WO2008135769A1

WO2008135769A1 - Universal packaging insert

Info

Publication number: WO2008135769A1
Application number: PCT/GB2008/001589
Authority: WO
Inventors: Dominic Bryant
Original assignee: Cellpak Solutions Limited
Priority date: 2007-05-08
Filing date: 2008-05-08
Publication date: 2008-11-13
Also published as: GB0708794D0; GB2441019A

Abstract

A packaging (2) insert for securing items within a larger carton, the packaging insert comprising at least one cavity within which an item may be retained, the cavity comprising a plurality of projections extending into the cavity against which an item disposed in the cavity will rest, the plurality of projections comprising a first projection (6, 8) extending a first distance into the cavity from one side wall and a second projection (10, 12) extending a second distance into the cavity from said one side wall, the first distance being greater than the second distance, whereby a first item having a first dimension may be retained by contact with the first projection and a second item having a second dimension, greater than the first dimension of the first item, may be retained by contact with the second projection.

Description

UNIVERSAL PACKAGING INSERT

The present invention relates generally to packaging inserts adapted for use with items so as to maintain them within a larger outer carton. The invention is particularly concerned with the packaging of electronic devices, principally cellular telephones and accessories.

The use of portable hand-held electronic devices, in particular cellular telephones and personal digital assistants, has increased rapidly in recent years resulting in sharp increases in sales of such items. Current packaging available for such items is generally not sufficient to protect them from damage during transportation, and is also not suitable to accommodate the immense range of devices, differing substantially in size and shape, firmly within the outer packaging to prevent it from damage whilst it is being transported. Devices such as those described above are currently packaged in larger outer cartons with different sized inserts needed for different devices. This can prove very costly and complicated given the vast array of different products available.

US 2004/0094448 describes a cushioning material used for transporting delicate packages. The packaging comprises a single cavity into which an item may be placed. The packaging does not allow for other components to also be transported in the same box. The cushioning material also comprises both an upper and lower portion, taking up a large amount of material and space.

An alternative packaging insert is disclosed in US 5,259,508. The insert is used as one of a pair within a carton or box, with items to be packaged being retained between opposing portions of the two inserts within the box or carton. This arrangement is again particularly inefficient in its use of space within the box or carton and its use of packaging material. Accordingly, there is a need for an improved packaging insert that will accommodate a large range of items, such as hand-held electronic devices and cellular telephones of varying size and shape within larger external canons. The insert also needs to be cost effective and simple to manufacture.

According to a first aspect of the present invention, there is provided a packaging insert for securing items within a larger carton, the packaging insert comprising at least one cavity within which an item may be retained, the cavity comprising a plurality of projections extending into the cavity against which an item disposed in the cavity will rest, the plurality of projections comprising a first projection extending a first distance into the cavity and a second projection extending a second distance into the cavity, the first distance being greater than the second distance, whereby a first item having a dimension may be retained by contact with the first projection and a second item having a dimension, greater than the dimension of the first item, may be retained by contact with the second projection.

The packaging insert of the present invention is particularly advantageous in that it allows a single insert to be used with a range of items of differing sizes, while still allowing each item to be securely retained. This reduces the number of different inserts required to package a range of items, in turn reducing the overall cost and wastage of insert materials.

The insert of the present invention comprises first and second projections. The projections are positioned and sized such that a first item having a first dimension of one size is retained by contact with the first projection. A second item having a first dimension of a greater size than that of the first item is retained by the second projection. The term 'dimension' is a reference to any dimension of the items to be packaged, such as the length, breadth or depth of the item. For example, the first item may have a length that is less than the second item. In the insert of the present invention, the first item is retained by having the item lengthwise extending in contact with the first projection. A second item having a length that is greater than the length of the first item is retained in the insert lengthwise extending in contact with the second projection. Alternatively, the second item may have a width that is greater than the length of the first item and the second item is retained by widthwise contact with the second projection.

The first and second projections may be disposed in any suitable position within the cavity in the insert. The first and second projections of the packaging insert are preferably disposed adjacent to one another. In such a case, both the first and second items will be oriented in the same manner within the insert, for example both oriented lengthwise or widthwise when retained in the insert cavity.

In a particularly preferred arrangement, the first and second projections are arranged adjacent one another in a stepped arrangement.

The second projection is preferably disposed below the first projection. That is, when the insert is in normal use, such as when being packed or unpacked, the first projection is below or beneath the second projection.

In one embodiment, the packaging insert preferably comprises a third projection, extending a third distance into the cavity. The third distance is preferably less than the second distance, that is the distance the second projection extends into the cavity. The third projection allows a third item, having a dimension greater than that of the dimension of the second item, to be retained by means of contact with the third projection. The third projection may be disposed at any suitable position in the insert. In one preferred arrangement, the second projection is disposed adjacent and between the first and third projections. The first, second and third projections are most preferably in a stepped arrangement, especially an arrangement in which the first projection is lowest and the third projection highest, with the insert in normal use.

The insert may comprise further projections that may be arranged as described hereinbefore in relation to the first, second and third projections.

Some or all of the first, second and, if present, third projections are preferably each one of a corresponding pair of opposing projections. The item to be retained in the insert is thus preferably retained between and in contact with a pair of the opposing projections.

In particular, the first projection is preferably one of a pair of first opposing projections. The second projection is also preferably one of a pair of second opposing projections. The first and second opposing projections are preferably arranged so as to retain the first and second items respectively in the same orientation in the insert. Most preferably, each one of the pair of first opposing projections is disposed adjacent a corresponding one of the pair of second opposing projections. The opposing projections are most preferably in a stepped arrangement, such that the insert comprises opposing sets of stepped projections, each set comprising two projections.

The packaging insert preferably comprises a third projection that is one of a pair of third opposing projections. The first, second and third pairs of opposing projections are preferably arranged to retain the dimension of a first item, a second item or a third item respectively. Each of the pair of second projections is preferably adjacent and between a corresponding first and third projection. The opposing first, second and third projections are preferably in a stepped arrangement, such that the insert comprises opposing sets of stepped projections, each set comprising three projections.

In one preferred embodiment, the first and second projections are arranged such that a second item retained by contact with the second projection is supported by the first projection. The packaging insert of this embodiment preferably further comprises a third projection. The second and third projections are preferably arranged such that a third item retained by contact with the third projection is supported by the second projection.

The insert of the present invention is particularly advantageous in use, as a result of the arrangement of the first and second projections and, if present, the third projections, in particular when arranged in opposing pairs, as described hereinbefore. In the vast majority of cases, packaging inserts are designed with a specific product in mind and are shaped and sized according to the dimensions of the product to be packaged. The insert of the present invention allows for a range of products of the same general type but of different sizes to be packaged using a single insert of one design. In particular, in the market for mobile telephones, the telephone units are typically all of a generally rectangular form. However, the precise dimensions of the units vary from one manufacturer to another and even from unit to unit within a given manufacturer's range. The insert of the present invention allows a wide range of such mobile telephone units to be retained. This is due to the arrangement of the projections, which are sized and shaped to accommodate a range of mobile telephone units having the same general configuration but different length and width dimensions.

The insert may be adapted to retain a single item, in contact with the relevant projection according to its size, as hereinbefore described. However, in one embodiment, the packaging insert preferably comprises a further one or more members for supporting a further item, in particular such that the further item overlies, at least in part, an item retained by the first, second or, if present, third projection. By having the items overlie one and another, the most efficient use of the space within the insert may be made.

In this respect, Ihe insert of the present invention is preferably arranged to be the only packaging insert disposed within the carton or box, with the one or more items stowed and secured within or on the insert. In this respect, the insert of the present invention is to be contrasted with known packaging inserts, where two or more opposing inserts are required to retain and support an item. This is particularly the case with larger electrical items, where a single unit may be packaged within a carton or box using two or more packaging inserts.

The packaging insert of the present invention may be prepared or constructed in any suilable manner using any suitable technique known in the art. The packaging insert as hereinbefore described is preferably moulded using techniques known to a person skilled in the art, such as vacuum forming. The insert is preferably manufactured from plastic, most preferably one that is transparent. Suitable plastics materials will be known to those skilled in the art.

Alternatively, the insert may be moulded from cardboard or paper. The cardboard or paper is preferably recycled. Suitable moulding techniques will again be apparent to those skilled in the art.

The packaging insert is preferably of a suitable design so as to allow the insert to be stacked vertically with other inserts of the same design. This is advantageous and will reduce the space required to store the inserts before they are used. For example, the inserts may be formed with the cavity having one or more tapered side walls, such that the major portion of one insert will fit within a similar insert, in known manner. According to a second aspect of the present invention, there is provided a packaging insert comprising a cavity therein for retaining an item, the insert further comprising a first stepped member within the cavity, the first stepped member having a plurality of steps formed therein, whereby a first item of a first size is supported on a first step of the first stepped member and a second item of a second size is supported on a second step of the first stepped member.

The packaging insert preferably comprises a second stepped member extending into the cavity in a position opposing the first stepped member, the second stepped member having a plurality of steps formed therein, at some of which correspond to the plurality of steps in the first stepped member.

The first stepped member preferably comprises two steps.

Alternatively, the stepped member may comprise three or more steps, as required.

In a further aspect, the present invention provides a package assembly comprising a carton or box, an insert as hereinbefore described disposed within the carton or box, and at least one item retained, in the carton or box by the insert.

As mentioned previously, the insert of the present invention is advantageous in that only a single insert is typically required within the carton or box.

As also noted, the insert is particularly suited to retaining a plurality of separate items, in particular electrical items. In particular, the insert is arranged to have one item overlie another item, with both items being supported by respective portions of the insert. The insert is particularly suitable for the packaging of a set of items, especially a set of electrical items such as a mobile telephone or the like and its associated charger, adaptors, memory or SIM cards, battery, earphones, etc.

Embodiments of the present invention will now be described, by way of example only, having reference to the accompanying drawings, in which:

Figure 1 is a cross-sectional view of the packaging insert according to a preferred embodiment of the present invention;

Figure 2 is a three dimensional view showing the inside of the packaging insert according to a preferred embodiment of the present invention; and

Figure 3 is a plan view of the packaging insert of Figure 2.

Referring to Figure 1 , there is shown a preferred embodiment of the packaging insert of the present invention, generally indicated as 2. The packaging insert 2 comprises an outer shell 4, having a generally rectangular configuration, with tapered side walls and a floor defining an open cavity. The insert 2 has a first projection 6 extending into the cavity from one side wall. A first opposing projection 8 extends upwards into the cavity from the floor . A second projection 10 extends into the cavity from the one side wall adjacent the first projection 6. A corresponding, opposing second projection 12 extends into the cavity from the floor of the insert adjacent the first opposing projection 8. A third projection 14 extends into the cavity from the one side wall adjacent the second projection 10. A corresponding opposing third projection 16 extends into the cavity from the floor of the insert adjacent the second opposing projection 12. As can be seen in Figure 1 , the projections are of a size that a first space is defined between the opposing first projections 6 and 8, a second space, larger than the first space, is defined between the opposing second projections 10 and 12, and a third space, larger than the second space, is defined between the opposing third projections 14 and 16. In this way, the cavity of the insert 2 can be viewed as having a pair of opposing stepped projections.

The shell 4 of the insert 2 and the projections may be formed of any suitable material, with a plastic material or a recycled paper or cardboard being preferred. The insert 2 may be conveniently formed by any of the techniques described above. The insert shown in Figure 1 is particularly suited to being moulded from plastic, paper or cardboard.

In use, an item, such as a mobile phone or other similar electronic device may be placed between any pair of opposing projections, depending upon its size, ensuring it is held securely for transportation. It will be noted that an item placed between the opposing projections 10 and 12 will be retained by contact with these projections, but will also be supported by the underlying projections 6 and 8. Similarly, an item of larger size fitted between the opposing projections 14 and 16 will be retained by contact with these projections, but will be supported by the underlying projections 10 and 12.

It will be appreciated that the arrangement of the projections 6, 8, 10 and 12 is such that a range of similar items, such as a range of different mobile telephone units, having the same general shape and configuration but different length and width dimensions, may all be supported and retained in a suitable carton or box using just a single packaging insert of the design shown in the figure. Referring to Figure 2, there is shown a three dimensional view of a preferred embodimeni of the packaging insert generally indicated as 2. The insert is shown in plan view in Figure 3. The packaging insert 2 comprises an outer shell 4. The insert comprises first, second and third projections 6, 10 and 14, as described above and shown in Figure 1. The corresponding opposing first, second and third projections 8, 12 and 16 respectively, are also visible. The projections 6, 8, 10, 12, 14 and 16 function to retain an item as described above.

The insert further comprises inner wall members 18, 20 and 22, which serve to divide the interior of the insert into additional separate cavities 24, 26 and 28. Items may be placed in these cavities 24, 26 and 28, according to their size. In addition, the inner wall members 18, 20 and 22 comprise stepped or cut-out portions, allowing one or more items to be laid so as to bridge one or more of these members and be supported and retained within the insert. It will be appreciated that larger items may be retained within and supported by the insert so as to overlie an item retained between the projections 6, 8, 10, 12, 14 and 16. Smaller items, such as sim and data cards and the like, can then be placed inside the cavity 24 formed by the inner wall member 22. Further, the chambers 26 and 28 are suitable for holding accessories, such as chargers and the like.

It will be noted that the insert shown in Figure 2 is of a form that allows all of the aforementioned items to be retained within a carton or box using just a single insert. There is no need for a second insert to oppose or cooperate with the one shown, in order to retain the items. This, in turn, reduces the amount of packaging material that is employed within the carton to retain the items being packaged and shipped. In addition, the insert of Figure 2 provides for a particularly compact arrangement of a plurality of items, as described above, in turn reducing the size of the carton or box within which the insert and items are packed. The insert of the present invention has been found to be particularly suitable for the packaging of electrical items, in particular mobile or cellular telephones, personal organisers, and the like, together with their accessories. This is particularly the case, as such items are provided in a range of sizes and shapes by different manufacturers, while having the same or similar requirements in terms of packaging and the range of accessories that generally accompanying the item when sold.

It is to be understood that the insert of the present invention is not limited to such products and may be used to package a wide range of other items, and their accessories and the scope of the present invention is to be construed accordingly.

Claims

1. A packaging insert for securing items within a larger carton, the packaging insert comprising at least one cavity within which an item may be retained, the cavity comprising a plurality of projections extending into the cavity against which an item disposed in the cavity will rest, the plurality of projections comprising a first projection extending a first distance into the cavity and a second projection extending a second distance into the cavity, the first distance being greater than the second distance, whereby a first item having a dimension may be retained by contact with the first projection and a second item having a dimension, greater than the dimension of the first item, may be retained by contact with the second projection.

2. A packaging insert according to claim 1 , wherein the first and second projections are disposed adjacent one another.

3. A packaging insert according to claim 2, wherein the first and second projections are in a stepped arrangement.

4. A packaging insert according to claim 3, wherein the first projection is disposed below the second projection.

5. A packaging insert according to any preceding claim, wherein the insert comprises a third projection extending a third distance into the cavity, the third distance being less than second distance, wherein a third item having a first dimension greater than the dimension of the second item may be retained by contact with the third projection.

6. A packaging insert according to claim 5, wherein the second projection is disposed adjacent and between the first and third projections

7. A packaging insert according to claim 6, wherein the first, second and third projections are in a stepped arrangement

8. A packaging insert according to any preceding claim, wherein the first projection is one of a pair of opposing projections, the dimension of the first item being such that the first item may be retained between the pair of opposing projections.

9. A packaging insert according to any preceding claim, wherein the second projection is one of a pair of opposing projections, the dimension of the second item being such that the second item may be retained between the pair of opposing projections.

10. A packaging insert according to any preceding claim, further comprising a third projection, the third projection being one of a pair of opposing projections, the dimension of a third item being such that the third item may be retained between the pair of opposing projections.

11. A packaging insert according to any preceding claim, wherein the first projection is one of a pair of first opposing projections, the second projection is one of a pair of second opposing projections, the first and second opposing projections being arranged to retain the dimension of the first and second items respectively.

12. A packaging insert according to claim 11 , wherein each of the pair of first opposing projections is disposed adjacent a corresponding one of the pair of second opposing projections.

13. A packaging insert according to claim 12, wherein the adjacent first and second opposing projections are in a stepped arrangement.

14. A packaging insert according to any of claims 11 to 13, wherein the inset further comprises a third projection, the third projection being one of a pair of third opposing projections, the first, second and third pairs of opposing projections being arranged to the dimension of a first item, a second item or a third item respectively.

15. A packaging insert according to claim 14, wherein each of the pair of second projections is adjacent and between a corresponding first and third projection.

16. A packaging insert according to claim 15, wherein the adjacent first, second and third projections are in stepped arrangement.

17. A packaging insert according to any preceding claim, wherein the first

^" and second projections are arranged such that a second item retained by contact with the second projection is supported by the first projection.

18. A packaging insert according to any preceding claim, further comprising a third projection, the second and third projections being arranged such that a third item retained by contact with the third projection is supported by the second projection.

19. A packaging insert according to any preceding claim, further comprising one or more members for supporting a further item, such that the further item overlies, at least in part, an item retained by the first, second, or, if present, the third projection.

20. A packaging insert according to any preceding claim, wherein the insert is moulded.

21. A packaging insert according to claim 20, wherein the insert is moulded from plastic.

22.A packaging insert according to claim 21 , wherein the insert is transparent.

23. A packaging insert according to claim 20, wherein the insert is moulded from cardboard or paper.

24.A packaging insert according to any preceding claim, wherein the insert may be stacked vertically within other inserts of the same design.

25. A packaging insert comprising a cavity therein for retaining an item, the insert further comprising a first stepped member within the cavity, the first stepped member having a plurality of steps formed therein, whereby a first item of a first size is supported on a first step of the first stepped member and a second item of a second size is supported on a second step of the first stepped member.

26. The packaging insert according to claim 25, wherein the insert comprises a second stepped member extending into the cavity in a position opposing the first stepped member, the second stepped member having a plurality of steps formed therein with at least some of the steps corresponding to the plurality of steps in the first stepped member.

27. The packaging insert according to either of claims 25 or 26, wherein the first stepped member comprises two steps.

28. The packaging insert according to any of claims 25 to 27, wherein the first stepped member comprises three steps.