CA3042653A1 - Drone delivery packaging system - Google Patents

Abstract

A lidded container includes a tray and a removable lid. The tray includes first and second locking panels hingedly connected to respective first and second tray side walls. The lid includes corner gussets disposed on the interior surfaces of first and second lid side walls. When the lid is placed on the tray to close it, the first and second locking panels are reverse folded against the exterior surfaces of the first and second tray side walls. In this configuration, angled edges defined by the lid's corner gussets mate with complementary angled edges of the first and second locking panels to lock the removable lid to the tray.

Description

DRONE DELIVERY PACKAGING SYSTEM
REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority under 35 U.S.C.
119(e) of United States provisional application serial number 62/417651 filed on November 4, 2016, and provisional application serial number 62/418318 filed on November 7, 2016 which is hereby incorporated by reference in its entirety.
BACKGROUND

[0002] The field of the invention relates generally to a packaging system including a carton and removable lid, and more particularly to a packaging system suitable for use as a drone delivery shipping container.

[0003] In recent years, exploration of the use of UAV (Unmanned Aerial Vehicles) or drones by industry for delivering goods and products has rapidly expanded. Drones are convenient for rapid point-to-point delivery; however, using drones to deliver packages presents some challenges. For example, packages delivered via drone may be more likely to be delivered to locations that are exposed to the elements, e.g., dropped off in a puddle or left out in the rain. If a suitably water-resistant container is not used in these situations, the container and/or its contents may be ruined.
As another example, a conventional shipping container may be difficult or impossible for a drone's pickup system to reliably grasp and release. As a third example, the shifting of contents within a container during flight may result in product damage or threaten the drone's flight performance and safety. Accordingly, it is an object of at least one aspect of the present invention to provide a packaging system that solves or mitigates one or more of the problems associated with drone delivery.
SUMMARY

[0004] According to a first aspect of the invention there is provided a lidded container that includes a tray and a removable lid. The tray includes a bottom wall, first and second tray side walls, a first locking panel hingedly connected to an upper edge of the first tray side wall, and a second locking panel hingedly connected to an upper edge of the second tray side wall. The removable lid includes a top wall, first and second lid side walls, first and second corner gussets disposed on an interior surface of the first lid side wall, and third and fourth corner gussets disposed on an interior surface of the second lid side wall. The first, second, third, and fourth corner gussets define respective first, second, third, and fourth gusset angled edges. The lidded container is configured to be placed in a closed and locked configuration by placing the removable lid over an open top of the tray and pressing downwards so as to cause the first and second locking panels to fold outwardly until exterior surfaces of respective first and second locking panels are at least substantially adjacent to respective exterior surfaces of the first and second tray side walls. This configuration allows the first gusset angled edge to mate with a first complementary angled edge of the first locking panel, the second gusset angled edge to mate with a second complementary angled edge of the first locking panel, the third gusset angled edge to mate with a third complementary angled edge of the second locking panel, and the fourth gusset angled edge to mate with a fourth complementary angled edge of the second locking panel so as to lock the removable lid to the tray.

[0005] Optionally, the first and second locking panels are substantially trapezoidal in shape.

[0006] Optionally, the first, second, third, and fourth corner gussets are substantially triangular in shape.

[0007] Optionally, the tray includes first, second, third, and fourth tray corner gussets.

[0008] Optionally, the first lid side wall defines a first access notch in a lower edge of the first lid side wall, and the second lid wall defines a second access notch in a lower edge of the second lid side wall. The first and second access notches are configured to provide access to the respective first and second locking panels when the lidded container is in the closed and locked configuration.

[0009] Optionally, the first locking panel defines a first generally-rectangular notch in a lower edge of the first locking panel, and the second locking panel defines a second generally-rectangular notch in a lower edge of the second locking panel.

[0010] Optionally, the removable lid is configured to be removed from the tray by pressing inwardly on portions of first and second locking panels that are exposed through the first and second access notches so as to move the first, second, third, and fourth gusset angled edges out of alignment with the respective first, second, third, and fourth complementary angled edges, thereby allowing the removable lid to be lifted up and off of the tray.

[0011] Optionally, the lidded container forms part of a drone delivery system including a drone that is configured to carry the lidded container to a destination.

[0012] According to a second aspect of the invention, there is provided a set of blanks for forming a lidded container. The set of blanks includes a tray blank for forming a tray and a lid blank for forming a lid. The tray blank includes a first plurality of panels that are hingedly connected to one another and including, in series:
a first locking panel that defines first and second angled locking edges; a first side panel configured to form a first tray side wall in a set-up tray; a bottom panel configured to form a bottom wall in the set-up tray; a second side panel configured to form a second tray side wall in the set-up tray; and a second locking panel defining third and fourth angled locking edges. The lid blank includes: a top panel configured to form a top wall in a set-up lid; a first lid side wall panel hingedly connected along a first side of the top panel and configured to form a first side wall in the set-up lid; a second lid side wall panel hingedly connected along a second side of the top panel and configured to form a second side wall in the set-up lid; a first pair of gusset panels configured to form a first corner gusset in the set-up lid, the first corner gusset defining a first gusset angled edge; a second pair of gusset panels configured to form a second corner gusset in the set-up lid, the second comer gusset defining a second gusset angled edge; a third pair of gusset panels configured to form a third corner gusset in the set-up lid, the third corner gusset defining a third gusset angled edge; and a fourth pair of gusset panels configured to form a fourth corner gusset in the set-up lid, the fourth corner gusset defining a fourth gusset angled edge. The set-up lidded container is configured to be placed in a closed and locked configuration by placing the set-up lid over an open top of the set-up tray and pressing downwards so as to cause the first and second locking panels to fold outwardly until exterior surfaces of respective first and second locking panels are at least substantially adjacent to respective exterior surfaces of the first and second tray side walls, such configuration allowing the first gusset angled edge to mate with the first angled locking edge, the second gusset angled edge to mate with the second angled locking edge, the third gusset angled edge to mate with the third angled locking edge, and the fourth gusset angled edge to mate with the fourth angled locking edge so as to lock the set-up lid to the set-up tray.

[0013] Within the scope of this application it is envisaged that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.
BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

[0015] Figure 1 is a perspective view of a packaging system that includes at least a lidded carton according to one embodiment of the invention.

[0016] Figure 2 is a perspective view of the assembled tray portion and lid portion of the packaging system of Figure 1.

[0017] Figure 3 is a top plan view of a blank used to form the tray portion of Figure 2.

[0018] Figure 4 is a top plan view of a blank used to form the lid portion of Figure 2.

[0019] Figure 5-8 are views showing various steps in the construction of the packaging system of Figure 1.

[0020] Figure 9 is a perspective view of the packaging system of Figure 1 being transported by a drone.
DETAILED DESCRIPTION

[0021] Detailed descriptions of specific embodiments of cartons and blanks are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word "exemplary" is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns.
Indeed, it will be understood that the crates and blanks described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

[0022] In the embodiments detailed herein, the term "carton" refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for shipping, transporting, storing, and/or dispensing articles, such as, e.g., one or more products being delivered to a consumer. However, it is contemplated that the teachings of the invention can be applied to various containers suitable for carrying a wide variety of articles.

[0023] Referring to FIG. 1, there is shown a packaging system 200 that includes at least a lidded carton 201. The lidded carton 201 includes a tray portion 202 and a removable lid 204.

[0024] Referring to FIG. 3, there is shown a first or tray blank 10 for forming tray portion or tray 202. Referring to FIG. 4, there is shown a second or lid blank 12 for forming removable lid 204. The blanks 10, 12 are formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term "suitable substrate" includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the lidded carton described in more detail below.

[0025] In one or more embodiments, blanks 10, 12 can be formed from a paperboard, corrugated board, or cardboard in which one or both sides of the blanks, are printed and/or treated with one or more coatings, such as for example, one or more waterproof coatings and/or one or more coatings designed to provide a smooth and/or visually-attractive surface (e.g., a white or other colored surface). In one or more embodiments, informational or promotional material such as, e.g., a brand name or logo, can be printed on a treated side. In addition to branding or promotional material, additional printing and/or embossing processes may be applied to the surfaces of the blanks 10, 12 to provide better airflow and reduced drag for optimized aerodynamics while in flight, potentially reducing drone energy requirements and increasing range and/or payload.

[0026] Referring to FIG. 3, tray blank 10 is generally rectangular in shape and is generally symmetrical about central longitudinal and transverse axes. Tray blank 10 has a base panel 14. Base panel 14 is hingedly connected to: a first side panel 16 via longitudinal fold line 48; a second side panel 18 via longitudinal fold line 44; a front end panel 20 via transverse fold line 50; and a rear end panel 22 via transverse fold line 46. In the illustrated embodiment the first and second side panels 16, 18, and front and rear end panels 20, 22 taper outward slightly from base panel 14.
This taper creates a visual and outward taper from the base of the tray to the top of the tray, once assembled.

[0027] Foldably connected to the first side edge 76 of the front panel 20 is a first front gusset panel 24. Foldably connected to the second side edge 54 of the front panel 20 is a second front gusset panel 38. Foldably connected to the front side edge 72 of first side panel 16 is a first forward side gusset panel 26.
Foldably connected to the rear side edge 70 of first side panel 16 is a first rear side gusset panel 28. Foldably connected to the first side edge 66 of the rear end panel 22 is a first rear gusset panel 30. Foldably connected to the second side edge 69 of rear end panel 22 is a second rear gusset panel 32. Foldably connected to the front side edge 58 of second side panel 18 is a second forward side gusset panel 36. Foldably connected to the rear side edge 60 of second side panel 18 is a second rear side gusset panel 34.

[0028] As shown, the first front gusset panel 24 and the first forward side gusset panel 26 are joined by an angled crease line 74. The second front gusset panel 38 and the second forward side gusset panel 36 are joined by an angled crease line 56. The first rear gusset panel 30 and the first rear side gusset panel 28 are joined by an angled crease line 68. The second rear gusset panel 32 and the second rear side gusset panel 34 are joined by an angled crease line 62.

[0029] When the tray 202 is constructed, the blank 10 forms four corner gussets 11, 13, 15, 17, each gusset being formed by two cooperating gusset panels. Each gusset collapses against itself during erecting to provide an enhanced seal around the sides of the finished tray.

[0030] Foldably connected to the outer edge 78 of first side panel 16 is a first side locking panel 40. First side locking panel 40 is generally trapezoidal in shape and includes an inwardly-angled front side edge 86 and an inwardly-angled rear side edge 88. A generally rectangular notch 84 is struck from the first side locking panel's outer edge 85. Notch 84 defines a notch edge 150. Foldably connected to the outer edge 82 of second side panel 18 is a second side locking panel 42.
Second side locking panel 42 is generally trapezoidal in shape and includes an inwardly-angled front side edge 90 and an inwardly-angled rear side edge 92. A generally-rectangular notch 83 is struck from the second side locking panel's outer edge 87. Notch 83 defines a notch edge 151.

[0031] Referring to FIG. 4, lid blank 12 is generally rectangular in shape and is generally symmetrical about central longitudinal and transverse axes. Lid blank 12 has a top panel 94. Top panel 94 is hingedly connected to: a first side panel 102 via longitudinal fold line 71; a second side panel 100 via longitudinal fold line 75;
a front end panel 98 via transverse fold line 73; and a rear end panel 96 via transverse fold line 77.

[0032] Foldably connected to the first side edge 105 of the front panel 98 is a first front gusset panel 51. Foldably connected to the second side edge 127 of the front panel 98 is a second front gusset panel 55. Foldably connected to the front side edge 109 of first side panel 102 is a first forward side gusset panel 53.
Foldably connected to the rear side edge 111 of first side panel 102 is a first rear side gusset panel 65. Foldably connected to the first side edge 115 of the rear end panel 96 is a first rear gusset panel 63. Foldably connected to the second side edge 117 of rear end panel 96 is a second rear gusset panel 61. Foldably connected to the front side edge 123 of second side panel 100 is a second forward side gusset panel 57. Foldably connected to the rear side edge 121 of second side panel 100 is a second rear side gusset panel 59.

[0033] As shown, the first front gusset panel 51 and the first forward side gusset panel 53 are joined by an angled crease line 107. The second front gusset panel 55 and the second forward side gusset panel 57 are joined by an angled crease line 125. The first rear gusset panel 63 and the first rear side gusset panel 65 are joined by an angled crease line 113. The second rear gusset panel 61 and the second rear side gusset panel 59 are joined by an angled crease line 61.

[0034] When the lid 204 is constructed, the blank 12 forms four corner gussets 140, 142, 144, 146, each gusset being formed by two cooperating gusset panels.
Each gusset collapses against itself during erecting to provide an enhanced seal around the sides of the finished tray.

[0035] First side panel 102 includes a generally-rectangular access notch 129 struck from the first side panel's outer edge 130. Second side panel includes a generally-rectangular access notch 131 struck from the second side panel's outer edge 132.

[0036] The tray 202 may be constructed by applying glue or other adhesive to: an outside surface of gusset panel 24 and/or gusset panel 26; an outside surface of gusset panel 28 and/or gusset panel 30; an outside surface of gusset panel 32 and/or gusset panel 34; and an outside surface of gusset panel 36 and/or gusset panel 38. The first and second side wall panels 16, 18 and front and rear end wall panels 20, 22 are then folded inwardly about their respective fold lines 48, 44, 50, 46 until they are generally perpendicular to base panel 14. This folding brings the outside surfaces of cooperating gusset panels into contact with one another and secures them together.
Glue or other adhesive treatment can be applied to an interior surface of gusset panels 24, 38, 30, 32. Gussets 11, 13 are folded inwardly about respective crease lines 76, 54, bringing the interior surfaces of gusset panels 24, 38 into contact with an interior surface of front end panel 20 and securing them thereto. Gussets 15, 17 are folded inwardly about respective crease lines 66, 64, bringing the interior surfaces of gusset panels 30, 32 into contact with an interior surface of rear end panel 22 and securing them thereto.
First and second side locking panels 40, 42 are folded outwardly about respective fold lines 78, 44 until they are generally parallel to base panel 14. This results in the fully-assembled tray 202 as shown in FIG. 2 and prepares tray 202 to receive lid 204.

[0037] The lid 204 may be constructed by applying glue or other adhesive to: an outside surface of gusset panel 51 and/or gusset panel 53; an outside surface of gusset panel 55 and/or gusset panel 57; an outside surface of gusset panel 59 and/or gusset panel 61; and an outside surface of gusset panel 63 and/or gusset panel 65. The first and second side wall panels 102, 100 and front and rear end wall panels 98, 96 are then folded inwardly about their respective fold lines 71, 75, 73, 77 until they are generally perpendicular to top panel 94. This folding brings the outside surfaces of cooperating gusset panels into contact with one another and secures them together.
Glue or other adhesive treatment can be applied to an interior surface of gusset panels 57, 59, 53, 65. Gussets 150, 151 are folded inwardly about respective crease lines 109, 111 bringing the interior surfaces of gusset panels 53, 65 into contact with an interior surface of first side panel 102 and securing them thereto. Gussets 152, 153 are folded inwardly about respective crease lines 123, 121 bringing the interior surfaces of gusset panels 57, 59 into contact with an interior surface of second side panel 100 and securing them thereto. This results in the fully-assembled lid 204 as shown in FIG. 2.

[0038] To close the carton 201, lid 204 is placed over top of the tray 202 and pressed downwards. This forces the locking panels 40, 42 to fold outwardly until their exterior surfaces are substantially parallel and adjacent to (e.g., in face-contacting relationship with) the exterior surfaces of respective first and second side panels 16, 18. This configuration causes the angled edges 160, 161, 162, 163 of lid gussets 150, 151, 152, 153 to automatically mate with respective complementary angled edges 86, 88, 90, 92 of first and second locking panels 40, 42, thereby locking the lid 204 in place so as to create a secure connection between lid 204 and tray 202.

Advantageously, the lid 204 can be locked to tray 202 without the need for an adhesive connection therebetween, although in certain embodiments glue or other adhesive may be used to strengthen the connection. To remove the lid 204, a user can push inwardly on the portions of locking panels that are exposed to view through access notches 129, 131. This moves the angled edges 86, 88, 90, 92 of locking panels out of alignment with respective angled edges 162, 163, 160, 161 of gussets 152, 153, 150, 151 allowing the lid 204 to be lifted up and off of tray 202.

[0039] Access notches 129, 131 provide access to respective notches 84, 83 of first and second locking panels 40, 42. Notches 40, 42 may be used by the pickup system of a drone 300 (see FIG. 9) to lock onto the shipping container 201 and prevent the shipping container 201 from shifting during transport. The drone's pickup system may include, e.g., first and second grasping arms 302, 304 that engage respective first and second notches 83, 84 via notch edges 151, 150.

[0040] In a preferred embodiment, a drone delivery system 200 includes, in addition to lidded container 201, an adhesive sheet 206. Adhesive sheet 206 may be of the type described in U.S. Patent No. 9,340,317, the entirety of which is incorporated herein by reference. A lower surface of adhesive sheet 206 may be centered on and adhered to interior surface of base panel 14 (as shown in FIG.
5) during assembly of the drone delivery system 200. One or more shipped articles 210 (see FIG.
6) may be placed on the upper surface of adhesive sheet 206, and the adhesive sheet 206 may then be adhered to itself so as to envelop the article 210 and fix it securely in place within the tray 202 (as shown in FIG. 7). This may be desired both to prevent damage to the article 210 from shifting during transport, as well as to prevent a weight shift that could negatively impact the drone's flight performance and safety.

[0041] In a preferred embodiment, one or both sides of blanks 10, 12 are treated with a water-proof or water-resistant coating. The use of gusset panels by tray 202 and lid 204 to form webbed corners also advantageously provides container 201 with enhanced water resistance. Water resistance may be considered particularly desirable based on the increased likelihood that a drone delivery service will need to deliver container to a location that is exposed to the elements.

[0042] Exemplary embodiments of blanks and methods for forming containers are described above in detail. The apparatus and methods are not limited to the specific embodiments described herein, but rather, components of apparatus and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other containers and methods, and are not limited to practice with only the containers and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other container applications. In particular, it will be recognized that the shipping containers and systems described herein may be suitable for use in applications other than drone delivery, e.g., as a general purpose shipping or storage container.

[0043] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

[0044] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art.
Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims (9)

WHAT IS CLAIMED IS:

1. A lidded container comprising:
a tray comprising a bottom wall, first and second tray side walls, a first locking panel hingedly connected to an upper edge of said first tray side wall, and a second locking panel hingedly connected to an upper edge of said second tray side wall;
and a removable lid comprising a top wall, first and second lid side walls, first and second comer gussets disposed on an interior surface of said first lid side wall, and third and fourth comer gussets disposed on an interior surface of said second lid side wall, said first, second, third, and fourth corner gussets defining respective first, second, third, and fourth gusset angled edges;
wherein said lidded container is configured to be placed in a closed and locked configuration by placing said removable lid over an open top of said tray and pressing downwards so as to cause said first and second locking panels to fold outwardly until exterior surfaces of respective first and second locking panels are at least substantially adjacent to respective exterior surfaces of said first and second tray side walls, such configuration allowing said first gusset angled edge to mate with a first complementary angled edge of said first locking panel, said second gusset angled edge to mate with a second complementary angled edge of said first locking panel, said third gusset angled edge to mate with a third complementary angled edge of said second locking panel, and said fourth gusset angled edge to mate with a fourth complementary angled edge of said second locking panel so as to lock said removable lid to said tray.

2. The lidded container of Claim1, wherein said first and second locking panels are substantially trapezoidal in shape.

3. The lidded container of Claim 2, wherein said first, second, third, and fourth comer gussets are substantially triangular in shape.

4. The lidded container of Claim 1, wherein said tray comprises first, second, third, and fourth tray corner gussets.

5. The lidded container of Claim 1, wherein said first lid side wall defines a first access notch in a lower edge of said first lid side wall, wherein said second lid wall defines a second access notch in a lower edge of said second lid side wall, wherein said first and second access notches are configured to provide access to said respective first and second locking panels when said lidded container is in said closed and locked configuration.

6. The lidded container of Claim 5, wherein said first locking panel defines a first generally-rectangular notch in a lower edge of said first locking panel and wherein said second locking panel defines a second generally-rectangular notch in a lower edge of said second locking panel.

7. The lidded container of Claim 5, wherein said removable lid is configured to be removed from said tray by pressing inwardly on portions of first and second locking panels that are exposed through said first and second access notches so as to move said first, second, third, and fourth gusset angled edges out of alignment with said respective first, second, third, and fourth complementary angled edges, thereby allowing said removable lid to be lifted up and off of said tray.

8. A drone delivery system comprising: a lidded container as claimed in Claim 1; and a drone configured to carry said lidded container to a destination.

9. A set of blanks for forming a lidded container comprising:
a tray blank configured to form a tray; and a lid blank configured to form a lid;
wherein said tray blank comprises a first plurality of panels that are hingedly connected to one another and comprising, in series:

a first locking panel, said first locking panel defining first and second angled locking edges;
a first side panel configured to form a first tray side wall in a set-up tray;
a bottom panel configured to form a bottom wall in the set-up tray;
a second side panel configured to form a second tray side wall in the set-up tray; and a second locking panel, said second locking panel defining third and fourth angled locking edges;
wherein said lid blank comprises:
a top panel configured to form a top wall in a set-up lid;
a first lid side wall panel hingedly connected along a first side of the top panel and configured to form a first side wall in the set-up lid;
a second lid side wall panel hingedly connected along a second side of the top panel and configured to form a second side wall in the set-up lid;
a first pair of gusset panels configured to form a first corner gusset in the set-up lid, said first corner gusset defining a first gusset angled edge;
a second pair of gusset panels configured to form a second corner gusset in the set-up lid, said second corner gusset defining a second gusset angled edge;

a third pair of gusset panels configured to form a third corner gusset in the set-up lid, said third corner gusset defining a third gusset angled edge;
and a fourth pair of gusset panels configured to form a fourth corner gusset in the set-up lid, said fourth comer gusset defining a fourth gusset angled edge;
wherein a set-up lidded container is configured to be placed in a closed and locked configuration by placing said set-up lid over an open top of said set-up tray and pressing downwards so as to cause said first and second locking panels to fold outwardly until exterior surfaces of respective first and second locking panels are at least substantially adjacent to respective exterior surfaces of said first and second tray side walls, such configuration allowing said first gusset angled edge to mate with said first angled locking edge, said second gusset angled edge to mate with said second angled locking edge, said third gusset angled edge to mate with said third angled locking edge, and said fourth gusset angled edge to mate with said fourth angled locking edge so as to lock said set-up lid to said set-up tray.