GB2591780A

GB2591780A - A packaging product, packaging assembly, packaging unit and methods relating thereto

Info

Publication number: GB2591780A
Application number: GB2001598.8A
Authority: GB
Inventors: Andrew Turner Timothy
Original assignee: Total Packaging Solutions Ltd
Current assignee: Total Packaging Solutions Ltd
Priority date: 2020-02-06
Filing date: 2020-02-06
Publication date: 2021-08-11
Also published as: WO2021156631A1; GB202001598D0

Abstract

A packaging assembly comprising a packaging product 1, 150, 160 comprising a first layer 3 and a second layer 4 with a support structure 5 in between. The support structure has a plurality of voids 7 between the layers. The product has a plurality of slits 8 or grooves 11, each extending through at least one layer and at least part way into the support structure to form a line of weakness 10 so that the product can fold and conform to the shape of the item that it is intended to protect. The packaging product 1 inserted into an outer container or tube 20, 151, 161, which is preferably cylindrical. A method of producing a packaging assembly comprises providing a package as described and providing a lid (14, fig. 3) and a base (15) for it so that when the product is folded the open ends of the product can be closed.

Description

A PACKAGING PRODUCT, PACKAGING ASSEMBLY, PACKAGING UNIT AND METHODS RELATING THERETO

Technical Field of the Invention

The present invention relates to a packaging product and a method of making such a product. More specifically, the present invention relates to a packaging product suitable to conform to the shape of an item to be protected, especially, but not exclusively, to a wine bottle.

Background to the Invention

When one packages and posts a fragile object, there is little certainty whether the object will make it to its destination in one piece. There are many opportunities during transit for a fragile object to be broken; the package will be handled numerous times, hastily stacked inside an automobile, either with numerous packages above it or placed at height with an associated risk of falling. Moreover, the object will most certainly be subjected to vibrations from the road surface.

Many courier services will refuse to deliver packages containing bottles because of the delicate handling that is required. Some courier services will accept packages containing bottles, but will not insure the contents of the package It is evident that courier services consider bottle delivery to be a high-risk activity, and that they consider present packaging techniques to be inadequate to guarantee delivery without breakage.

It is known to package bottles for posting in a box or tube and surround the bottle with void-fill materials such as polystyrene chips, inflated bags and bubble wrap. It is also known to package bottles in hollow polystyrene tubes. These techniques, whilst providing inadequate protection to the object held within as they are too soft or rigid respectively, are also made from non-recyclable materials. It is known to package bottles in a cardboard box using a cardboard grid divider. It is also known to package bottles in a clamshell package made from moulded pulp. Although both of these products are widely recyclable, the grid divider does not provide sufficient protection to prevent neighbouring bottles from striking one another, and the clamshell package offers similarly inadequate protection, is too soft and is expensive to manufacture.

In all conventional instances of packaging a fragile object, an internal structure or filler material is provided to fill the space between the object and the inside of the packaging container or at least form an abutment between the object and the inside of the packaging container to support the structural integrity of the packaging container. However, if the packaging container is submitted to external stress then the space filler or abutment can transfer the external stress to the fragile object It is an object of embodiments of the present invention to provide an improved packaging product and/or to address the problems discussed above.

Summary of the Invention

According to a first aspect of the present invention there is provided a method of manufacturing a packaging product comprising the steps of providing a sheet of material having a first layer and a second layer with a support structure provided therebetween; the support structure defining a plurality of voids between the first layer and the second layer, and scoring the sheet to produce a plurality of slits or grooves, each slit or groove extending through at least one layer and at least part way into the support structure forming a line of weakness so that the product can fold about the line of weakness and conform to the shape of the item that it is intended to protect Providing a sheet of material having a first and a second layer ensures that pressure applied to a layer of the product is spread across a wider area of the support structure, which helps the support structure to retain its shape under moderate loads. The voids defined by the support structure provide cushioning for an object held within as they allow for the support structure to collapse during impact. The voids also reduce the weight of the packaging product which is an important consideration in posting items.

By scoring the sheet to produce a plurality of slits or grooves at predetermined positions based on the object that it is desired to protect, the packaging product can be made to conform to the shape of said object to provide a protective surround.

One or more slits or grooves may extend through at least one layer and the whole of the support structure. Each slit or groove may extend through at least one layer and the whole of the support structure. Each slit or groove may extend through only one layer and the whole of the support structure. By this construction, a line of weakness is defined along the uncut layer about which the packaging product can be folded, and thereby provides flexibility to the packaging product.

Each slit or groove may extend through the same layer. This allows the packaging product to be folded inwardly the same direction in a concave manner. The packaging product may be foldable to form a hollow polygonal prism.

One or more slits or grooves may extend through at least the first layer and one or more slits or grooves may extend through at least the second layer. One or more slits or grooves may extend through only the first layer and one or more slits or grooves may extend through only the second layer. This allows the packaging product to be folded initially out of the plane of the packaging product and then back parallel to the plane of the packaging product, thereby producing a Z-shape fold One or more slits or grooves may have a portion which extends through one layer and a portion which extends through both layers. The two portions together may extend from one edge of the packaging product to another. A further slit or groove may be formed which extends through one layer and intersects the portion of the one or more slits or grooves which extend through both layers. In this manner, folding of the packaging product is facilitated in a direction which is different to the fold direction of the portion of the one or more slits or grooves which extends through one layer. The further slit or groove may extend through the whole of the support structure. The further slit or groove may be substantially perpendicular to the one or more slits or grooves comprising two portions.

The sheet of material may be scored with at least 2, 3, 4, 5 or 6 slits or grooves. Two or more slits or grooves may be substantially parallel. All of the slits or grooves may be substantially parallel. This allows a part or all of the packaging product to be folded into a cylinder. The slits may be separated equidistantly. This allows a part or all of the packaging product to be rolled to form a regular polygon in cross section.

The product may be made from paper, card or other fibrous material. Paper, card and other like materials are widely recyclable and low in weight. Such materials can have a high strength to weight ratio, especially when folded or rolled. Reducing the weight of packaging is an important consideration in posting items as postage costs are often based on total package weight.

The support structure may be a multi-cell structure. The support structure may extend substantially perpendicularly between the first layer and the second layer. Alternatively, the support structure may be made from fluted corrugated cardboard. The support structure extending substantially perpendicularly to the plane of the first and second layers allows the support structure to retain its shape when pressure is applied in a direction that is parallel to the direction in which the support structure extends. However, the walls can collapse into the voids when pressure is applied to the side, or where the support structure is weakened by slits or grooves formed therein, allowing the packaging product to provide cushioning in the event of heavy impact. The support structure may be a lattice of honeycomb structures. The support structure may be a cardboard lattice of honeycomb structures. A multi-cell structure, such as a honeycomb structure, can have a high strength to weight ratio. Moreover, planar sections of the packaging product are sturdy as a result of the support structure between the layers, whereas at the edges of slits or grooves formed in the product, the product is compressible which provides cushioning for an item protected by the packaging product. A honeycomb support structure is particularly advantageous in this context, as slits or grooves formed in the product intersect the honeycomb cells thereby weakening the structure at the edges that are formed so that the cell walls may collapse under impact. However, the product remains structurally sound as the honeycomb cells within the sheet away from the slits and grooves support the planar sections of the packaging product. The honeycomb cell structure is also easy to form by folding and bonding two strips of material, such as strips of cardboard, and is also readily commercially available.

The support structure may be made from solid fibreboard. Fibrous materials are readily formed into complex structures. Alternatively, the support structure may be a multi-cell plastic structure.

The support structure may be bonded between the first and second layer. In this manner, the layers and support structure are securely connected. This allows for the packaging product to remain as a single piece when scored whilst remaining structurally sound.

The sheet may have a width of between 30-1500mm, a length of between 50 -5000mm and a thickness of between 5 -100mm. Slits may be separated at a distance of between 10 -300mm. In one embodiment, the sheet may have a width of 250mm, a length of 320mm and a thickness of 1 Omm, and slits separated by 30mm. Such dimensions are particularly suited to package a wine bottle.

The method may further comprise the step of providing a base layer of material; and bonding the scored sheet of material on to the base layer.

In the case where the slits or grooves are cut through one layer and the whole of the support structure, bonding the scored sheet to the base layer provides additional protection to the weakened packaging product, ensuring that it does not tear along lines of weakness. Where slits or grooves are cut through both layers and the whole of the support structure, bonding the scored sheet to the base layer reattaches the separated sheet pieces so that they remain in a one-piece form.

According to a second aspect of the invention there is provided a method of using a packaging product according to the first aspect of the invention, the method comprising the steps of: providing an item to be protected; and folding the packaging product around the item so that the product conforms to the shape of the item The method of use of the second aspect of the invention may comprise any or all of the features of the first aspect of the invention, as desired or as appropriate.

Where the packaging product comprises slits or grooves, the packaging product may be foldable away from the slits along one or more lines of weakness defined by the slits i.e. opening the slits into grooves, and grooves into wider grooves.

Advantageously, the edges of the grooves there defined are more compressible than the flat surfaces of the sheet thereby providing cushioning to a packaged item in the event of a moderate impact, whilst in the event of a heavy impact the entire structure can be compressed. Further, where a plurality of slits or grooves extend through only one layer of the sheet, the packaging product may be folded around the item to be protected such that the layer along which the lines of weakness are defined is contiguous to the item, and the support structure extends outwardly away from the item. Advantageously, the weakened layer is protected by the cushioning of the support structure, and the more compressible edges which protrude outwardly.

The item to be protected may have a generally cylindrical shape. The item may comprise a protrusion. The item may have a generally cylindrical body and comprise a protrusion. The item may be a bottle. The item may be a wine bottle. The item may be a mug or teacup.

According to a third aspect of the invention there is provided a packaging product comprising a first and second layer with a support structure provided therebetween, the support structure defining a plurality of voids between the first layer and the second layer, the product having a plurality of slits or grooves, each slit or groove extending through at least one layer and at least part way into the support structure forming a line of weakness so that the product can conform to the shape of the item that it is intended to protect.

The product of the third aspect may be made according to the method of the first aspect of the invention and may optionally comprise any optional feature of the first aspect According to a fourth aspect of the invention there is provided a packaging assembly comprising a packaging product according to the third aspect.

The packaging assembly may comprise a lid and a base. A lid and base protect the top and bottom of an item protected by the packaging product. The lid and base may have substantially the same dimensions as the upper and lower ends of the packaging product when the packaging product is folded to conform to the shape of the item that it is intended to protect.

The lid and base may have a circular cross section. The lid and base may have a circumference that is substantially equal to the width of the sheet. Where the packaging product is folded to form a hollow polygonal prism, the lid and base may be sized to be inserted into the prism ends. Alternatively, the lid and base may have a diameter that is substantially equal to an outer cross-sectional dimension of the polygonal prism.

The packaging assembly may comprise an outer container into which the packaging product is locatable. The outer container can have any configuration. The outer container may be configured as a box. The box may have any shape. In an embodiment, the at least one packaging product may be locatable within the outer container when folded such that the groove edges are oriented outermost relative to the outer tube and a majority of the strips extend away from an interior surface on a facing sidewall of the outer container at an angle. Preferably all of the strips, or substantially all of the strips extend away from an interior surface on a facing sidewall of the outer container at an angle.

In an embodiment, the outer container may be a tube. The tube can be a postal tube with one or more packaging products or assemblies inserted into the tube. In this manner, a protected bottle may be transported in a compact package using a standard postal tube. Where a plurality of packaging products or assemblies are inserted into the outer tube, one or more spacer elements may be provided to separate the products or assemblies. Spacer elements can protect the multiple items by preventing them from contacting and potentially damaging one another. The outer tube may have an inner radius substantially equal to the sum of the intended bottle radius and the product thickness. The length of the outer tube may be no less than the product length, or, if lid and base are used, the sum of the product length and lid and base thicknesses.

Void fill materials may be provided in the outer tube at the ends. This is advantageous where a outer tube is used having a length which is greater than the sheet length or sum of sheet length and lid and base thicknesses. The void fill materials will prevent significant movement of the packaging product where there is excess space within the outer tube.

The packaging assembly may comprise an outer containing element such as a box. One or more packaging products or assemblies may be inserted into the box. Such a construction is advantageous as it alleviates the need for a separate grid divider to be positioned within the box. The packaging products or tube inside the box may be close-fitting, thereby preventing movement and providing structural rigidity to the box. The packaging assembly may be provided with a floor and roof having substantially the same cross section as the inner profile of the box. The floor and roof may comprise one or more recesses suitable to receive packaging products.

A packaging unit may be created by provision of at least one packaging assembly and an outer container to contain the at least one packaging assembly. The outer container may preferably contain a plurality of packaging assemblies The outer containing element may be a cylindrical tube with a circular cross-sectional shape. The lid and the base may engage with the cylindrical tube. At least a portion of at least one of the lid and/or the base may abut an end of the packaging product when in place relative to the cylindrical tube. This may assist with minimising any linear movement of the item within the packaging product.

Where the packaging products are received in outer containing element, the outer containing element may be located within the box prior to insertion of an item into the or each packaging product. The floor and roof of the box may comprise a plurality of recesses suitable to receive the outer containing element.

In one form, a prefilled box of outer containing element may be provided, each with a packaging product inserted thereinto may be prepared. This prepared configuration may be sent to a distributor of wine for example in order that the distributor simply has to either place the bottles within the prepared packing product within an outer containing element, seal the box and send, or alternatively, one or more of the outer containing element with a packaging product therein may be removed from the box and an item inserted before dispatch.

The outer containing element may be non-circular. A non-circular outer containing element will normally have at least three sidewalk When the packaging product is folded about the line of weakness, a number of groove edges will preferably be formed In an embodiment, the at least one packaging product may be locatable within the outer containing element when folded such that the groove edges are oriented outermost relative to the outer tube and a majority of the strips extend away from an interior surface on a facing sidewall of the outer containing element at an angle. Preferably all of the strips, or substantially all of the strips extend away from an interior surface on a facing sidewall of the outer containing element at an angle.

The outer containing element need not be cylindrical. Provided that a majority of the strips extend away from an interior surface on a facing sidewall of the outer containing element at an angle, then the groove edges are oriented outermost and will be the initial point of contact with an inner surface of the outer containing element in the case of any force applied laterally that may damage the item. As outlined above, these groove edges are more compressible and may act as "crumple zones" The effectiveness of the groove edges acting as "crumple zones" may allow the packaging product to effectively protect a fragile object without needing any contact with the interior surface on a facing sidewall of the outer containing element.

Normal folding of the packaging product described above will typically form a number of substantially planar strips on an outer portion of the product. The strips are typically separated by a slit which will open into a groove when the packaging product is folded. Each groove will typically have an apical or pointed groove edge.

In particular, the groove edges formed by the slits or grooves when folded about the lines of weakness, are exposed to the inside of the outer containing element. In use, preferably only the apical or pointed grooves are positioned to abut the inner surface of the outer container, unless a significant deforming force is applied. A small range deforming force of the magnitude likely to be applied during normal transit or delivery, will not be sufficient to cause any portion of the first layer other than the groove edges, to abut an inner surface of the outer container.

If the packaging product is received within the outer container in a friction fit, it is preferably the groove edges that make contact with the inner surface of the outer container.

If the packaging product is received within the outer container in a spaced fit, in which the apical or pointed groove edge(s) is spaced from an internal surface of the outer container, some movement of the packaging product may be possible due to agitation of the tube but the apical or pointed groove edge may preferably maintain the orientation of the packaging product within the outer container and abut the inner surface of the walls of the outer container, maintaining a majority of the strips extending away from an interior surface on a facing sidewall of the outer container at an angle The packaging product may further comprise one or more lines of perforations. A line of perforations may be located along one or more lines of weakness. One or more lines of perforations may be located extending transversely to the one or more lines of weakness. This may allow separation of a larger packaging product into one or more smaller packaging products. Preferably a line of perforations may be provided along at least a part of the length of one or more lines of weakness. Perforations may be provided along some or all of the lines of weakness on a packaging product This would increase the flexibility of use of the packaging product.

According to another aspect of the invention there is provided a method for packaging an item using a packaging assembly according to the third aspect utilising the postal tube and comprising the steps of inserting an item into a packaging product to form a partially packaged item, and inserting the partially packaged item into a postal tube.

Alternatively, the method may comprise the steps of inserting a packaging product into an outer containing element and then inserting an item to be packaged into the packaging product within the outer containing element.

A plurality of outer containers with a packaging product within the outer container may be packed into a box. Ii

Detailed Description of the Invention

In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure I shows a packaging product according to a first embodiment of the present invention formed from a cardboard sheet scored to form slits; Figure 2 shows the packaging product of Figure I folded to form a hollow polygonal prism; Figure 3 shows the folded packaging product of Figures t and 2 and lid and base for inserting into the open ends of the hollow prism; Figure 4 shows the folded packaging product of Figures 1 -3 being placed inside a postal tube; Figure 5 shows two folded packaging products according to Figures 1 -4 and a spacer element being placed in side a postal tube, Figure 6 shows a cross section through the postal tube of Figure 4 or 5 with the folded packaging product held within, Figure 7 shows a plurality of packaging products of Figures land 2 packaged in a cardboard box, Figure 8 shows a packaging product assembly according to a second embodiment of the invention used to protect a mug; Figure 9 shows a packaging product according to a first embodiment of the present invention formed from a cardboard sheet scored to form grooves; Figure 10 shows a packaging product according to a further embodiment having a first slit extending through an upper layer and a second slit extending through a lower layer; Figure 11 shows the packaging product of Figure 10 folded to form a Z-shape, Figure 12 shows a packaging product according to a further embodiment having a first slit extending through both layers and a second, perpendicular slit extending through only the upper layer; and Figure 13 shows the packaging product of Figure 12 with the corner section folded along the line of weakness defined by the second slit.

Figure 14 is a plan view of a plurality of packaging products of Figure 6 packaged in a box.

Figure 15 is a plan view of a packaging assembly including a packaging product in a triangular tube Figure 16 is a plan view of a packaging assembly including a packaging product in a rectangular tube or box.

In what follows the terms upper, lower, top, bottom, left and right are used to refer to the invention in the orientation in which it is illustrated which is the orientation in which it is intended to be used, but should not be taken as otherwise limiting. The drawings are not to scale.

Referring to Figures 1 -7, a packing product 1 is formed from a rectangular cardboard sheet 2 comprising a first, upper cardboard layer 3 and a second, lower cardboard layer 4 with a cardboard support structure 5 provided therebetween. The support structure 5 is formed from a plurality of cardboard strips 6 which are bonded to, and extend perpendicularly between, the upper layer 3 and lower layer 4. The strips 6 are arranged to form a honeycomb lattice structure when viewed in cross section parallel to the upper layer 3 and lower layer 4. The support structure 5 thereby defines a plurality of voids 7 between the upper layer 2 and lower layer 3 as the volume within each honeycomb cell.

In this exemplary embodiment, the sheet has a width W of 250mm, a length L of 320mm and a thickness T of lOmm. Such dimensions are optimal dimensions for retaining a typical wine bottle. The width is substantially equal to the circumference of a typical wine bottle. Such a sheet is obtainable for example from Smurfit Kappa Hexacomb BV of Ermelo, Nt.

The sheet 2 is scored to form slits 8 which run parallel to the length of the rectangular sheet 2 along its entire length. The slits 8 extend down through the upper layer 3 and through the support structure 5, but stop short of the lower layer 4. Strips 9 are thereby defined, each strip 9 being separated by a slit 8. A line of weakness 10 in the structure is defined along the uncut lower layer 4 at the base of each slit 8 about which the sheet 2 may be folded inwardly, away from the upper layer 3. As illustrated in Figure 2, the equidistantly separated parallel slits 8 allow the sheet to be folded to form a packaging product 1 having a regular polygonal inner cross section. In this exemplary embodiment, the polygon has nine sides as a result of the provision of eight slits 8 scored in the sheet 2. It will be clear to the skilled person that the number of sides is determined by the number of slits 8 scored in the sheet 2 By folding the product 1, the slits 8 are opened into grooves 11 and the groove edges 12 are exposed and protrude outwardly to define the maximum radial dimension of the folded product 1.

IS The packaging product 1 can be folded inwardly around a wine bottle (not shown) along the lines of weakness 10 with the uncut lower layer 4 contiguous to the bottle. The product 1 can then be secured in its resulting hollow polygonal prism shape by providing a piece of adhesive tape 13 to connect the now adjacent longest sides of the packaging product 1. As the width W of the sheet 2 is substantially equal to the circumference of the wine bottle, when the packaging product 1 is folded inwardly around the bottle along the parallel slits 8 formed across its width W and along its length L, the bottle fits tightly within the folded packaging product 1. As the length L of the sheet 2 is sized to be equal to the height of the wine bottle, the packaging product 1 completely encompasses the height of the wine bottle. By suitable sizing of width W and length L, the bottle is protected from side impacts. As the bottle fits snugly within the folded packaging product, the bottle will not be subjected to vibrations during transit, as these will be absorbed by the packaging product.

Advantageously in this exemplary embodiment, the lower layer 4, along which the lines of weakness 10 are defined, is on the surface of the packaging product 1 that is contiguous to the bottle, and the support structure 5 extends outwardly, which results in the weakened, folded layer 4 being protected by the cushioning of the support structure 5, and in particular the edges 12 of the grooves 11, in the event of an impact. As shown in Figure 6, pockets 23 defined between the packaging product and the bottle held within allow the packaging product 1 to flex around the bottle when pressure is applied to the product 1, in particular when pressure is applied to the edges 12 of the grooves 11. The pockets 23 and voids 7 formed within the support structure 5 allows the product to flex under light loads and light impacts, such as vibrations in transit, which provides cushioning to the bottle or item protected. The edges 12 of the grooves 11 are compressible and can collapse under moderate loads and impacts, and the entire strip may compress under heavy loads and impacts, providing protection for the bottle in all manner of situations which would otherwise lead to damage of the bottle.

To package a bottle in a manner which provides maximum protection, it is advantageous to provide additional protective elements to form a packaging assembly.

Such an assembly can be formed from a combination of packaging products, lids and bases, floors and roofs, postal tubes and boxes. Other elements such as void fill materials and spacer elements can also be provided as part of the packaging assembly as desired or appropriate.

A lid 14 and a base 15 are formed from an additional sheet, the sheet being identical to that from which the product 1 is formed. The product 1, lid 9 and base 10 are assembled by providing the lid 14 and base 15 at the top 16 and bottom 17 end of the packaging product t respectively, thereby enclosing the bottle in the assembly and protecting its ends. In an exemplary embodiment illustrated in Figure 3, the lid 14 and base 15 have a circular cross section of diameter substantially equal to the smallest inner cross-sectional dimension from the centre of the polygonal folded packaging product 1 to the inner wall 4. The lid 14 and base 15 can therefore be inserted into the open top 16 and bottom 17 ends of the product 1. In an alternative embodiment, the lid 14 and base 15 may have a diameter that it substantially equal to the largest outer cross-sectional dimension of the packaging product 1, in which case the lid 14 and base 15 can be placed over the open top 16 and bottom 17 ends of the product 1 and secured in place using adhesive tape.

IS

Once the lid 14 and base 15 have been inserted to close the ends of the prism, the packaging assembly with wine bottle enclosed is inserted into a postal tube 20. As can be seen from Figure 4, the postal tube 20 is suitably sized to receive the folded product 1 with lid 14 and base 15 enclosing the bottle as the tube has an inner diameter slightly greater than the sum of the bottle diameter and two times the sheet thickness. The tube 20 length that is slightly greater than the length L of one sheet 2, the excess length allowing for the end caps 21, 22 of the postal tube to be inserted to close the ends of the tube 20.

It is also possible for two wine bottles to be packaged in a single tube. For this purpose, a packaging assembly is provided comprising a postal tube 30, two packaging products 1, two pairs of lids 14 and bases 15, and a cardboard spacer disc 33, as illustrated in Figure 5. The packaging products 1 are of the kind as described in relation to Figures 1 -4, that is that they are also adapted to protect a wine bottle. As before, the postal tube 30 has an inner diameter equal to the sum of the bottle diameter and two times the packaging product thickness so that the folded products 1 with attached lids 14 and bases 15, with bottles enclosed therein, fit snugly in the tube. However, the tube 30 length is sized to accommodate the spacer thickness and two times the length L of a packaging product 1 with lids 14 and bases 15 attached, in addition to sufficient excess length to allow for the end caps 31, 32 of the postal tube 30 to be inserted to close the ends of the tube 30. With the bottles secured within their packaging products 1, the lids 14 and bases 15 are attached before inserting the two products 1 separated by the spacer disc 33 into the tube 30.

As shown in Figure 6, owing to the suitably sized postal tube 20, 30 and the protruding edges 12 of the grooves 11, the only points of contact of the packaging product 1 with the postal tube 20, 30 are the groove edges 16. Advantageously, this provides cushioning for the bottle in the postal tube 20, 30 as a gap 40 is formed between the upper face 41 of each strip 9 (which is the upper layer 3 of the packaging product 1) and the postal tube 20, 30, which, in combination with the pockets 23 defined below the bottle and the lower layer 2 in the regions of the lines of weakness, allows the packaging product 1 to flex within the postal tube 20, 30 in response to light impact. Additionally, the groove edges 12 are more compressible than the planar upper face 41 of each strip 9 as the support structure 5 is weakened by the slits 8 cut through it. This, as mentioned above, offers improved cushioning against moderate impact, whilst the ability of the entire strip to compress provides cushioning under heavy impact.

One or more bottles of wine protected by packaging products 1 can be securely packaged in a cardboard box 50. As shown in Figure 7, the packaging products are arranged in rows and columns in the box 50, the box 50 being sized to receive an integer number of packaging products 1 along its length and width. In this manner, the packaging products 1 fit snugly inside the box 50, alleviating the need for an additional grid divider. The packaging products 1 also provide additional rigidity to the box structure and much improved cushioning compared to a grid divider.

In the exemplary embodiment shown, the interior of the box has a length slightly greater than 4 x (bottle thickness + 2 x product thickness), a width slightly greater than 3 x (bottle thickness + 2 x product thickness) and a height that is substantially equal to the length L of a single packaging product 1. The box 50 therefore accommodates twelve packaging products 1, and hence twelve bottles of wine. However, it is also envisaged that the box may have a height that is substantially equal to or greater than an integer multiple of the length L of a single packaging product 1 to allow multiple packaging products to be stacked vertically, or to accommodate multiple packaging products stacked vertically with external lids and bases attached. Additional height may also allow for spacer discs 33 or partition portions to be provided to separate the products and bottles.

As illustrated in Figure 8, in a further embodiment of the present invention a packaging product 60 may be used to package an object having a protrusion, such as a tea cup or mug 62. The packaging product 60 is manufactured from a cardboard sheet having an identical structure to the sheet described above. The sheet has a length equal to the height of the mug 62 and a width equal to the outer circumference of the cylindrical body of the mug less the handle width. In this exemplary embodiment, the sheet has a length of 90mm and a width of 110mm. The sheet thickness is substantially equal to the maximum radial extent of the protruding handle.

As described above, the sheet is scored to form slits parallel to the length of the sheet, thereby defining line of weakness 64 along the uncut lower layer 65 at the base of each slit about which the sheet may be folded. The sheet is then folded inwardly around the mug 62, opening the slits into grooves 63, with the handle 66 extending through the gap in the packaging product 60 resulting from the aforementioned sheet width.

Advantageously in this exemplary embodiment, the lower layer 65, along which the lines of weakness 64 are defined, is on the surface of the packaging product 60 that is contiguous to the mug 62, and the support structure 67 extends outwardly, which results in the weakened layer 65 being protected by the cushioning of the support structure 67 in the event of an impact.

The mug 62 and folded packaging product 60 are then inserted into a box 68 having a square cross-section and sized to receive the mug 62 and product 60 with a tight fit. The mug 62 is positioned in the box such that the handle 65 extends towards an edge of the box 68, but the thickness of the sheet prevents the fragile handle from contacting the walls of the box. A floor 69 and roof 70 are provided in the box 68 to protect the rim and base of the mug 62. The floor 69 and roof 70 are manufactured from a cardboard sheet having an identical structure to that of the packaging product 60 and, in this exemplary embodiment, a length and width equal to those of the box interior and a lOmm thickness. The floor 69 and roof 70 are not scored, but can be provided with recesses to receive and retain the packaging product 60 and mug 62.

Figure 9 shows a packaging product 75 according to the present invention with triangular cut outs forming grooves 76 which extend down through the upper layer 77 and the whole of the support structure 78 but do not penetrate the lower layer 79.

The skilled person will understand that a portion of a packaging product comprising grooves may be folded away from the grooves to open the grooves into wider grooves. This approach to shaping the grooves allows tailoring of the response to impact based on the angle of cut Figures 10 and 11 show a packaging product 80 having a first slit 84 extending through the upper layer 81 and the whole of the support structure 82 but not penetrating the lower layer 83, and a second slit 85 extending through the lower layer 83 and the whole of the support structure 82 but not penetrating the upper layer 81 A first line of weakness 86 is thereby defined along the lower layer 83 (for the first slit 84) and a second line of weakness 87 is defined along the upper layer 81 (for the second slit 85). The packaging product 80 can be folded to open the slits into grooves 88 to produce a substantially Z-shape fold, wherein the product 80 is folded (looking from left to right in Figure 11) initially out of the plane of the packaging product and then back parallel to the plane of the packaging product.

Figures 12 and 13 show a packaging product 90 formed from a cardboard sheet of identical structure to those described above. The sheet is scored with a first slit 92 which extends through the upper layer 93 and runs parallel to the length of the sheet. A first portion 94 of the slit 92 extends down through the upper layer 93 and through the whole of the support structure 95 but stops short of the lower layer 96. A second portion 97 of the slit 92 extends down through the upper layer 93, through the whole of the support structure 95 and through the lower layer 96. As can be seen in the figure, the two slit portions together extend from one edge of the packaging product to the another.

A second slit 99 is formed perpendicular to the first slit 92 and runs from one edge of the sheet 91 to intersect the first slit 92. The second slit 99 meets the first slit 92 at the intersection of the first portion 94 and second portion 97 of the first slit 92, such that a part 100 of the packaging product 90 may be folded along an axis 101 which is perpendicular to the fold axis along the line of weakness defined by the first portion 94 of the first slit 92. The second slit 99 extends through the upper layer 93 and the support structure 95, but does not penetrate the lower layer 98, so that the part 100 defined remains attached to the packaging product 90.

As can be seen in Figure 13, the product can be folded to open the slits into grooves 102; the part 100 defined by the perpendicular first and second slit being foldable along a perpendicular axis such that under suitable construction, the packaging product may comprise an integrated lid and/or base portion.

Figure 14 is a plan view showing a plurality of packaging products 140 as illustrated in Figure 6 packaged in an outer box 141 to form a packaging unit. The packaging products 140 are arranged in a regular array. A series of divider walls 142 are provided in the configuration illustrated in Figure 14 but these are optional. This configuration is similar to that illustrated in Figure 7 but each of the packaging products shown in Figure 14 are located in a cylindrical tube 143 and then within the outer box 141.

Figure 15 is a plan view of a packaging assembly including a packaging product 150 in a triangular tube 151. As explained above, by folding the product 150, the slits 8 are opened into grooves 11 and the groove edges 12 are exposed and protrude outwardly to define the maximum radial dimension of the folded product 150. As illustrated, it is the groove edges 12 which abut the inner side of the walls of the triangular tube 151. As mentioned above, the groove edges 12 are more compressible than the planar upper face 41 of each strip 9 as the support structure 5 is weakened by the slits 8 cut through it. This, as mentioned above, offers improved cushioning against small to moderate impact, whilst the ability of the entire strip to IS compress provides cushioning under heavy impact.

Figure 16 is a plan view of a packaging assembly including a packaging product 160 in a rectangular tube or box 161 with features which are similar to those described above in relation to Figure 15.

The one or more embodiments are described above by way of example only.

Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims

CLAIMSA packaging assembly comprising a packaging product comprising a first layer and a second layer with a support structure provided therebetween; the support structure defining a plurality of voids between the first layer and the second layer, the product having a plurality of slits or grooves, each slit or groove extending through at least one layer and at least part way into the support structure to form a line of weakness so that the product can fold about the line of weakness to form a plurality of groove edges and conform to the shape of the item that it is intended to protect and an outer container with the packaging product inserted into the outer container such that the groove edges are oriented outermost relative to the outer container and a majority of the strips extend away from an interior surface on a facing sidewall of the outer container at an angle.
2. A packaging assembly according to claim 1 wherein the outer container is cylindrical in shape A packaging assembly as claimed in either of claims 1 or 2 wherein each slit or groove extends through at least one layer and the whole of the support structure.4. A packaging assembly as claimed in any one of claims 1 to 3 wherein each slit or groove extends through the same layer.A packaging assembly as claimed in either of claims 1 or 2 wherein one or more slits or grooves extend through at least the first layer and one or more slits or grooves extend through at least the second layer.6. A packaging assembly as claimed in any one of the preceding claims wherein two or more slits or grooves are substantially parallel A packaging assembly as claimed in any one of the preceding claims wherein all slits or grooves are substantially parallel.A packaging assembly as claimed in any one of the preceding claims wherein the product is made from paper, card or other fibrous material.A packaging assembly as claimed in any one of the preceding claims wherein the support structure is a multi-cell structure.10. A packaging assembly as claimed in any one of the preceding claims wherein the support structure extends substantially perpendicularly between the first layer and the second layer.11. A packaging assembly as claimed in any one of the preceding claims wherein the support structure is formed of a lattice of honeycomb structures.U. A packaging assembly as claimed in any one of the preceding claims wherein the sheet has a width of between 30 -1500mm, a length of between 50 - 5000mm and a thickness of between 5 -100mm.13. A packaging assembly as claimed in any one of the preceding claims further comprising one or more lines of perforations.14 A packaging assembly as claimed in claim 13 wherein a line of perforations is located along one or more lines of weakness.15. A packaging assembly as claimed in claim 13 or claim 14 wherein one or more lines of perforations are located extending transversely to the one or more lines of weakness.16. A packaging unit comprising at least one packaging assembly as claimed in any one of the preceding claims and an outer unit to contain the at least one packaging assembly.17 A packaging unit as claimed in claim 16 wherein the outer unit contains a plurality of packaging assemblies.18 A method of producing a packaging assembly comprising the steps of providing a packaging assembly according to any of claims 1 to 15 or a packaging unit according to either one of claims 16 or 17; and providing a lid and a base for the packaging product so that when the packaging product is folded, open ends of the packaging product can be closed by the lid and base. 19. 20. 21. 22A method of producing a packaging assembly as claimed in any one of claims 1 to 15, comprising the steps of: providing an outer container; and inserting one or more of packaging products into the outer container.A method of producing a packaging unit comprising the steps of providing a packaging assembly according to any of claims 1 to 15; and providing an outer box; and inserting one or more of the packaging assemblies into the outer box.A use of a packaging assembly according to any of claims 1 to 15, comprising the steps of providing an item to be protected, folding the packaging product around the item; and inserting the packaging product into the container.A use of a packaging assembly as claimed in claim 21, further comprising the step of: folding the packaging product around the item such that the layer on which a plurality of lines of weakness are defined is contiguous to the item, and the support structure extends outwardly away from the item.23. A use of a packaging assembly according to any of claims 1 to 15, comprising the steps of providing an item to be protected; inserting the packaging product into the outer container; and inserting item to be protected into the packaging product in the container.24. A use of a packaging assembly as claimed in any one of claims 21 to 23 wherein the item to be protected is a bottle.A use of a packaging unit as claimed in either one of claims 16 or 17, comprising the steps of loading at least one packaging assembly into the outer unit; and delivery of the packaging unit to a provider of items to be protected.