommodate contents, e.g. trays {(B65D81/053 takes precedence; thermally insulated trays B65D81/3816, B65D81/3827)} · CPC title

• B65D71/403

  formed by folding several blanks · CPC title

• B65D2581/053

  Paper in general, e.g. paperboard, carton, molded paper · CPC title

• B65D5/5059 Primary

  Paper panels presenting one or more openings or recesses in wich at least a part of the contents are located (B65D5/5038, B65D5/5052, B65D5/5057 and B65D5/5286 take precedence) · CPC title

• B65D25/108

  Devices, e.g. plates, presenting apertures through which the articles project · CPC title