US20200198832A1

US20200198832A1 - Corrugated accordion shaped insert for shipping container

Info

Publication number: US20200198832A1
Application number: US16/806,090
Authority: US
Inventors: McCarthy Timothy L
Original assignee: WestRock Shared Services LLC
Current assignee: WestRock Shared Services LLC
Priority date: 2018-10-05
Filing date: 2020-03-02
Publication date: 2020-06-25

Abstract

A corrugated insert for supporting products within a shipping container is disclosed, which includes a plurality of panels foldably connected to one another in such a manner so as to form an accordion configuration that includes an upper panel, a lower panel and a plurality of medial panels, each medial panel having a matrix of apertures formed therein, wherein the matrix of apertures formed in each medial panel is aligned with the matrix of apertures formed in an adjacent medial panel when the medial panels are in the accordion configuration to receive and support a plurality of products within the shipping container.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject application is a continuation-in-part of U.S. application Ser. No. 16/152,912, filed Oct. 5, 2018.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention is directed to packaging, and more particularly, to a corrugated accordion shaped insert for supporting and protecting a plurality of products in a shipping container.

2. Description of Related Art

It is known to package and ship fragile products such as glassware and pottery for retail sale in shipping containers or cartons using protective cushioning materials such as tissue paper, craft paper, packing peanuts, air-filled packing pillows, foam wrap and bubble wrap. These types of cushioning materials are relatively costly, they are often difficult to use and some are not readily biodegradable. They also do not provide an aesthetically pleasing way to display or otherwise present the products within the shipping container in a manner that is suitable for retail sale.
It would be beneficial therefore to provide a more convenient, cost effective and aesthetically pleasing way to package fragile products such as glassware and pottery for shipping and retail display within a shipping container, without the need for common cushioning material.
The subject invention provides such a solution in the form of a corrugated accordion shaped insert for supporting and protecting a plurality of fragile products within a shipping container.

SUMMARY OF THE DISCLOSURE

The subject invention is directed to a new and useful insert for supporting and protecting fragile products within a shipping container. For example, the insert of the subject invention is well suited for shipping fragile glassware or pottery, and it is particularly adapted and configured for accommodating products that have a tapered cylindrical shape.
The insert includes a plurality of panels which are foldably connected to one another along longitudinally extending edges. More particularly, the panels of the insert are foldably connected to one another in such a manner so as to form an accordion configuration that includes an upper panel, a lower panel and a plurality of medial panels. Preferably, the insert is constructed from a plurality of rectangular panels. However, it envisioned and well within the scope of the subject disclosure that the insert may be constructed from a plurality of square panels.
Each medial panel of the insert has at least one aperture formed therein, and preferably, each medial panel of the insert has a set of longitudinally spaced apart apertures formed therein, wherein the apertures formed in each medial panel are aligned with the apertures formed in an adjacent medial panel when the medial panels are in the accordion configuration so as to receive and support the products within the shipping container.
Preferably, the insert is formed from a die cut blank of corrugated cardboard material having corrugations that run either perpendicular or horizontally to the longitudinal edges of the panels. Those skilled in the art will readily appreciate that the size of the panels may vary depending upon the number and size of the products, providing adequate containment, and cushioning, that are supported within the shipping container, or to facilitate a minimal shipping container size.
In a preferred embodiment of the subject invention, the plurality of medial panels of the insert includes first, second and third medial panels, and each medial panel may include a single, or multiple circular apertures. Preferably, each aperture in the first medial panel has a diameter that is greater or equal to the diameter of each aperture in the second medial panel, and each aperture in the second medial panel has a diameter that is equal to or greater than a diameter of each aperture in the third medial panel. The upper panel of the insert may include an engagement notch formed in an outer longitudinal edge thereof to lift the upper panel away from the products supported by the insert.
When the insert is located with the shipping container and the top and bottom flaps of the container are closed, the upper panel of the insert will be in surface-to-surface planar contact with the top flaps of the shipping container, and the lower panel of the insert will be in surface-to-surface planar contact with the bottom flaps of the shipping container. At such a time, the angled medial panels in their accordion configuration will provide a cushion curve on impact, reducing damage to the products supported therein.
While the subject invention provides a novel solution for supporting and protecting a plurality of fragile products within a shipping container, it is also envisioned that an accordion shaped insert could be utilized to receive and support a plurality of beverage containers within a shipping container. Thus, in another embodiment of the subject invention, each medial panel of the inert has a matrix of circular apertures of equal diameter formed therein, wherein the matrix of circular apertures formed in each medial panel is aligned with the matrix of circular apertures formed in an adjacent medial panel when the medial panels are in the accordion configuration to receive and support a plurality of beverage containers within the shipping container.
Preferably, the matrix of circular apertures formed in each of the medial panels includes twelve circular apertures, and these apertures may be arranged in a three by four rectangular matrix or in a four by three rectangular matrix. It is envisioned that there may be fewer or greater than twelve circular apertures formed in each of the medial panels of the insert, and the circular apertures can be arranged different matrix configurations, such as a hexagonal matrix configuration of eight circular apertures or the like.
These and other features of the corrugated accordion shaped packaging insert of the subject invention will become more readily apparent to those having ordinary skill in the art to which the subject invention appertains from the detailed description of the preferred embodiments taken in conjunction with the following brief description of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art will readily understand how to make and use the accordion shaped insert of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to the figures wherein:

FIG. 1 is a top plan view of a die cut blank for erecting the corrugated accordion shaped insert of the subject invention;

FIG. 2 is a perspective view of the corrugated accordion shaped insert in a compressed state with a plurality of products accommodated therein;

FIG. 3 is a perspective view of the corrugated accordion shaped insert in an expanded state with a plurality of products accommodated therein;

FIG. 4 is another perspective view of the corrugated accordion shaped insert in an expanded state with a plurality of products accommodated therein;

FIG. 5 is a side elevational view of the corrugated accordion shaped insert in an expanded state with a plurality of products accommodated therein;

FIG. 6 is a perspective view of the corrugated accordion shaped insert in an expanded state with a plurality of products accommodated therein, as it is being loaded into a shipping container;

FIG. 7 is a perspective view of the corrugated accordion shaped insert in an expanded state with a plurality of products accommodated therein, loaded in the shipping container, with the top flaps of the container in an open condition for ease of illustration;

FIG. 8 is a top plan view of another die cut blank for erecting a corrugated accordion shaped insert, which is configured to accommodate a plurality of products having a continuous outer diameter, such as beverage containers; and

FIG. 9 is a perspective view of the corrugated accordion shaped insert shown in FIG. 8 in an expanded state with a plurality of beverage containers accommodated therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals identify similar structural elements of the subject invention, there is illustrated in FIG. 1 a die cut blank for forming an insert used to support and protect fragile products within a shipping container, which is designated generally by reference numeral 10.
The die cut blank 10 includes a plurality of rectangular panels which are foldably connected to one another along longitudinally extending edges. More particularly, the rectangular panels of the die cut blank 10 include an upper panel 12, a lower panel 14 and three successive medial panels 16, 18 and 20.
The upper panel 12 of blank 10 is foldably connected to the first medial panel 16 along a horizontal perforated crease 22, the first medial panel 16 is foldably connected to the second medial panel 18 along a horizontal perforated crease 24, the second medial panel 18 is foldably connected to the third medial panel 20 along a perforated crease 26, and the third medial panel 20 is foldably connected to the lower panel 14 along a horizontal perforated crease line 28.
Preferably, the die cut blank 10 is formed from a sheet of corrugated cardboard material having corrugations that run perpendicular to the horizontal creases or edges of the panels, and each panel is of equal width and length. Those skilled in the art will readily appreciate that the corrugations could run parallel to the horizontal creases or edges of the panels, and the size of the panels can vary depending upon the number and size of the products that are supported within the shipping container.
With continuing reference to FIG. 1, each medial panel 16, 18 and 20 of the blank 10 includes at least one aperture and preferably each medial panel of the blank includes a set of longitudinally spaced apart circular apertures. More preferably, the first medial panel 16 of blank 10 includes three equally sized longitudinally spaced apart circular apertures 30 a, 30 b and 30 c, the second medial panel 18 of blank 10 includes three equally sized longitudinally spaced apart circular apertures 32 a, 32 b and 32 c, and the third medial panel 20 of blank 10 includes three equally sized longitudinally spaced apart circular apertures 34 a, 34 b and 34 c.
In a preferred embodiment of the subject invention, wherein the blank 10 is designed to form an insert to accommodate products that have a tapered outer diameter, the diameter D₁of the longitudinally spaced apart apertures 30 a, 30 b and 30 c in the first medial panel 16 of blank 10 is greater than the diameter D₂of the longitudinally spaced apart apertures 32 a, 32 b and 32 c in the second medial panel 18 of blank 10, and the diameter D₂of the longitudinally spaced apart apertures 32 a, 32 b and 32 c in the second medial panel 18 is greater than the diameter D₃of the longitudinally spaced apart apertures 34 a, 34 b and 34 c in the third medial panel 20 of blank 10. Thus, D₁>D₂>D₃.
Those skilled in the art will readily appreciate that the sets of longitudinally spaced apart apertures in each of the three medial panels 16, 18 and 20 of blank 10 could be of equal diameter so as to accommodate products that have a constant outer diameter, instead of a tapered outer diameter.
A semi-circular engagement notch 36 is formed in an upper longitudinal edge 38 of the upper panel 14 of blank 10 to enable a purchaser to lifting the upper panel 14 and access the products thereunder. Those skilled in the art will readily appreciate that the engagement notch 36 is an optional feature.
Referring FIG. 3, there is illustrated the accordion shaped insert 40 in a compressed state for receiving a set of products 42, 44 and 46, which have a tapered outer diameter. More particularly, the three medial panels 16, 18 and 20 are foldably compressed against the lower panel 14, so that apertures 30 a, 32 a and 34 a are in axial alignment with each other, apertures 32 a, 32 b and 34 c are in axial alignment with each other, and apertures 34 a, 34 b and 34 c are in axial alignment with each other. At such a time, the upper panel 12 is folded away from the first medial panel 16 and the three identically shaped products 42, 44 and 46 can be loaded into the insert 40. The medial panels 16, 18 and 20 can then be moved into an expanded condition and the upper panel 14 can be folded over the top of the products, as shown in FIG. 3.
Thereupon, the insert 40 assumes its accordion shaped configuration, which is further illustrated for clarity in FIGS. 4 and 5. At such a time, the three angled medial panels 16, 18 and 20 of insert 40 in their accordion configuration will provide a cushion curve on impact, reducing damage to the products supported therein.
Once the accordion shaped insert 40 is filled with the products 42, 44 and 46, it can be top loaded into the interior space of a shipping carton 50, as best seen in FIG. 6. When the accordion shaped insert 40 is located within the shipping container 50 and the top and bottom flaps of the container 50 are closed, the upper panel 12 of the accordion shaped insert 40 will be in surface-to-surface planar contact with the top flaps of the shipping container 50, and the lower panel 14 of the accordion shaped insert 40 will be in surface-to-surface planar contact with the bottom flaps of the shipping container 50, as best illustrated in FIG. 7. Thereupon, the semi-circular engagement notch 36 in the upper panel 12 will be readily accessible when the top flaps of the container 50 are opened.
Referring now to FIG. 8, there is illustrated a die cut blank for another embodiment of the corrugated cardboard insert of the subject invention, which is designated generally by reference numeral 100. The die cut blank 100 is designed to form an accordion shaped insert that can accommodate a plurality of products having a continuous outer diameter, such as, for example, a group of twelve ounce beverage containers or the like.
The die cut blank 100 has a plurality of foldably connected rectangular panels including an upper panel 112, a lower panel 114 and three successive medial panels 116, 118 and 120. Each medial panel 116, 118 and 120 of the blank 100 has a matrix of circular apertures of equal diameter formed therein. More particularly, the first medial panel 116 of blank 100 includes a three by four matrix of twelve equally sized spaced apart circular apertures 130, the second medial panel 118 of blank 100 includes a three by four matrix of twelve equally sized spaced apart circular apertures 132, and the third medial panel 120 of blank 100 includes a three by four matrix of twelve equally sized spaced apart circular apertures 134. It is envisioned that the matrix of twelve equally sized spaced apart circular apertures in each medial panel could also be arranged in a four by three rectangular.
Regardless of the matrix configuration that is employed, the diameter D₁of the apertures 130 in the first medial panel 116 of blank 100 are equal to the diameter D₂of the apertures 132 in the second medial panel 118 of blank 100, and are also equal to the diameter D₃of the apertures 134 in the third medial panel 120 of blank 100. Thus, in this embodiment of the subject invention D₁=D₂=D₃.
Referring now FIG. 9, the blank 100 is shown after it has been folded or otherwise formed into an accordion shaped configuration that is designated by reference numeral 140, wherein the circular apertures 130, 132 and 134 provided in the medial panels 112, 118 and 120 are in axial alignment with each other and they are filled with beverage containers 142, so that the arrangement of containers can be top loaded into the interior space of a shipping carton, similar to the loading process illustrated in FIGS. 6 and 7. It is envisioned that two filled accordion shaped inserts 140 could be stacked one atop the other, and top loaded together into the interior space of a shipping carton, so that the carton would contain twenty-four beverage containers 142.
Those skilled in the art should readily appreciate that the medial panels of the blank 100 could be provided with fewer (e.g., six equally sixed circular apertures) or greater than twelve equally sized circular apertures, and the circular apertures can be arranged in different matrix configurations. For example, each of the medial panels of the blank 100 could have eight equally sized circular apertures arranged in a hexagonal matrix configuration.
While the subject disclosure has been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes or modifications may be made thereto without departing from the spirit or scope of the subject disclosure.

Claims

What is claimed is:

1. An insert for supporting products within a shipping container, comprising:

a plurality of panels foldably connected to one another in such a manner so as to form an accordion configuration that includes an upper panel, a lower panel and a plurality of medial panels, each medial panel having a matrix of apertures formed therein, wherein the matrix of apertures formed in each medial panel is aligned with the matrix of apertures formed in an adjacent medial panel when the medial panels are in the accordion configuration to receive and support a plurality of products within the shipping container.

2. An insert as recited in claim 1, wherein the insert is constructed from a corrugated cardboard material.

3. An insert as recited in claim 1, wherein the insert is constructed from a plurality of panels each having a rectangular configuration.

4. An insert as recited in claim 1, wherein the plurality of medial panels includes first, second and third medial panels.

5. An insert as recited in claim 1, wherein the matrix of apertures formed in each of the medial panels include circular apertures.

6. An insert as recited in claim 5, wherein the matrix of apertures formed in each of the medial panels include circular apertures of equal diameter.

7. An insert as recited in claim 6, wherein the matrix of circular apertures formed in each of the medial panels is a three by four rectangular matrix consisting of twelve circular apertures of equal diameter.

8. An insert for supporting products within a shipping container, comprising:

a plurality of panels foldably connected to one another in such a manner so as to form an accordion configuration that includes an upper panel, a lower panel and a plurality of medial panels, each medial panel having a matrix of circular apertures of equal diameter formed therein, wherein the matrix of circular apertures formed in each medial panel is aligned with the matrix of circular apertures formed in an adjacent medial panel when the medial panels are in the accordion configuration to receive and support a plurality of products each having a continuous outer diameter within the shipping container.

9. An insert as recited in claim 8, wherein the insert is constructed from a corrugated cardboard material.

10. An insert as recited in claim 8, wherein the insert is constructed from a plurality of panels each having a rectangular configuration.

11. An insert as recited in claim 8, wherein the plurality of medial panels includes first, second and third medial panels.

12. An insert as recited in claim 8, wherein the matrix of circular apertures formed in each of the medial panels is a three by four rectangular matrix consisting of twelve circular apertures of equal diameter.

13. A corrugated cardboard insert for supporting products within a shipping container, comprising:

a plurality of rectangular panels foldably connected to one another in such a manner so as to form an accordion configuration that includes an upper panel, a lower panel and a plurality of medial panels, each medial panel having a rectangular matrix of twelve circular apertures of equal diameter formed therein, wherein the rectangular matrix of twelve circular apertures formed in each medial panel is aligned with the rectangular matrix of twelve circular apertures formed in an adjacent medial panel when the medial panels are in the accordion configuration so as to receive and support twelve beverage containers within the shipping container.

14. A corrugated cardboard insert as recited in claim 13, wherein the plurality of medial panels includes first, second and third medial panels.

15. A corrugated cardboard insert as recited in claim 13, wherein the rectangular matrix of twelve circular apertures formed in each of the medial panels is a three by four rectangular matrix.