GB2265133A

GB2265133A - Packaging

Info

Publication number: GB2265133A
Application number: GB9206208A
Authority: GB
Inventors: Derek David Muir
Original assignee: Hewlett Packard Ltd
Current assignee: Hewlett Packard Ltd
Priority date: 1992-03-21
Filing date: 1992-03-21
Publication date: 1993-09-22
Anticipated expiration: 2012-03-21
Also published as: GB2265133B; JPH0575122U; DE9302845U1; GB9206208D0

Abstract

Packaging 10 for protecting equipment or articles includes at least one sheet 18 of a first material (eg. corrugated fibreboard or plastics) having an aperture 24 with flaps 20 around its periphery, a body 14 of a second material (eg. rubber or plastics foam) protruding through the aperture 24 and being retained by engagement with the flaps 20. A tongue (22, fig 2) at the base of one or more of the flaps provides additional grip. The packaging may further have an inner layer 16 of sheet material. <IMAGE>

Description

Packaging This invention relates to packaging, for example for the transport of equipment or articles which it is desirable to protect from impacts.

It is known to fabricate such packaging from a combination of sheet material, such a corrugated fibreboard (also colloquially known as corrugated cardboard), and block material, such as plastic foam or expanded polystyrene. The fibreboard provides an overall enclosure while the foam or polystyrene absorbs impacts which the packaging may sustain.

The block material is retained in position relative to sheet material typically by engaging the block material around corners of the article to be transported (see for example EP 0 369 869) or by gluing the block material to the sheet material. However, the first method involves special moulding or machining of the block material which increases fabrication and inventory costs. Gluing together dissimilar materials such as fibreboard and plastic is environmentally undesirable, since is renders difficult or impossible the recovery and recycling of the raw materials. Indeed in some jurisdictions fastening of different materials in an inseparable manner is now discouraged or even prohibited.

It is an object of this invention to provide packaging which alleviates these problems.

According to one aspect of this invention, there is provided packaging comprising at least one sheet of a first material (for example fibreboard, corrugated fibreboard or corrugated plastic) and at least one body of a second material (for example plastic foam, expanded plastic, rubber or expanded rubber), wherein said body is located in an aperture in said sheet and engages a flap formed in said sheet at the periphery of said aperture.

Preferably the body engages a plurality of flaps at the periphery of the aperture.

In addition, a tongue of the sheet material may protrude towards the body from the base of one or more flaps.

Such packaging can be quickly and easily assembled to form a secure container for transport of an article. The container can also be easily disassembled to separate the different constituent materials for re-use or recycling.

According to another aspect of the invention, there is provided a method of manufacturing packaging comprising the steps of cutting a sheet of a first material to define an area to receive a body of a second material and at least one flap at the periphery of said area, and urging a body of said second material into said area to displace said flap such that said body occupies an aperture vacated by said flap and engages said flap.

Packaging according to this invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is an isometric view of an embodiment of the invention; Figure 2 is a sectional view showing the relative location of an impact absorbent body and a sheet in the embodiment of Figure 1; and Figure 3 is an enlarged plan view of a sheet forming part of the embodiment of Figure 1 prior to assembly.

Referring to Figure 1, an item of packaging indicated generally at 10 comprises a container 12 and impact absorbent bodies 14 made of blocks of foam plastic. The wall of the container 12 has an inner layer 16 and an outer layer 18, both layers being formed of folded corrugated fibreboard (also colloquially known as corrugated cardboard). The surface of the inner layer 16 in the illustrated embodiment is continuous, whereas the outer layer 18 has apertures which are occupied by the impact absorbent bodies 14. Each face of the container 12 has at least one body 14 protruding outwardly from it, the bodies 14 being intended to engage the inside surface of an outer container or box (not shown).

The bodies 14 are restrained against lateral movement across the face of the container 12 by flaps 20 which are formed of the material of, and bent outwardly from, the outer layer 18. These flaps are urged by the inherent resilience of the corrugated fibreboard into firm contact with the bodies 14 to grip them, as shown in the sectional view in Figure 2. Figure 2 also shows tabs 22 which extend towards the centre of the aperture from the bases of an opposed pair of flaps 20 to engage the body 14 and provide additional grip.

The apertures and flaps 20 are made by stamping a cut-out, as shown in solid line in Figure 3, at the required location in a corrugated sheet intended to form the outer layer 18. This cut-out defines an aperture 24 and two pairs of opposed flaps 20a and 20b extending into the aperture 24 from a generally rectangular baseline 26 (shown in dashed line). A slot extends from each corner of the baseline 26 towards the centre, separating the facing edges of adjacent flaps 20. Additional cut lines 28 are made along three sides of a rectangular portion 30 located centrally within each of the flaps 20a and on the baseline 26, the side of the rectangular portion 30 on this baseline being left uncut.It is preferable for the aperture 24 to be oriented on the corrugated fibreboard so that the flutes of the fibreboard extend transversely to the long edge of the rectangular portion 30, as indicated by the arrow 32.

If desired score lines may be formed along the baseline 26, except along the edge of the rectangular portion 30, to aid folding during subsequent assembly of the packaging 10. Scorelines may also be formed elsewhere on the outer layer 18 to define the overall shape of the container 12.

To assemble the packaging 10, the sheet with the stamped cut-outs is folded to form the outer layer 18 of the container 12, and its free edges may be secured for example with staples. Blocks of foam plastic are then pushed through the apertures 24 from the inside of the container 12 until the inner faces of the blocks are flush with the inside surface of the layer 18. In the course of this operation the flaps 20 are displaced outwards by the blocks of foam plastic, leaving the rectangular portions 30 protruding into the apertures 24 at the base of the flaps 20a to form the tabs 22. The sheet of corrugated fibreboard for the inner layer 16 is then folded and placed within the outer layer 18 and may be secured to it by, for example, stapling.

As a result, and as shown in Figure 2, each body 14 of foam plastic has a base portion sandwiched between the inner layer 16 and the flaps 20 of the outer layer 18, and additionally engaged by the tabs 22. It has been found that this construction provides secure retention of the bodies 14 which remain in position Throughout conventional drop tests of complete assemblies incorporating the packaging 10, and provide adequate protection for articles placed within the container 12. However, when the packaging 10 is discarded it can be readily disassembled into its constituent differing materials, facilitating recycling and conservation of those materials.

As an example, the flaps 20 may be sized to extend into the aperture 24 by an amount equal to approximately one-third of the height of the bodies 14 above the outer layer 18. The longer side of each rectangular portion 30 may be equal to approximately one-third of the side of the baseline 26 on which it is located, and the shorter side of this portion may be equal to approximately twice the thickness of the corrugated fibreboard.

However, considerable variation is possible in these dimensions to suit specific situations and choice of materials.

As described above the layer 18 is formed from a single, folded piece of fibreboard; however, it may instead comprise several separate panels, each carrying at least one body 14 and sandwiched between a respective face of the inner layer 16 and a face of an outer container or housing. Various other modifications may be made. Thus the apertures 24 may be formed in the inner layer 16 and the bodies 14 pushed through the apertures from the outside, so that they extend into the inside of the container 12 and have portions sandwiched between inwardly directed flaps and the outer layer 18. Alternatively, only a single layer of fibreboard containing the apertures 24 may be provided, with the bodies 14 protruding from both faces thereof; in this case, the packaging would be used in circumstances in which both ends of the bodies 14 have surfaces to bear against.

Various different materials, and various densities thereof, may be used for the layers 16 and/or 18 and for the bodies 14. Thus the layer(s) may be made for example of solid fibreboard or corrugated plastic sheet instead of corrugated fibreboard; and the bodies may be made of expanded plastic (such as expanded polystyrene), expanded rubber or solid rubber instead of foam plastic.

Claims

1. Packaging comprising at least one sheet of a first material and at least one body of a second material, wherein said body is located in an aperture in said sheet and engages a flap formed in said sheet at the periphery of said aperture.

2. Packaging according to claim 1, wherein said body engages a plurality of flaps at the periphery of said aperture.

3. Packaging according to claim 1 or claim 2, wherein said first material comprises fibreboard, corrugated fibreboard or corrugated plastic.

4. Packaging according to any one of the preceding claims, wherein said second material comprises plastic foam, expanded plastic, rubber or expanded rubber.

5. Packaging according to any one of the preceding claims, wherein a tongue of the sheet material protrudes towards said body from the base of said flap.

6. A method of manufacturing packaging comprising the steps of cutting a sheet of a first material to define an area to receive a body of a second material and at least one flap at the periphery of said area, and urging a body of said second material into said area to displace said flap such that said body occupies an aperture vacated by said flap and engages said flap.

Amendments to the claims have been filed as follows 1. Packaging comprising at least one sheet of a first material and at least one body of a second material, wherein said body is located in an aperture in said sheet and engages a flap formed in said sheet at the periphery of said aperture.

2. Packaging according to claim 1, wherein said flap extends at an angle to said sheet.

3. Packaging according to claim 1 or claim 2, wherein said body engages a plurality of flaps at the periphery of said aperture.

4. Packaging according to any one of the preceding claims, wherein said first material comprises fibreboard, corrugated fibreboard or corrugated plastic.

5. Packaging according to any one of the preceding claims, wherein said second material comprises plastic foam, expanded plastic, rubber or expanded rubber.

6. Packaging according to any one of the preceding claims, wherein a tongue of the sheet material protrudes towards said body from the base of said flap.

7. A method of manufacturing packaging comprising the steps of cutting a sheet of a first material to define an area to receive a body of a second material and at least one flap at the periphery of said area, and urging a body of said second material into said area to displace said flap such that said body occupies an aperture vacated by said flap and engages said flap.

8. Packaging substantially as hereinbefore described with reference to the accompanying drawings.

9. A method of manufacturing packaging substantially as hereinbefore described with reference to the accompanying drawings.