PACKAGING SYSTEMS AND KITS

Abstract

Packaging systems can include a substantially rigid member and a resilient member, wherein the resilient member is spaced from a portion of the substantially rigid member. In some embodiments, the substantially rigid member can be configured to be foldable into a complete container with a lid having pivotal flaps. The pivotable flaps can be configured to engage a resilient film so as to generate tension in the film when enclosed about an article of commerce, for shock-absorbent packaging purposes. Packaging systems can also include internal pivotable flaps with interference members disposed in a hinge area to cause the internal pivotable flaps to function as leaf springs.

Description

BACKGROUND

1. Field of the Inventions

Embodiments described herein are directed to packaging systems and kits.

2. Description of the Related Art

Protective packaging devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact with the inner walls of the box that might be caused by shocks imparted to the box during loading, transit, and unloading.

In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.

SUMMARY

A resilient member, such as a pliable film, can be used to secure an article within a container. For example, the pliable film can be configured to stretch around or over an article to minimize the article's movement within the container. The pliable film can be coupled to the container using an adhesive, staples, or the like. The use of these additional materials, however, can be expensive, time-consuming, and/or procedurally complicated.

As described herein, a substantially rigid member, such as a piece of corrugated cardboard, can be folded into a container. The substantially rigid member can be cut from a rectangular piece of starting material, such as a rectangular piece of corrugated cardboard, which has a length and a width at least equal to the length and the width of the substantially rigid member when it is in an unfolded configuration. Accordingly, an aspect of at least one of the embodiments disclosed herein includes the realization that a substantially rigid member can be designed with an overall reduced length and/or width, without reducing the inner volume of the container. For example, some embodiments are directed to a substantially rigid member that does not include a tongue portion, described further herein. A reduced amount of starting material can result in a reduced burden on environmental resources, reduced storage space, and increased cost savings.

As described herein, a resilient member, such as a pliable film, can be used to apply a downward force to an article to secure it within a container. An aspect of at least one of the embodiments disclosed herein includes the realization that the article can be additionally supported (e.g., may be less prone to movement within the container) when one or more compliant members are placed beneath the article, such that the article is sandwiched between the pliable film and the compliant member. The compliant member can resist and respond to the downward force. This compliant member can include, for example, a cardboard flap or a second pliable film. Another aspect of at least one of the embodiments disclosed herein includes the realization that the article can be further protected when it is spaced from the outer walls of the container. Accordingly, the flap or the second pliable film can be configured to space the article from the bottom wall, in addition to providing increased support.

Thus, in accordance with another embodiment, a packaging kit for packaging an article can include a substantially rigid member, wherein the substantially rigid member includes a container portion configured to form a portion of a container capable of containing an article; and a lid portion that includes at least a top panel and two opposing pivotable side portions, the top panel being pivotable relative to the container portion; the lid portion further configured to be movable between an open configuration and a closed configuration, wherein when in the closed configuration, at least a portion of each of the two opposing pivotable side portions is pivoted towards an interior surface of the top panel at an angle of about 90 degrees relative to the interior surface. The packaging kit can further include a pliable film configured to couple with the opposing pivotable side portions, wherein when the pliable film is coupled with the opposing pivotable side portions and the lid portion is in the closed configuration, each of the opposing pivotable side portions space the pliable film from the top panel.

In accordance with another embodiment, a packaging kit for packaging an article can include a substantially rigid member, wherein the substantially rigid member includes a container portion configured to form a portion of a container capable of containing an article; and an article portion that includes at least a base and first and second pivotable side portions, the base being pivotable relative to the container portion; the article portion further configured to be movable between an open configuration and a closed configuration, wherein when in the closed configuration, at least a portion of each of the first and second pivotable side portions is pivoted towards an interior surface of the base of the article portion. The packaging kit can further include a resilient member configured to couple with the first and second pivotable side portions, wherein when the resilient member is coupled with the first and second pivotable side portions and the article portion is in the closed configuration, each of the first and second pivotable side portions space the resilient member from the base of the article portion.

In accordance with another embodiment, a packaging kit for packaging an article can include a substantially rigid member, wherein the substantially rigid member includes a container portion configured to form a portion of a container capable of containing an article; the container portion comprising at least a base and a support panel configured to resist a force applied by the article; and an article portion that can include at least a base and first and second pivotable side portions, the base being pivotable relative to the container portion; the article portion further configured to be movable between an open configuration and a closed configuration, wherein when in the closed configuration, at least a portion of each of the first and second pivotable side portions is pivoted towards an interior surface of the base of the article portion. The packaging kit can further include a resilient member configured to couple with the first and second pivotable side portions, wherein when the resilient member is coupled with the first and second pivotable side portions and the article portion is in the closed configuration, each of the first and second pivotable side portions space the resilient member from the base of the article portion.

In accordance with another embodiment, a substantially rigid member configured to form a container capable of containing an article can include a container portion, the container portion comprising at least a base and a support panel pivotable relative to the base, wherein the support panel is configured to resist a force applied by the article.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the packaging systems and kits are described herein with reference to the drawings of several embodiments of the present packaging systems and kits. These are intended to illustrate but not to limit the inventions. The drawings contain the following figures:

FIG. 1 is a plan view of a substantially rigid member in an unfolded and unassembled state, the substantially rigid member including a container portion and an article portion;

FIG. 1A is a plan view of an alternative embodiment of an article portion in an unfolded and unassembled state that includes two securing flaps;

FIG. 2 is a perspective view of the substantially rigid member of FIG. 1 in a first partially folded state;

FIG. 3 is a perspective view of the substantially rigid member of FIG. 1 in a second partially folded state;

FIG. 4 is a plan view of a resilient member having pockets;

FIG. 5 is a top view of the assembled packaging system in an open configuration and with the resilient member coupled to the article portion of the substantially rigid member;

FIG. 6 is a front view of the packaging system illustrated in FIG. 5;

FIG. 6A is a front view of an assembled packaging system including the article portion of FIG. 1A in an open configuration;

FIG. 6B is a plan view of a retention member that can be used with the article portion of FIG. 1A;

FIG. 6C is a front view of an assembled packaging system including the article portion of FIG. 1A and the retention member of FIG. 6B in an open configuration;

FIG. 6D is a front view of the assembled packaging system of FIG. 6C, further including a resilient member coupled with and secured to the article portion;

FIG. 6E is a side view of the assembled packaging system of FIG. 6D;

FIG. 7 is a top view of the packaging system of FIG. 5 with the article portion of the substantially rigid member in a closed configuration;

FIG. 8 is a cross-sectional view of the packaging system illustrated in FIG. 5;

FIG. 8A is a cross-sectional view of another embodiment of the packaging system of FIG. 8, wherein the packaging system includes the container portion illustrated in FIG. 13;

FIG. 9 is a perspective view of the packaging system illustrated in FIG. 5 with the article portion in the closed configuration;

FIG. 10 is a top view of the container portion of the packaging system illustrated in FIG. 1 and illustrates the pivotable flap disposed within the container portion of the substantially rigid member;

FIG. 11 illustrates an alternative embodiment to the container portion depicted in FIG. 10 and illustrates a container portion with additional pivotable flaps;

FIG. 12 is a top view of the container portion of FIG. 11 and illustrates the pivotable flaps being folded along the dotted fold lines illustrated in FIG. 11;

FIG. 13 is a cross-sectional view of the container portion illustrated in FIG. 12 and illustrates the pivotable flaps being pivoted towards the base.

FIG. 14 is a plan view of a frame in an unfolded and unassembled state;

FIG. 15 is a plan view of a second resilient member having pockets;

FIG. 16 is a perspective view of a removable retention member in an assembled configuration;

FIG. 17 is a cross sectional view of an assembled packaging kit that includes a substantially rigid member coupled to a first resilient member and a removable retention member coupled to a second resilient member;

FIG. 18 is a plan view of an alternate embodiment of a substantially rigid member that includes a tongue portion, a top panel, and a wall panel;

FIG. 19 is a cross sectional view of the substantially rigid member of FIG. 18 in a closed configuration.

DETAILED DESCRIPTION

Disclosed herein are packaging systems, kits, and methods for assembling and using the same. The packaging kits can include any of the substantially rigid members and resilient members disclosed below, such as the substantially rigid member 10 and the resilient member 128.

As described herein, terms of orientation, such as upper, lower, top, bottom, left, right, front, back, side, longitudinal, horizontal, vertical, lateral, mid-point and end are used here to simplify the description in the context of the illustrated embodiments. Because other orientations are possible, however, the packaging systems described herein should not be limited to the illustrated orientations. Those skilled in the art will appreciate that other orientations of the components of the systems described herein are possible.

With reference to FIG. 1, a substantially rigid member 10 is illustrated therein in an unfolded state and is constructed in accordance with an embodiment. The substantially rigid member 10 includes a container portion 12 and an article portion 14. The container portion 12 is configured to form a container capable of containing an article. The container can have a cavity or recess. In some embodiments, the article portion can be a lid portion of the container. In other embodiments, the article portion can be a tongue portion, such as the tongue portion 368 of substantially rigid member 10″, described herein.

The substantially rigid member 10 can be constructed from various materials, including but without limitation, paper, cardboard, corrugated cardboard, plastic, and other appropriate materials. The chosen material for constructing the substantially rigid member 10 can be any substantially rigid but foldable material. It will be appreciated that, although denominated as rigid or substantially rigid, the chosen material would preferably have an amount of flexibility in the cases of extreme physical impact. In some embodiments, the substantially rigid member 10 includes a single piece of corrugated cardboard. In some embodiments, the material used to form the substantially rigid member is a single wall corrugated C-flute cardboard. Advantageously, a single piece of corrugated cardboard (or a single piece of other substantially rigid material) can be shipped and stored in a compact and/or efficient manner as compared to other materials that may have to be shipped or stored in a non-planar configuration. Furthermore, a single piece of starting material can be assembled into a container more easily than multiple, separate pieces of a substantially rigid material.

The substantially rigid member 10 can have a planar, unassembled configuration, as illustrated in FIG. 1. The substantially rigid member 10 can also be folded into an assembled configuration, described further herein. When the substantially rigid member 10 is in the assembled configuration, a container portion 12 of the substantially rigid member 10 can be assembled into a container capable of containing an article. In the illustrated embodiment, when assembled into a container, the substantially rigid member 10 has an outer appearance of a box commonly used for shipping or retail packaging for goods.

The container can have a base 16 surrounded by four walls extending generally perpendicularly from the base 16. An article portion 14 having first and second pivotable side portions 94, 96 can be assembled such that at least a portion of the first and second pivotable side portions 94, 96 (e.g., a first panel, such as the inner panel 98) are folded towards an inner surface 108 of the base 86.

Once in the assembled configuration, the substantially rigid member 10 can form a container capable of moving between an open configuration and a closed configuration. Specifically, at least the article portion can be movable between an open configuration and a closed configuration. In the open configuration, illustrated in FIGS. 5-6, the container portion 12 can be open. In the closed configuration, illustrated in FIGS. 7-9, at least a portion of each of the first and second pivotable side portions 94, 96 of the article portion 14 (e.g., the inner panels 98, 150) can be pivoted towards an interior surface 108 of the base 86 of the article portion 14.

For example, the inner panels 98, 150 can be pivoted at an angle of about 90 degrees relative to the interior surface 108. In the closed configuration, at least a part of the article portion 14 can be nested in the container portion 12, forming a cavity 126 for holding an article 148 that is enclosed on all sides.

As described herein, the substantially rigid member 10 can include a container portion 12. As illustrated in FIG. 1, the container portion 12 can include a plurality of foldable portions, such as a base 16. The designation as a “base” does not impart any particular significance to that portion of the container portion 12. Rather, the base 16, in this embodiment, forms a bottom or a top of the packaging system described herein. For example, in some embodiments the base 16 can be a bottom panel of the container portion 12.

The base 16 can have a periphery that is defined by fold lines 26, 54, 66, and 74. The periphery can delineate the size and shape of the base 16. The size (e.g., dimensions) of the base 16 can be chosen by one of ordinary skill in the art to provide the desired amount of surface area of the bottom or top of the packaging system formed by the substantially rigid member 10. In some embodiments, the base 16 can have four edges, and can be, e.g., square-shaped. In one embodiment where the substantially rigid member 10 is intended to package a modem or a hard drive, the base 16 can be a square with a length and width of about ten inches each. However, those skilled in the art can appreciate that the base 16 can have other dimensions (e.g., square or rectangular) for use in packaging modems, hard drives, or any other article that is to be packaged in the packaging systems described herein.

The container portion 12 can include opposing lateral wall portions 18, 20 that extend from the periphery of the base 16, as illustrated in FIG. 1. When the base 16 has four edges bounded by four fold lines (e.g., when the base 16 has a quadrilateral shape), the opposing lateral wall portions 18, 20 can pivotably extend from two opposite edges (e.g., left and right edges of the base 16). The container portion 12 can also include opposing end wall portions 22, 24 that extend from the periphery of the base 16. When the base 16 has four edges, the opposing end wall portions 22, 24 can pivotably extend from the other two opposite edges (e.g., front and back edges). In some embodiments, the opposing wall portions 18, 20, 22, 24 of the container portion 12 can be referred to as the left, right, front, and back walls of the container portion 12, respectively.

For brevity, the construction of the lateral wall portion 18 will be described. However, it is to be understood that the lateral wall portion 20 also can include the same features. The lateral wall portion 18 can be pivotably connected to the base 16 at a fold line 26 of the base 16. As illustrated in FIG. 1, the fold line 26 can define one edge of the base 16. The lateral wall portion 18 can include one or more panels. For example, the lateral wall portion 18 can include an outer panel 28 and an inner panel 30. In some embodiments, the lateral wall portion 18 can also include a support panel 32 and/or an intermediate panel 44. The panels of the lateral wall portion 18 can be pivotably connected to one another, for example, along fold lines 34, 36, 38. As illustrated in FIG. 1, the outer panel 28 can be pivotably connected to the base 16 at fold line 26. The inner panel 30 can be pivotably connected to the support panel 32 at fold line 38. The intermediate panel 44 can be pivotably connected to the outer panel 28 and the inner panel 30 at fold lines 34, 36, respectively.

The fold lines described herein can be formed as perforations in the substantially rigid member 10, e.g., broken cut lines passing partially or completely through the material forming the substantially rigid member 10. In the alternative, or in addition, the fold lines can be crushed portions of the material forming the substantially rigid member 10. Depending on the material used to construct the substantially rigid member 10, the fold lines can be formed as mechanical hinges, thinned portions, adhesive tape, or any other appropriate mechanical connection which would allow various portions of the substantially rigid member to be folded, pivoted, and/or rotated with respect to each other. These concepts apply to all of the fold lines described herein, although this description may not be repeated with respect to any particular fold line.

As described herein, the panels of the lateral wall portion 18 can be configured to form a double wall portion when folded. In the illustrated embodiment, when the lateral wall portion 18 is folded upwardly and inwardly toward the base 16, the inner panel 30 forms an inner wall of the container and the outer panel 28 forms an outer wall. The intermediate panel 44, in between fold lines 34, 36, can form an upper edge of the lateral wall portion 18.

The lateral wall portion 18 can also include structures for securing the walls in place when folded. As illustrated in FIG. 1, one or more of fold lines 34, 36, 38 and the fold line defining the edge 26 can be a non-straight line and can include one or more tabs 40 and/or apertures 42 adapted to receive the tabs 40. Those skilled in the art can appreciate that the tabs 40 and apertures 42 can cooperate to maintain the container portion 12 in the assembled configuration as a container having an interior volume defined by a horizontal base portion and four vertically extending wall portions. Furthermore, other structures for securing the lateral wall portion 18 in the assembled configuration can be used.

In some embodiments, the inner panel 30 can be substantially narrower than the outer panel 28. In these embodiments, the lateral edges 44, 46 of the inner panel 30 can be enlarged or can include tabs for securing the inner panel 30. These embodiments can be advantageous because the inner panel 30 can affect one of the major dimensions (e.g., the width) of the substantially rigid member 10 when the substantially rigid member 10 is in an unfolded, planar configuration. By reducing the overall width of the substantially rigid member, the overall size and thus the waste of raw material used to form the substantially rigid member 10 can be reduced.

For example, as is known in the art for using bulk cardboard, anything cut from cardboard begins as a large rectangular piece. The large rectangular piece must be at least as large, in every dimension, as the final product. Thus, by reducing the greatest dimensions of the finished piece, the size of the original raw material can be reduced, thus resulting in less wasted cardboard.

As illustrated in FIG. 1, the container portion 12 or a portion thereof, such as the lateral wall portion 18, can include the support panel 32. The support panel 32 can be configured to resist a force applied by an article 148 when the article is contained within the container. As described herein, when in an assembled configuration, the outer panel 28 and the inner panel 30 can extend vertically and perpendicular to the base 16, to form a double-walled container. In the assembled configuration, the support panel 32 can extend generally parallel to the base 16. The support panel 32 can optionally include one or more apertures 48 that are configured to accommodate the article to be packaged. As described further herein, the support panel 32 can also include one or more pivotable flaps 50. The pivotable flaps 50 can be located anywhere on the support panel 32 and can be configured to adjustably space the support panel 32 from the base 16, thus helping to secure an article within the assembled package.

The end wall portion 22 can include a single wall panel 52. The single wall panel 52 can be pivotably connected to the base 16 along a fold line 54. The end wall portion 22 can also include corner flaps 56, 58, connected to the single wall panel 52 along fold lines 60, 62. In some embodiments, a lid or tongue portion (not shown) can be connected to the single wall panel 52 at an upper edge 64.

The end wall portion 24 can include a single wall panel 72. The single wall panel 72 can be pivotably connected to the base 16 along a fold line 74. The end wall portion 24 can also include corner flaps 76, 78, connected to the single wall panel 72 along fold lines 80, 82. The end wall portion 24, single wall panel 72, and corner flaps 76, 78 can include features and/or dimensions identical or similar to those described herein with respect to the end wall portion 22, single wall panel 52, and/or corner flaps 56, 58, respectively. Those skilled in the art can appreciate that the depth of the cavity 126 formed when the container portion 12 is in the assembled configuration can be determined by the height of the outer panels 28, 210, and the single wall panels 52, 72. In some embodiments, the height of each panel is about the same. In these embodiments, the height can be measured as the distance from the fold line adjacent the base 16 to the opposite fold line.

As illustrated in FIG. 1, the single wall panel 72 can be pivotably connected to the article portion 14 along a fold line 84. In some embodiments, the article portion 14 can form a top portion of the substantially rigid member 10 when in the assembled configuration. For example, the article portion 14 can be a lid portion. In these embodiments, the lid portion can form an outermost surface of the substantially rigid member when in the assembled, closed configuration. In other embodiments, the article portion 14 can form a tongue portion of the substantially rigid member. In these embodiments, the substantially rigid member can further include an additional lid portion extending from the article portion 14 or the container portion 12.

The article portion 14 can include a plurality of foldable portions, such as a base 86. The designation as a “base” does not impart any particular significance to that portion of the article portion 14. Rather, the base 86 in this embodiment forms a bottom or a top of the packaging system described herein. For example, in some embodiments, the base 86 can be a top panel of the article portion 14. The base can be pivotable relative to the container portion 12. The base 86 can include a periphery having four edges defined by fold lines 84, 88, 90, and 92. In some embodiments, the base 86 has a length and a width that are each generally proportional to the length and the width of the base 16. The base 86 can also be slightly smaller than the base 16 so that the article portion 14 can fit snugly with the container portion 12 when in the closed configuration. For example, in some embodiments the base 16 can be an 11-inch square, and the base 86 can be a 10.5-inch square.

The article portion can further include first and second pivotable side portions 94, 96. The first and second pivotable side portions 94, 96 can be opposing side portions, e.g., they can pivotably extend from opposite edges of the base 86 (e.g., the left and right edges). For brevity, the construction of the first pivotable side portion 94 will be described. However, it is to be understood that the second pivotable side portion 96 also can include the same features. The first pivotable side portion 94 can be pivotably connected to the base 86 of the article portion 14 at the fold line 90. The first pivotable side portion 94 can include one or more panels. For example, the first pivotable side portion 94 can include a first panel, such as an inner panel 98. The inner panel 98 can include a reduced width segment 214. At least a portion of the perimeter of segment 214 can be curved. The shape and dimensions of the reduced width segment 214 can ease the nesting of the article portion 14 into the container portion 12 when the container is closed. As illustrated in FIG. 1, the inner panel 98 can be connected to the base 86 at the fold line 90. In some embodiments, the first pivotable side portion 94 can include two or more panels (e.g., two, three, four, or more panels). As illustrated in FIG. 1, the first pivotable side portion can further include a middle panel 100 and an outer panel 102. The middle panel 100 can be pivotably connected to the inner panel 98 and the outer panel 102 via fold lines 104, 106. Thus, each of the panels 98, 100, 102 can be pivotably connected to at least one other panel.

The relative dimensions of the panels of the first pivotable side portion 94 can vary. In some embodiments, the inner panel 98 can have a maximum width 212 that is greater than the widths of any of the other panels, e.g., the middle panel 100 and/or the outer panel 102. In these embodiments, the width 212 of the inner panel 98 can define the depth of the article portion 14 when the article portion 14 is in a closed configuration. In some embodiments, the width 212 of the inner panel 98 can be less than the depth of the container portion 12 when the container portion 12 is in an assembled configuration. In these embodiments, the width 212 of the inner panel 98 of the article portion 14 can be less than the height of each of the wall panels 52, 72 and/or each of the outer panels 28, 210 of the container portion 12 (wherein the height is measured from the fold line adjacent the base to the opposite fold line). In other embodiments, the outer panel 102 of the article portion 14 can have a width (measured from fold line 106 to edge 206) that is less than the height of each of the wall panels 52, 72 and/or each of the outer panels 28, 210 of the container portion 12. In some embodiments, the inner panel 98 can have a width 212 of about 2 inches, the middle panel 100 can have a width of about 0.5 inches, and/or the outer panel 102 can have a width of about 1.25 inches.

An alternative embodiment of the article portion is illustrated in FIG. 1A and is denoted by reference number 14′. In any of the embodiments described herein, article portion 14′ can be used as an alternative to the article portion 14. As illustrated in FIG. 1A, the article portion 14′ can include a plurality of foldable portions, including a base 86′ that is bounded by fold lines 84′, 88′, 90′, 92′. Those skilled in the art will recognize that the base and the four fold lines of the article portion 14′ are substantially similar to the base 86 and fold lines 84, 88, 90, 92 of article portion 14 described herein. Furthermore, although not illustrated in FIG. 1A, those skilled in the art will appreciate that the base 86′ is pivotably connected to a securing portion similar to the securing portion 110 described herein along fold line 88′. Additionally, the base portion 86′ can be pivotably connected to a single wall panel of a container portion, similar to the single wall panel 72 of the container portion 12 described herein, along the fold line 84′.

The base 86′ can be sized similar to base 86 and, for example, can have a length and width that are generally proportional to the length and width of the base 16. In some embodiments, the base 86′ can be an 11-inch square. In other embodiments, the base 86′ can have a length of about 12 inches and a width of about 14 inches, or vice versa.

The article portion 14′ can further include first and second pivotable side portions 316, 318. The first and second pivotable side portions 316, 318 can pivotably extend from opposite edges of the base 86′, for example, the left and right edges along fold lines 92′ and 90′. For brevity, the construction of the first pivotable side portion 316 will be described. However, it is to be understood that the second pivotable side portion 318 can also include the same features.

The first pivotable side portion 316 can be pivotably connected to the base 86′ of the article portion 14′ of the fold line 90′. The first pivotable side portion 316 can include one or more panels. For example, the first pivotable side portion 316 can include a first panel, such as an outer panel 320. The outer panel 320 can be configured to couple with the resilient member 128. The outer panel 320 can include a securing flap 322. The securing flap 322 can be connected pivotably to the outer panel 320 along a fold line 324. The securing flap 322 can be disposed within a body portion of the outer panel 320. For example, the securing flap 322 can be surrounded by the outer panel 320 on all sides except along the side defined by the fold line 324. In some embodiments, the securing flap 322 can have a free portion, such as one or more corners 364, 366, that is configured to reversibly couple with the outer panel 320, such as via a friction fit.

As illustrated in FIG. 1A, the outer panel 320 can have one more tabs 326 that correspond with and are complementary to one or more cutouts 328 in the securing flap 322. As illustrated in FIG. 1A, the securing flap 322 and the outer panel 320 can both be pivotably connected along the fold line 324 to a second panel 330. The second panel 330 can include notches 334, 336, described further herein. Additionally, the second panel 330 can optionally be pivotably connected along fold line 338 to a third panel 332. Thus, each of panels 320, 330 and 332 can be pivotably connected to at least one other panel. The relative dimensions of the panels of the first pivotable side portion 316 can vary.

In some embodiments, the width 340 of the outer panel 320 can define the depth of the article portion 14′ when the article portion 14″ is in a closed configuration. In some embodiments, the width 340 of the outer panel 320 can be less than the depth of the container portion 12 when the container portion 12 is in an assembled configuration, so that the article portion 14′ can nest within the container portion 12. In these embodiments, the width 340 of the outer panel 320 of the article portion 14′ can be less than the height of each of the wall panels 52, 72 and/or each of the outer panels 28, 210 of the container portion 12 (where the height is measured from the fold line adjacent the base 16 to the opposite fold line). In some embodiments, the width 342 of the second panel 330 can be greater than the width 340 of the outer panel 320. In other embodiments, the outer panel 320 can have a maximum width 340 that is generally equal to the maximum width 342 of the second panel 330. In some embodiments, the outer panel 320 can have a width 340 of about 2.75 inches. The second panel 330 can have a width 342 of about 3.25 inches and/or the third panel 332 can have a width of about 1.75 inches.

As illustrated in FIG. 1, the substantially rigid member 10 can further include a securing portion 110. The securing portion 110 can include an end wall 112 that is pivotable relative to the article portion 14. In some embodiments, the securing portion 110 can be pivotably connected to the base 86 of the article portion 14 at the fold line 88. The securing portion 110 can further include opposing flaps 114, 116, pivotably connected to opposite ends of the end wall 112 at fold lines 118, 120, respectively. The flaps 114, 116 can each have a perimeter, at least a portion of which is curved. In some embodiments, the end wall 112 can have an inner surface 122 that is configured to contact an outer surface of the single wall panel 52 of the end wall portion 22 when the substantially rigid member 10 is in an assembled, closed configuration.

Advantageously, the substantially rigid member 10 described herein can form a fully enclosed container (e.g., substantially enclosing a cavity on all sides) from the container portion 12 and the article portion 14, without requiring other portions (e.g., a tongue portion, a suspension portion, and/or a tensioning portion) attached to, e.g., the end wall portion 22. As described herein, in some embodiments the substantially rigid member 10 can be cut from a single rectangular substantially rigid material, such as a piece of cardboard. The distance from the upper edge 64 of the single wall panel 52 to the lower edge 124 of the end wall 112 defines the outermost extremes of one of the dimensions (e.g., length or width) of the starting material. Those skilled in the art can appreciate that a substantially rigid member having a length measured from the lower edge 124 to the upper edge 64 will have a smaller length than a substantially rigid member having additional portions extending above or below either the securing portion 110 or the end wall portion 22 from the lower edge 124 or the upper edge 64, respectively. Assuming that all other dimensions (e.g., width) are the same, the substantially rigid members 10 described herein can be cut from a smaller piece of starting material as compared to other substantially rigid members that can include additional portions. Advantageously, the substantially rigid members 10 described herein can form closed containers having the same or similar internal dimensions as compared to other packages in the art, while requiring less starting material. Requiring less starting material can advantageously conserve both environmental and financial resources.

The assembly of the container portion 12 is illustrated in FIGS. 2-3. In the assembled configuration, the container portion 12 can be folded to create a cavity that is bounded by the base 16, lateral wall portions 18, 20, and end wall portions 22, 24. In the assembled configuration, the single wall panel 52 of the end wall portion 22 can be folded towards the base 16 along fold line 54 such that the end wall portion 22 is generally perpendicular to the base 16, as illustrated in FIG. 2. Additionally, the corner flaps 56, 58 can be folded towards the base 16 along fold lines 60, 62, such that the corner flaps 56, 58 are generally perpendicular to both the base 16 and the single wall panel 52, as illustrated in FIG. 2. In this configuration, the corner flaps 56, 58 can also be generally parallel to the edges 26, 66. The corner flaps 56, 58 can partially overlap each adjacent aperture 42. In some embodiments, the corner flaps 56, 58 can be generally parallel but also offset from the edges 26, 66, to define a spacing between, e.g., the corner flap 56 and the outer panel 28. As described further herein, this spacing can receive the flap 114 when the substantially rigid member is in the secured configuration.

As illustrated in FIG. 2, the single wall panel 72 of the end wall portion 24 can be folded towards the base 16 along the fold line 74 such that the end wall portion 24 is generally perpendicular to the base 16. The corner flaps 76, 78 can be folded towards the base 16 along the fold lines 80, 82, such that the corner flaps 76, 78 are generally perpendicular to both the base 16 and the single wall panel 72, as illustrated in FIG. 2. In this configuration, the corner flaps 76, 78 can also be generally parallel to the opposing edges 26, 66, of the base 16. The corner flaps 76, 76 can, inc some embodiments, partially overlap each adjacent aperture 42.

After the single wall panels 52, 72 have been folded upwards and the corner flaps 56, 58, 76, 78 have been folded inwards, the lateral wall portions 18, 20 can be folded over the corner flaps 56, 58, 76, 78 as illustrated in FIG. 3. As such, for example, the corner flap 56 can be sandwiched between the outer panel 28 and the inner panel 30. The corner flap 76 can be sandwiched between the outer panel 28 and the inner panel 30. In some embodiments, the corner flaps 56, 58, can each include a notch 68, 70. When in the assembled configuration, the notches 68, 70 can provide a space to allow tab 40 to be received in the aperture 42. Without the notch 68, for example, the corner flap 56 can block the aperture 42. In other embodiments, the corner flap 56 can be shortened so as to not block the aperture 42 from receiving the tab 40, or can only partially block the aperture 42. The corner flaps 76, 78 can also include similar notches.

When in the assembled configuration, those skilled in the art can appreciate that folding along fold line 38 can create a first crease and folding along fold line 26 can crate a second crease. As illustrated in FIG. 8, when in the assembled configuration, the first crease can nest, or fit into, the second crease.

As illustrated in FIG. 3, when the container portion 12 is in the assembled configuration, the inner panel 30 and the corresponding panel of the lateral wall portion 20 now form inner walls of a cavity 126. Similarly, the single wall panels 52, 72 form end walls of the cavity 126, with the base 16 forming the bottom thereof.

The packaging systems described herein can include a resilient member 128. In some embodiments, the packaging systems described herein can include a single resilient member 128. One embodiment of a resilient member 128 is illustrated in FIG. 4. The resilient member 128 can include a resilient body 130. For purposes of convenience for the following description, the resilient body 130 is identified as having a midpoint M positioned in the vicinity of the middle of the resilient body 130. In some embodiments, the resilient member 128 can also include first and second pockets 132, 134 at opposite ends thereof. The pockets 132, 134 can be configured to receive at least a portion of each of the first and second pivotable side portions 94, 96. In other embodiments, the resilient member 128 does not include pockets. For example, the resilient member 128 can be a single-layer, planar piece of film having resilient properties. In the illustrated embodiment, the resilient member 128 is formed of a single piece of resilient material, and is sized to cooperate with the first and second pivotable side portions 94, 96 of the article portion 14 of the substantially rigid member 10.

In the illustrated embodiment, the pockets 132, 134 are formed of folds 136, 138 formed in the resilient body 130 which have been attached (e.g., heat sealed) along lateral opposite edges thereof. In this embodiment, the heat sealing process forms heat sealing lines 140, 142, 144, 146. The heat sealing lines 140, 142, 144, 146 can be continuous or formed of a plurality of heat sealed points.

Those skilled in the art can appreciate that there are numerous methods for forming pockets in a resilient sheet material such as the resilient body 130. However, it has been found that heat sealing is particularly advantageous as it does not require expensive adhesives and the time-consuming steps required for using such adhesives. Regardless, such adhesives can be used if desired.

The resilient member 128 has a length L₁ that is sized depending on the other devices with which the resilient member 128 is to cooperate. Thus, the length L₁ can be sized such that when the resilient member 128 is engaged with the first and second pivotable side portions 94, 96, it generates the desired tension for the corresponding application. In some embodiments, the length L₁ can be less than the length of the article portion 14, where the length of the article portion 14 is measured as the distance from edge 206 to edge 208. For example, the length L₁ can be about 14 inches and the length of the article portion 14 can be about 18 inches. In these embodiments, because the length L₁ of the resilient member 128 is less than the length of the article portion 14, the resilient member 128 experiences tension when it is coupled with the article portion 14. Thus, the length L₁ will be smaller where a higher tension is desired and will be larger where a lower tension is desired. Additionally, the length L₁ might be different for different sized articles that are to be packaged. Those skilled in the art can determine the length L₁ for the desired application.

The resilient member 128 can be formed of any material that is plastic, elastic, pliable, resilient, flexible, and/or compliant. In use, the resilient member 128 can stretch and deform to fit the shape of an article over which it is stretched. In some embodiments, the resilient member 128 can be made of a polymeric film, such as a polyethylene film. However, virtually any polymer, elastomer, or plastic film can be used to form the resilient member 128. In some embodiments, the resilient member 128 is a pliable film. The density of the film can be varied to provide the desired retention characteristics such as overall strength, resiliency, and vibrational response. In some embodiments, the density of the resilient member 128 is determined such that the resilient member 128 is substantially resilient when used to package a desired article.

The resilient member 128 can be configured to couple with the article portion 14 of the substantially rigid member 10. In some embodiments, the resilient member 128 is configured to couple with the first and second pivotable side portions 94, 96. As described herein, the coupling of the resilient member 128 with the article portion 14 can occur via a variety of mechanisms, including but not limited to inserting a portion of each of the first and second pivotable side portions 94, 96 into the pockets 132, 134.

As illustrated in FIGS. 5-6, in the assembled configuration, the inner panel 98 of the article portion 14 can be folded towards the inner surface 108 of the base 86 along fold line 90. The middle panel 100 can be folded away from the inner surface 108 of the base 86 along fold line 104. The outer panel 102 can be folded away from the inner surface 108 of the base 86 along fold line 106.

When the article portion 14 has achieved the assembled configuration illustrated in FIGS. 5-6, the first and second pivotable side portions 94, 96 can be coupled with the resilient member 128. As illustrated in FIGS. 5-6, the first and second pivotable side portions 94, 96 can be placed at least partially or fully into the pockets 132, 134 of the resilient member 128. In the illustrated embodiment, the outer panel 102 and the corresponding structure on the second pivotable side portion 96 are disposed within the pockets 132, 134. However, those skilled in the art can appreciate that in embodiments that do not include an outer panel, the resilient member 128 can be coupled with other portions of the first and second pivotable side portions 94, 96.

As described herein, in some embodiments the resilient member 128 does not include pockets 132, 134. In these embodiments, the resilient member 128 can be coupled with the first and second pivotable side portions 94, 96, by any other method known in the art. For example, the resilient member 128 can be attached or secured to at least a portion of the first and/or second pivotable side portions 94, 96, for example with an adhesive or through heat sealing.

As illustrated in FIG. 6 and as described herein, the resilient member 128 can be sized so that tension exists across the length L₁ of the resilient member 128 when it is coupled to the first and second pivotable side portions 94, 96. As illustrated in FIG. 6, the resilient member 128 stretches from the first pivotable side portion 94 to the second pivotable side portion 96. The resilient member 128 is separated from the inner surface 108 of the base 86 of the article portion 14 by the width 212 of the inner panel 98 and the corresponding width of the inner panel of the second pivotable side portion 96. Also, as illustrated in FIG. 6, the resilient member 128 does not contact the inner surface 108 of the base 86 when the inner panels are folded towards and perpendicular to the inner surface 108 of the base 86.

As described herein, in some embodiments the substantially rigid member 10 can include article portion 14′. The article portion 14′ can also be movable to an assembled configuration as illustrated in FIG. 6A. In FIG. 6A, an assembled article portion 14 is shown attached to an assembled container portion 12. In the assembled configuration, the outer panel 320 can be folded towards the inner surface 360 of the base 86′ along fold line 90′. The second panel 330 can also be folded towards the inner surface 360 along fold line 324. The third panel 332 can be folded towards the outer panel 320 along fold line 338. As illustrated in FIG. 6A, when in the assembled configuration, the first pivotable side portion 316 has a cross section generally in the shape of a right triangle, wherein the outer panel 320 and the third panel 332 form with the two legs and the second panel 330 forms the hypotenuse. The second pivotable side portion 318 can be folded in a similar manner.

In some embodiments, the packaging kit can further include a retention member 344, which is illustrated in FIG. 6B. The retention member 344 can include an elongate body 346, which is pivotably connected to two flaps 348, 350 along fold lines 352, 354, respectively. As further illustrated in FIG. 6B, the body 346 can include one or more notches 356, 358 along an edge of the body. The body 346 can have a width, as measured from fold line 352 to fold line 354, that is generally equal to or slightly less than the width of base 86′, as measured from fold line 90 to fold line 92. The width of the flap 348, as measured from fold line 352 to the opposite edge, can be generally equal to or slightly less than the width 340 of the outer panel 320. The width of the flap 350 can be about the same as the width of the flap 348.

In embodiments that include a retention member 344, the retention member 344 can be mated with the article portion 14′ as illustrated in FIG. 6C. In these embodiments, the notches 356, 358 on the retention member 344 can mate with the notches 334 and the corresponding notch on the second pivotable side portion 318. Although not illustrated, those skilled in the art will appreciate that some embodiments can include two retention members 344, wherein the first retention member 344 mates with the notch 334 and the corresponding notch on the second pivotable side portion 18, while the second retention member 344 mates with the notch 336 on the first pivotable side portion and also with the corresponding notch on the second pivotable side portion 318. As illustrated in FIG. 6C, the retention member 344 can be coupled with the article portion 14′. The body portion 346 of the retention member can be generally planar and can be oriented generally parallel to the inner surface 360 of the base 86′. Flaps 348, 350 can be folded upwards along fold lines 352, 354 to extend at a generally right angle with respect to the body portion 346 of the retention member 344. Furthermore, as illustrated in FIG. 6C, the flaps 348, 350 can be generally parallel to the outer panel 320 on the first pivotable side portion 316, as well as to the corresponding outer panel on the second pivotable side portion 318. Advantageously, the retention member 344 can help to maintain the triangular cross-sectional shape of the first and second pivotable side portions 316, 318 when they are in an assembled configuration. Accordingly, this configuration can yield a multi-wall construction where an inner wall, such as the second panel 330, is securely spaced from the outer panel 320. As described further herein, spacing the inner panel from the outer wall can help to cushion the article 148 therein from any bumps or other damage that may occur to the outermost surface. Accordingly, this configuration of the article portion 14′, optionally in combination with the retention member 344, can help to further secure the article 148. Once the article portion 14′ is folded into the configuration illustrated in FIG. 6C, the article portion 14′ can be coupled to a resilient member 128. As described herein, at least a portion of the first and second pivotable side portions 316, 318 can be coupled with the resilient member 128. For example, the securing flaps 322, 362 can be placed at least partially or fully into the pockets 132, 134 of the resilient member 128.

Once the resilient member 128 is coupled with the securing flaps 322, 362, the resilient member and the securing flaps can be secured in place, as illustrated in FIGS. 6D to 6E. This can be accomplished by tucking the corner of securing flaps 364, 366 into the outer panel 320 such that the corners of the securing flaps 364, 366 are held in a friction fit with the outer panel 320, as illustrated in FIG. 6E. As illustrated in FIG. 6D, when the securing flaps 322 are mated with the outer panel 320, tension can be created across the resilient member 128. As illustrated in FIG. 6D, resilient member 128 can be nearly planar when the securing flaps 322, 362 have been coupled with the outer panel 320. As described herein, the tension across the resilient member 128 contributes to securing the article 148 that is secured within the container. Advantageously, tension across the resilient member 128 can be established and maintained without the use of additional materials such as glue, tape, staples, or the like.

When the substantially rigid member 10 has been assembled as described herein and coupled with the resilient member 128, an article 148 to be packaged can be placed into the cavity 126. When received in the cavity 126, the article 148 can directly contact and/or be placed on the base 16, the support panel 32, and/or the support panel 154. The substantially rigid member 10 can then be closed.

In the closed configuration, illustrated in FIGS. 7-9, at least a part of the article portion 14 can be nested or placed in the container portion 12. As illustrated in FIG. 8, in the closed configuration, a first panel, such as the inner panel 98, can be folded towards an inner surface 108 of the base 86 along fold line 90, such that the inner panel 98 is generally perpendicular to the base 86. Where the first pivotable side portion 94 further includes a middle panel 100, the middle panel 100 can be folded away from the inner surface 108 of the base 86 along fold line 104, such that the middle panel 100 is generally perpendicular to the inner panel 98 and generally parallel to the base 86. Where the first pivotable side portion 94 further includes an outer panel 102, the outer panel 102 can be folded away from the inner surface 108 of the base 86 along fold line 106, such that the outer panel 102 is generally parallel to the inner panel 98 and generally perpendicular to the base 86. As illustrated in FIG. 8, the middle panel 100 can space the inner panel 98 from the outer panel 102 to yield a double-wall construction. Advantageously, the space created between the inner panel 98 and the outer panel 102 can act to absorb shock and further cushion the article being packaged.

When the substantially rigid member is moved to the closed configuration, each of the first and second pivotable side portions 94, 96 can space the resilient member 128 from the base of the article portion 14. As illustrated in FIG. 8, when the article portion 14 is nested in the container portion 12, the inner panels 98, 150 space the resilient member 128 from the opposite side edges of the base 86, as defined by fold lines 90, 92, at least by a distance defined by the width 212, 152 of the inner panels 98, 150. As further illustrated in FIG. 8, the resilient member 128 is positioned adjacent the inner surface 108 of the base 86 of the article portion 14. The resilient member 128 can be pressed over the article 148, helping to secure the article 148 in place. Those skilled in the art can appreciate that the tension in the resilient member 128 created as the resilient member 128 stretches over the article 148 can help to secure the article 148 in place. The support panels 32, 154 can further help to cushion and secure the article 148, and are described further herein.

Although not illustrated herein, those skilled in the art will appreciate that article portion 14′ can be pivotably moved to a closed configuration in the same way as described herein with respect to the article portion 14. When in the closed configuration, the article portion 14′ can be nested in the container portion 12. Each of the outer panels can space the resilient member 128 from the base of the article portion at least by a distance defined by a width each of the outer panels, such as width 340. Furthermore, the second panel 330, optionally in combination with one or more retention members 344, yields a multiwall construction that can space the article 148 from the outermost walls of the container, thus advantageously providing further protection to the article 148 from outside forces. Additionally, those skilled in the art will appreciate that when the article portion 14′ is in the closed configuration, the resilient member 128 can be pressed over the article 148 to contribute to securing the article 148, as described herein with respect to the article portion 14 as illustrated in FIG. 8.

As illustrated in FIG. 9, in the closed configuration, the flaps 114, 116 can be folded towards the inner surface 122 of the end wall 112 along fold lines 118, 120, such that the flaps 114, 116 can be generally perpendicular to the end wall 112. The end wall 112 can be pivoted towards the inner surface 108 of the base 86, such that the inner surface 122 of the end wall 112 can contact the outer surface of the single wall panel 52. When the end wall 112 is pivoted towards the base 86, the folded flap 114 can be inserted into a space between the corner flap 56 and the outer panel 28 of the container portion 12. The folded flap 116 can be inserted into a space between the corner flap 58 and the outer panel of the lateral wall portion 20. When the article portion 14 is pivoted along fold line 84 and nested in the container portion 12, the end wall 112 is pivoted along fold line 88 towards the single wall panel 52, and the flaps 114, 116 are folded perpendicular to the securing portion 110 and received by the container portion 12, then the substantially rigid member is in its fully assembled, closed, and secured configuration.

As described herein, in some embodiments, the article portion of the substantially rigid member 10 can be a tongue portion instead of a lid portion. In these embodiments, the substantially rigid member can further include a separate top panel that forms an outermost surface of the resulting container. One embodiment of a substantially rigid member 10″ that includes a tongue portion 368 and a top panel 370 is illustrated in FIG. 18. As illustrated in FIG. 18, the substantially rigid member 10″ can include a container portion 12″ and a tongue portion 368. The tongue portion 368 can be substantially similar to the article portion 14 and/or the article portion 14′ described herein, except that the tongue portion 368 does not include a securing portion 110. Furthermore, the tongue portion 368 does not form an outermost surface of the assembled container when it is in a closed configuration.

Container portion 12″ can be generally similar to container portion 12, although in some embodiments the end wall portion 22″ and/or the end wall portion 24″ can be modified. For example, the end wall portion 24″ can include a single wall panel 72″ and flaps 76″, 78″. The single wall panel 72″ and flaps 76″, 78″ can each have a width (also referred to as a “height” when in the assembled configuration) that is less than the width of the outer panels 28, 210 and also that is less than the width of single wall panel 52″.

As illustrated in FIG. 19, a single wall panel 72″ can be shorter than single panel 52″ in order to allow the top panel 370 to comfortably pass over the tongue portion 368 to close the container. Those skilled in the art will appreciate that if the single wall panel 72″ and the single wall panel 52″ were the same height, then the tongue portion 368 might interfere with the top panel 370 when the top panel 370 is folded over the tongue portion 368, and can prevent the container from fully closing.

As further illustrated in FIG. 18, single wall panel 52″ can be modified in that instead of having a fold line 64, the single wall panel 52″ has a fold line 62″ that pivotably connects the single wall panel 52″ to the top panel 370. The top panel 370 can be further pivotably connected to a wall panel 372 via a fold line 374. The wall panel 372 can also be pivotably connected on opposite ends to corner flaps 376, 378 by means of fold lines 380, 382. The dimensions of the top panel 370 can vary. Generally, the dimensions of the top panel 370 can be equal to the dimensions of the base 16. In some embodiments, the dimensions of the top panel 370 can be slightly greater than the dimensions of the tongue portion 368. Those skilled in the art can appreciate that this is because the tongue portion 368 can nest within the container portion 12″, whereas the top panel 370 can cover the tongue portion 368 to form an outermost surface of the container. The dimensions of the wall panel 372 can be generally equal to or slightly greater than the dimensions of the single wall panel 72″. When in an assembled closed configuration, the wall panel 372 will cover the single wall panel 72″.

To assemble the substantially rigid member 10″, the container portion 12″ can be assembled as described herein with regards to container portion 12. The tongue portion 368 can also be assembled generally as described herein with regards to article portion 14 and/or article 14″. Accordingly the tongue portion 368 can be coupled with a resilient member. An article can be placed into the cavity 126 that is formed by the container portion 12″ in the assembled configuration. The tongue portion 368, when coupled with a resilient member, can be nested or placed in the container portion 12″ in a manner described herein with regards to the article portion 14 and/or the article portion”. At that point, the resilient member can be pressed over the article that is in the cavity helping to secure the article in place.

One example of a tongue portion 368 nested in a container portion 12″ is illustrated in FIG. 19. As illustrated in FIG. 19, the top panel 370 can be folded along fold line 64″ towards the tongue portion 368. In this configuration, the top panel 370 can generally cover and can be generally parallel to the tongue portion 368. Furthermore, as illustrated in FIG. 19, the top panel 370 can form an outermost surface of the container. The corner flaps 376, 378 can then be folded along fold lines 380, 382 towards an inner surface of the wall panel 376, similar to the manner described herein with regards to the substantially rigid member 10 as illustrated in FIG. 9. In this configuration, the corner flaps 376, 378 can be generally perpendicular to the wall panel 372. As illustrated in FIG. 19, the wall panel 372 can be pivoted towards the single wall panel 72″ in the direction indicated by the arrow, such that an inner surface of the wall panel 372 can contact an outer surface of the single wall panel 72″. When the wall panel 372 is pivoted towards the single wall panel 72″, the folded corner 376 can be inserted into a space between the corner flap 76″ and the outer panel 28″ of the container portion 12″, similar to the analogous components of the securing portion 110 described herein. The folded corner flap 378 can be inserted into a space between the corner flap 78″ and the outer panel 210 of the lateral wall portion 20. At this point, the substantially rigid member 10″ can be in its fully assembled and closed configuration.

Some embodiments herein are directed to a substantially rigid member that can include a container portion 12 having a support panel 32, 154 that includes one or more pivotable flaps 156, 158, 160, 162, 164, 166, as illustrated in FIGS. 8A and 10-13. As illustrated in FIG. 10, the pivotable flaps 156, 158 can be located at the outer edges 168, 170 of the support panels 32, 154. The pivotable flaps 156, 158 can have three free edges and can be connected to the support panel 32, 154 by a fold line 172, 174. As illustrated in FIG. 10, the fold line 172, 174 can extend generally perpendicular to the fold lines 38, 176 that define the side wall boundaries of the cavity 126. The pivotable flaps 156, 158 can be spaced from the inner panels 30, 178 by a distance 180, 182, respectively.

As illustrated in FIG. 10, the pivotable flaps 156, 158 can be folded under the support panels 32, 154 and towards the base 16. This step can be completed when the container portion 12 is being folded into the assembled configuration. Upon folding, the pivotable flaps 156, 158 do not fully contact the base 16. Those skilled in the art can appreciate that the area of contact between the pivotable flaps 156, 158 and the base 16 can increase as a downward force (e.g., a force applied in a direction towards the base 16) is applied to the pivotable flaps 156, 158. The pivotable flaps 156, 158 can experience an increase in downward force for a variety of reasons, such as placing an article onto the support panels 32, 154. In another embodiment, when the substantially rigid article 10 is arranged in the closed configuration such that the article portion 14 is nested in the container portion 12, the tension applied to the article 148 by the resilient member 128 and/or the article portion 14 can result in the application of force to the pivotable flaps 156, 158.

Advantageously, the pivotable flaps 156, 158 can act as compression springs that absorb force when pressed towards the base 16. In addition, the pivotable flaps 156, 158 in their folded positions provide an upward force that acts in an opposite direction as compared to the force being applied by the article 148, resilient member 128, and/or article portion 14. This combination of forces helps to secure the article 148 in a tight fit within the cavity 126. The upward force can also space the article 148 from the base 16, further protecting the article 148 from bumps or other damage that can occur to the exterior of the base 16.

Additional embodiments of pivotable flaps 160, 162, 164, 166 are illustrated in FIG. 11. Those skilled in the art will appreciate that in FIG. 11, the end wall portion 22 is depicted in an unfolded state so as to more clearly illustrate the pivotable flaps 164, 166. In use, however, the end wall portion 22 can be folded upwards and the corner flaps 56, 58 secured between the inner and outer panels of the lateral wall portions 18, 20. Pivotable flap 160 is located in a body portion of the support panel 32, as opposed to an edge portion. Pivotable flap 160 is generally rectangular with three free edges and a fold line 184 that extends generally parallel to the fold lines 38. The fold line 184 is separated from the fold line 38 by a distance 188 that is generally equal to a width 190 of the pivotable flap 160. To assemble pivotable flap 160, the pivotable flap 160 is folded under the support panel and towards the base. The pivotable flap 160 in the folded position is illustrated in FIG. 12.

Because the pivotable flap 160 is separated from the fold line 38 by a distance generally equal to the width of 190 of the pivotable flap 160, when the pivotable flap 160 is folded, an edge 192 of the pivotable flap 160 is wedged into a crease created by fold line 26. Accordingly, the pivotable flap 160 can interfere with the crease created by fold line 26.

Those skilled in the art can appreciate that when the pivotable flap 160 is in an interference position with the crease, the support panel can be prevented from fully contacting the base 16. When an article 148 is placed on a support panel that includes a pivotable flap 160, the pivotable flap 160 can prevent the article 148 from directly contacting the base 16. As described herein the space between the article 148 and the base 16 can help to cushion the article 148 from any bumps or damage that can occur to the exterior of the base 16. Additionally, as described herein with respect to the pivotable flaps 156, 158, the pivotable flap 160 in the folded position can exert an upwards force (e.g., a force in the opposite direction as that which is being applied by the article 148, resilient member 128, and/or article portion 14) to the article 148. This upwards force can provide a tight fit for the article 148 and contribute to securing the article within the cavity 126.

In some embodiments, the support panel can include pivotable flap 162. The pivotable flap 162, as illustrated in FIG. 11-12, is similar to the pivotable flap 160, except that the pivotable flap 162 further includes a latch mechanism that retains the pivotable flap 162 in a pivoted position. The latch mechanism can include a latch 194 that is configured to be received within an aperture 196. In this embodiment, the latch 194 is configured as a tab, and the aperture has a size and shape configured to receive the tab therein in a friction fit. However, those skilled in the art can appreciate that other latch styles can be used to secure the pivotable flap 162 in the folded position. Advantageously, the pivotable flap 162 can be folded towards the base 16 along fold line 186 and secured in place with the combination of the latch 194 and aperture 196. This embodiment can be useful in assembly processes where it is important for a pivotable flap to be secure in its folded position.

In other embodiments, the support panel can include pivotable flap 164, as illustrated in FIGS. 11-13. The pivotable flap 164 can extend outside of the perimeter of the support panel 32. Similar to the pivotable flap 156, the pivotable flap 164 can be connected to the support panel 32 by a fold line 198 that extends generally perpendicular to the fold 38. The pivotable flap 164 can include an edge 200 that is aligned with the fold 38. Accordingly, when the pivotable flap 164 is folded towards the base 16 (e.g., downwards), the pivotable flap 164 can be in an interference fit with a crease defined by the fold 26, as illustrated in FIGS. 12-13. The pivotable flap 164 can function in a manner similar to that described for the pivotable flap 160.

In yet other embodiments, the support panel can include pivotable flap 166, as illustrated in FIGS. 11-13. The pivotable flap 166 is similar to the pivotable flap 164, except that it includes a latch 202 that is configured to be received within an aperture 204. In this embodiment, the latch 202 is in the shape of a flange, and the aperture has a size and shape for receiving and retaining the flange therein. However, those skilled in the art can appreciate that other latch styles can be used to secure the pivotable flap 166 in the folded position. As illustrated in FIG. 13, the pivotable flap 166, when in the folded position, can be in an interference fit with a crease defined by the fold line 66.

In use, a downward force F can be applied to the support panels 32 and/or 154. For example, the downward force F can be applied by an article that is placed within the cavity of the container portion and onto the support panels. As illustrated in FIG. 13, as the force F is applied to the support panel 154, a portion of the support panel 154 can be deflected into a deflected position 155. However, the pivotable flap 166 in the folded position can interfere with and thus hinder the support panel 154 from fully contacting the base 16. Accordingly, the support panel 154 can resist the downward force F. Those skilled in the art can therefore appreciate that the support panel 154 and the pivotable flap 166 together can operate as a leaf spring that can suspend the article and absorb outside forces such as bumps, vibrations, and the like. The support panel 32 and the pivotable flap 164 can also operate together as a leaf spring for these same reasons.

Those skilled in the art can appreciate that all of the substantially rigid members 10 described herein can include one or more pivotable flaps 156, 158, 160, 162, 164, and/or 166 in any combination. For example, the substantially rigid members illustrated in FIGS. 10-13 can include a container portion, an article portion, a securing portion, and/or any of their respective features as described herein. Furthermore, in some embodiments, the substantially rigid member 10 does not include any pivotable flaps 156, 158, 160, 162, 164, and/or 166. Those skilled in the art can also appreciate that the positions of the pivotable flaps 156, 158, 160, 162, 164, and/or 166 as illustrated in FIGS. 10-13 are provided as examples, and that other positions can also be used. For example, in some embodiments the pivotable flap 156 can be located adjacent the end wall portion 22, rather than the end wall portion 24. Similarly, in some embodiments the pivotable flap 164 can be located adjacent the end wall portion 24, rather than the end wall portion 22.

Some embodiments herein are directed to a packaging kit that can include a removable retention member 216 that is configured to fit within the cavity 126 of the container portion 12. In some embodiments, the removable retention member 216 can be configured to fit completely or wholly within the cavity 126. The removable retention member 216 can include a frame 218 and a second resilient member 220 configured to couple with the frame 218. The removable retention member 216 can be reversibly movable from a planar unassembled configuration, illustrated in FIGS. 14-15, to a non-planar assembled configuration, illustrated in FIG. 16.

The frame 218 in an unassembled configuration is illustrated in FIG. 14. As illustrated in FIG. 14, the frame 218 can include an interfacing panel 222. The interfacing panel 222 can include a periphery having four edges defined by fold lines 222, 224, 226, 228. The periphery can delineate the size and shape of the interfacing panel 222. As described herein, the removable retention member 216 can be configured to fit within the cavity 126 of the container portion 12. Accordingly, the size (e.g., dimensions) of the interfacing panel 222 can be chosen by one of ordinary skill in the art depending on the size (e.g., dimensions) of the cavity 126. For example, the interfacing panel 222 can have a length and a width that are each less than the length and the width of the base 16. As illustrated in FIG. 14, the interfacing panel can have four edges defined by the four fold lines and can be square-shaped. However, those skilled in the art can appreciate that the interfacing panel 222 can have other dimensions (e.g., square or rectangular) for use in packaging modems, hard drives, or any other article that is to be packaged in the packaging systems described herein.

As illustrated in FIG. 14, the interfacing panel 222 can include a window 232. The window 232 can be cut out from the body of the interfacing panel 222, such that the interfacing panel 222 surrounds the window 232 in at least one plane. As described further herein, the second resilient member 220 can cover the window 232 to contact the article 18. Accordingly, the size (e.g., dimensions) and shape of the window 232 can be chosen by one of ordinary skill in the art depending on the size and shape of the article 148. In some embodiments, the length and width of the window 232 will be larger than the length and width of the article 148. As illustrated in FIG. 14, the window 232 can be in the shape of a square with rounded corners. However, those skilled in the art can appreciate that the interfacing panel 222 can have other dimensions (e.g., square, rectangular, circular, or variations thereof) for use in packaging modems, hard drives, or any other article that is to be packaged in the packaging systems described herein.

As illustrated in FIG. 14, the interfacing panel 222 can include one or more apertures 242. The aperture can be configured to receive a tab disposed on an inner panel of one of the lateral wall portions 234, 236, as discussed further herein. The aperture 242 can be aligned with (e.g., can have one edge along) one of the fold lines 226, 230 that pivotably connects one of the lateral wall portions 234, 236. In some embodiments, the interfacing panel 222 has two apertures 242 (e.g., one along each fold line 226, 230). In other embodiments, the interfacing panel 222 has four apertures 242 (e.g., two along each fold line 226, 230).

As illustrated in FIG. 14, the frame 218 can include opposing lateral wall portions 234, 236 that extend from the periphery of the interfacing panel 222. The opposing lateral wall portions 234, 236 can pivotably extend from opposite edges 226, 230, as illustrated in FIG. 14. In some embodiments, the opposing lateral wall portions 234, 236 can pivotably extend from left and right edges, respectively, of the interfacing panel 222. The frame 218 can also include opposing end wall portions 238, 240 that extend from the periphery of the interfacing panel 222. The opposing end wall portions 238, 240 can pivotably extend from opposite edges 224, 228, as illustrated in FIG. 14. In some embodiments, the opposing end wall portions 238, 240 can pivotably extend from the front and back edges, respectively, of the interfacing panel 222. In some embodiments, the opposing wall portions 234, 236, 238, 240 can be referred to as the left, right, back, and front walls of the frame 218, respectively.

For brevity, the construction of the lateral wall portion 234 will be described. However, it is to be understood that the lateral wall portion 236 also can include the same features. The lateral wall portion 236 can be pivotably connected to the interfacing panel 22 at fold line 230. As illustrated in FIG. 14, the fold line 230 can define one edge of the interfacing panel 222. The lateral wall portion 234 can include one or more panels. For example, the lateral wall portion 234 can include an outer panel 244 and an inner panel 246. In some embodiments, the lateral wall portion 234 can include an intermediate panel 248. The panels of the lateral wall portion 234 can be pivotably connected to one another, for example, along fold lines 250, 252. As illustrated in FIG. 14, the outer panel 244 can be pivotably connected to the interfacing panel 222 at fold line 230. The intermediate panel 248 can be pivotably connected to the outer panel 244 and the inner panel 246 at fold lines 250, 252, respectively.

Those skilled in the art will appreciate that the fold lines described herein with respect to the frame 218 of the removable retention member 216 can have all of the properties of the fold lines described herein with respect to the substantially rigid member 10. For example, the fold lines can be formed as perforations in the frame 218, e.g., broken cut lines passing partially or completely through the material forming the frame 218. Furthermore, the frame 218 can be constructed from any of the materials described herein with respect to the substantially rigid member 10. For example, the frame 218 can be formed from a single wall corrugated C-flute cardboard.

The panels of the lateral wall portion 234 can be configured to form a double wall portion when folded. In the illustrated embodiment, when the lateral wall portion 234 is folded upwardly and inwardly toward the interfacing panel 222, the inner panel 246 forms an inner wall of the assembled frame 218 and the outer panel 244 forms an outer wall. The intermediate panel 248, in between fold lines 250, 252, can form a bottom edge of the lateral wall portion 234.

The lateral wall portion 234 can also include structures for securing the walls in place when folded. As illustrated in FIG. 14, the inner panel 246 can include one or more tabs 254 extending from an edge of the inner panel 246 that is opposite of the fold line 252. As described further herein, the tabs 254 can be received in the apertures 242 when the frame 218 is in the assembled configuration. Accordingly, the number, size, and position of the tabs 254 can be adjusted based on the number, size, and position of the apertures 242. Those skilled in the art can appreciate that the tabs 254 and the apertures 242 can cooperate to maintain the frame 218 in the assembled configuration wherein the interfacing panel 222 extends generally horizontally and the wall portions assemble into four walls extending generally vertically.

Those skilled in the art can appreciate that the width 256 of the outer panel 244 can generally define the height of the assembled frame 218. In some embodiments, the inner panel 246 can have a width (not including the tabs 254) that is generally equal to the width 256 of the outer panel 244.

For brevity, the construction of the end wall portion 238 will be described. However, it is to be understood that the end wall portion 240 also can include the same features. The end wall portion 238 can include a single wall portion 260. The single wall panel 260 can be pivotably connected to the interfacing panel 222 along the fold line 224. The end wall portion 238 can also include corner flaps 262, 264 connected to the single wall panel 260 along fold lines 266, 268. The single wall panel 260 can have a width 270 that is generally the same as the width of the outer panel 244. When in the assembled configuration, the widths of the single wall panels and the widths of the outer panels can define the height of the frame 218.

The removable retention member 216 can also include a second resilient member 272, illustrated in FIG. 15. The second resilient member 272 can include many of the same features as the resilient member 128. The second resilient member 272 can include a resilient body 274. For purposes of convenience for the following description, the resilient body 274 is identified as having a midpoint M₂ positioned in the vicinity of the middle of the resilient body 274. In some embodiments, the second resilient member 272 can also include first and second pockets 276, 278 at opposite ends thereof. As described herein, the second resilient member 272 can be configured to couple with the frame 218. Accordingly, the pockets 276, 278 can be configured to receive at least a portion of each of the lateral wall portions 234, 236. In other embodiments, the second resilient member 272 does not include pockets. For example, the second resilient member 272 can be a single-layer, planar piece of film having resilient properties. In the illustrated embodiment, the second resilient member 272 is formed of a single piece of resilient material, and is sized to cooperate with the lateral wall portions 234, 236 of the frame 218.

In the illustrated embodiment, the pockets 276, 276 are formed of folds 280, 282 formed in the resilient body 274 which have been attached (e.g., heat sealed) along lateral opposite edges thereof. In this embodiment, the heat sealing process forms heat sealing lines 284, 286, 288, 290. The heat sealing lines 284, 286, 288, 290 can be continuous or formed of a plurality of heat sealed points.

Those skilled in the art can appreciate that there are numerous methods for forming pockets in a resilient sheet material such as the resilient body 274. However, it has been found that heat sealing is particularly advantageous as it does not require expensive adhesives and the time-consuming steps required for using such adhesives. Regardless, such adhesives can be used if desired.

The second resilient member 272 has a length L₂ that is sized depending on the other devices with which the second resilient member 272 is to cooperate. Thus, the length L₂ can be sized such that when the second resilient member 272 is engaged with the lateral wall portions 234, 236, it generates the desired tension for the corresponding application. In some embodiments, the length L₂ can be less than the length of the frame 218, where the length of the frame 218 is measured as the distance from tab edge 292 to tab edge 294. For example, the length L₂ can be about 18 inches and the length of the frame 218 can be about 19 inches. In these embodiments, because the length L₂ of the second resilient member 272 is less than the length of the frame 218, the second resilient member 272 experiences tension when it is coupled with the frame 218. Thus, the length L₂ will be smaller where a higher tension is desired and will be larger where a lower tension is desired. Additionally, the length L₂ might be different for different sized articles that are to be packaged. Those skilled in the art can determine the length L₂ for the desired application.

As illustrated in FIG. 15, the second resilient member 272 also has a width W that is sized depending on the other devices with which the second resilient member 272 is to cooperate (e.g., the frame 218). In some embodiments, the second resilient member 272 is configured to completely cover the window 232 of the frame 218. Accordingly, the second resilient member 272 can have a width W that is at least equal to the width of the window 232, where the width of the window 232 is measured generally as the shortest distance from the edge adjacent to fold line 224 to the edge adjacent to fold line 228. In some embodiments, the width W of the second resilient member 272 can be generally equal to the width of the interfacing panel 222, wherein the width of the interfacing panel is defined as the shortest distance from fold line 224 to fold line 228.

The second resilient member 272 can be formed of any of the materials disclosed herein as being suitable for the resilient member 128. In some embodiments, the second resilient member 272 can be made of a polymeric film, such as a polyethylene film.

The second resilient member 272 can be configured to couple with the lateral wall portions 234, 236 of the frame 218. As described herein, the coupling of the second resilient member 272 with the frame 218 can occur via a variety of mechanisms, including but not limited to inserting at least a portion of each of the inner panels 246, 296 into the pockets 276, 278.

As illustrated in FIG. 15, in the assembled configuration, the single wall panels 260, 298 can be folded towards the interfacing panel 222 along fold lines 224, 228, respectively, such that the end wall portions 238, 240 are generally perpendicular to the interfacing panel 222. Additionally, the corner flaps 262, 264, 300, 302 can be folded toward the base along fold lines 266, 268, 304, 306 such that the corner flaps 262, 264, 300, 302 are generally perpendicular to the interfacing panel 222 and the single wall panels 260, 298. In this configuration, the corner flaps 262, 264, 300, 302 can also be generally parallel to fold lines 226, 230. In some embodiments, the corner flaps 262, 264, 300, 302 can be generally parallel but also offset (e.g., just inside) from the fold lines 226, 230, so as to not interfere with the folding of the outer panels 244, 308.

Either before or after this step, the second resilient member 272 can be coupled with the frame 218. At least a portion of each of the inner panels 246, 296 can be at least partially or fully placed into the pockets 276, 278 of the second resilient member 272. The resilient member 272 can contact an outer surface of the interfacing panel 222 (e.g., the surface opposite the inner surface 310 illustrated in FIG. 14.

After the single wall panels 260, 298 have been folded upwards and the corner flaps 262, 264, 300, 302 have been folded inwards, the lateral wall portions 234, 236 can be folded over the corner flaps 262, 264, 300, 302. The tabs 254 can also be secured in the apertures 242. As such, for example, the corner flap 300 can be sandwiched between the outer panel 244 and the inner panel 246. In some embodiments, the corner flaps 262, 264, 300, 302 can include a notch similar to the notch 68, 70 described with respect to corner flaps 56, 58, above.

As illustrated in FIG. 16, when in the assembled configuration, the second resilient member 272 stretches taut across the outer surface of the interfacing panel 222 (and also across the outer surface of the outer panels 244, 296) to cover the window 232. Accordingly, the second resilient member 272 is generally planar and exhibits tension across the window 232.

A cross sectional view of an assembled packaging kit that includes a substantially rigid member 10 coupled to a first resilient member 128 and a removable retention member 216 coupled to a second resilient member 272 is illustrated in FIG. 17.

In use, the assembled removable retention member 216 is placed into the cavity 126 of the container portion 12 of any of the substantially rigid members 10 described herein, such as that illustrated in FIG. 17. The assembled removable retention member 216 is oriented such that the second resilient member 272 comprises a top surface for contacting article 148, with a cavity 314 below. The intermediate panels 248, 312 comprise a bottom surface that contacts the bottom (e.g., the base 16) of the container portion 12. An article 148 can be placed on the second resilient member 272. The downward force of the article 148 is counteracted at least in part by the tension exhibited across the second resilient member 272. As illustrated in FIG. 17, the article 148 is distanced from the base 16 of the container portion 12. Advantageously, distancing or spacing the article 148 from any of the outer walls of the container can help to insulate the article 148 from any outside forces. As illustrated in FIG. 17, the article portion 14 can then be moved to a closed configuration similar to that illustrated in FIG. 8 and described in the accompanying description. As illustrated in FIG. 17, the article 148 can be advantageously suspended from both the top and bottom walls of the container. Furthermore, the two resilient members 128, 272 can cooperate to provide a snug fit around the article 148, minimizing shifting or movement of the article 148 within the container, e.g., during transit.

Those skilled in the art will appreciate that in some embodiments, the packaging kits described herein can include a removable retention member 216 instead of one or more support panels 32, 154, or vice versa. In other embodiments, the packaging kit can include a removable retention member 216 and one or more support panels 32, 154.

Although the present inventions have been described in terms of certain embodiments, other embodiments apparent to those of ordinary skill in the art also are within the scope of these inventions. Thus, various changes and modifications can be made without departing from the spirit and scope of the inventions. For instance, various components can be repositioned as desired. Moreover, not all of the features, aspects and advantages are necessarily required to practice the present inventions.

Claims

1. A packaging kit for packaging an article, comprising:

a substantially rigid member comprising: a container portion configured to form a portion of a container capable of containing an article; and a lid portion comprising at least a top panel and two opposing pivotable side portions, the top panel being pivotable relative to the container portion; the lid portion further configured to be movable between an open configuration and a closed configuration, wherein when in the closed configuration, at least a portion of each of the two opposing pivotable side portions is pivoted towards an interior surface of the top panel at an angle of about 90 degrees relative to the interior surface; and

a pliable film configured to couple with the opposing pivotable side portions, wherein when the pliable film is coupled with the opposing pivotable side portions and the lid portion is in the closed configuration, each of the opposing pivotable side portions space the pliable film from the top panel.

2. The packaging kit of claim 1, wherein the container portion comprises at least a bottom panel having four edges, opposing side wall portions pivotably extending from two of the edges, and opposing end wall portions pivotably extending from the other two edges.

3. A packaging kit for packaging an article, comprising:

a substantially rigid member comprising: a container portion configured to form a portion of a container capable of containing an article; and an article portion comprising at least a base and first and second pivotable side portions, the base being pivotable relative to the container portion; the article portion further configured to be movable between an open configuration and a closed configuration, wherein in the closed configuration at least a portion of each of the first and second pivotable side portions is pivoted towards an interior surface of the base of the article portion; and

a resilient member configured to couple with the first and second pivotable side portions, wherein when the resilient member is coupled with the first and second pivotable side portions and the article portion is in the closed configuration, each of the first and second pivotable side portions space the resilient member from the base of the article portion.

4. The packaging kit of claim 3, wherein the substantially rigid member further comprises a securing portion having an end wall and two opposing flaps, the end wall pivotable relative to the article portion and configured to contact an outer surface of another of the opposing end wall portions.

5. The packaging kit of claim 3, wherein the resilient member comprises a body portion and first and second pockets disposed at opposite ends of the body portion, and wherein each of the first and second pockets are configured to receive at least a portion of each of the first and second pivotable side portions.

6. The packaging kit of claim 3, wherein the first and second pivotable side portions each comprise an outer panel configured to couple with the resilient member.

7. The packaging kit of claim 6, wherein a securing flap disposed within a body portion of the outer panel, the securing flap configured to couple with the resilient member and having a free portion that is configured to reversibly couple with the outer panel.

8. The packaging kit of claim 7, wherein the securing flap comprises a corner that is configured to reversibly couple with the outer panel in a friction fit.

9. The packaging kit of claim 3, wherein the resilient member is configured to be attached to at least a portion of each of the first and second pivotable side portions.

10. The packaging kit of claim 3, wherein the resilient member and the article portion each have a length extending in generally the same direction, the length of the resilient member being less than the length of the article portion.

11. The packaging kit of claim 3, wherein the first and second pivotable side portions each comprise three panels, and wherein each panel is pivotably connected to at least one other panel.

12. The packaging kit of claim 2, wherein the pivotable side portions each comprise a first panel pivotably connected to the base of the article portion, and wherein when the article portion is moved to the closed configuration, each of the first panels space the resilient member from the base of the article portion at least by a distance defined by a width of each of the first panels.

13. The packaging kit of claim 12, wherein the first panels each have a width, the width of each first panel being less than a height of each of the inner and outer panels of the opposing lateral wall portions.

14. The packaging kit of claim 3, further comprising a removable retention member configured to fit within the container portion, the removable retention member comprising a frame and a second resilient member configured to couple with the frame.

15. A packaging kit for packaging an article, comprising:

a substantially rigid member comprising: a container portion configured to form a portion of a container capable of containing an article, the container portion comprising at least a base and a support panel pivotable relative to the base and configured to resist a force applied by the article; and an article portion comprising at least a base and first and second pivotable side portions, the base being pivotable relative to the container portion; the article portion further configured to be movable between an open configuration and a closed configuration, wherein when in the closed configuration at least a portion of each of the first and second pivotable side portions is pivoted towards an interior surface of the base of the article portion; and

a resilient member configured to couple with the first and second pivotable side portions, wherein when the resilient member is coupled with the first and second pivotable side portions and the article portion is in the closed configuration, each of the first and second pivotable side portions space the resilient member from the base of the article portion.

16. The packaging kit of claim 15, wherein the support panel further comprises a pivotable flap.

17. The packaging kit of claim 15, wherein:

the container portion comprises the base, opposing lateral wall portions, and opposing end wall portions, wherein at least one opposing lateral wall portion comprises an outer panel, an inner panel, and the support panel; and

the inner panel is connected to the support panel at a first fold line and the outer panel is connected to the base at a second fold line, the first and second fold lines when folded creating first and second creases; and

the first crease is configured to nest in the second crease.

18. The packaging kit of claim 15, wherein the substantially rigid member comprises a single piece of corrugated cardboard.

19. The packaging kit of claim 17, wherein the first and second pivotable side portions each comprise an outer panel, the outer panels of the article portion having a width that is less than a height of each of the opposing end wall portions of the container portion.

20. The packaging kit of claim 15, wherein the resilient member comprises a body portion and first and second pockets disposed at opposite ends of the body portion, and wherein each of the first and second pockets are configured to receive at least a portion of each of the first and second pivotable side portions.

21. The substantially rigid member of claim 15, wherein when the pivotable flap is pivoted towards the base, an edge of the pivotable flap is in an interference fit with the second crease.

22. The substantially rigid member of claim 15, wherein the pivotable flap comprises a latch mechanism configured to retain the pivotable flap in a pivoted position.

23. A substantially rigid member configured to form a container capable of containing an article, the substantially rigid member comprising a container portion, the container portion comprising at least a base and a support panel, the support panel pivotable relative to the base and configured to resist a force applied by the article.

24. The substantially rigid member of claim 23, wherein the support panel comprises a pivotable flap.

25. The substantially rigid member of claim 24, wherein the container portion further comprises opposing lateral wall portions extending from a periphery of the base, and opposing end wall portions extending from the periphery of the base.

26. The substantially rigid member of claim 25, wherein each opposing lateral wall portion comprises an outer panel, an inner panel, and the support panel, the inner panel and the support panel connected at a first crease that is configured to nest in a second crease dividing the base from the lateral wall portion.

27. The substantially rigid member of claim 24, wherein the pivotable flap is located at an outer edge of the support panel.

28. The substantially rigid member of claim 24, wherein the pivotable flap is located in a body portion of the support panel.

29. The substantially rigid member of claim 24, wherein when the pivotable flap is pivoted towards the base, an edge of the pivotable flap is in an interference fit with the second crease.

30. The substantially rigid member of claim 24, wherein the pivotable flap comprises a latch mechanism configured to retain the pivotable flap in a pivoted position.

31. The substantially rigid member of claim 30, wherein the latch mechanism comprises a tab and an aperture, the aperture configured to retain the tab in a friction fit.

32. The substantially rigid member of claim 23, further comprising an article portion and a securing portion.