Suspension Packaging System

A retention package is formed from a tray member containing a retention member which includes a stiff board and a flexible, stretchable film attached to end panels of the stiff board. The end panels are folded under thus pulling the film taut for retaining an object between the film and the stiff board. The stiff board has two vertical walls that abut the interior of two walls of the tray member. An end cap is placed over the tray member thereby forming an enclosed retention package. The end cap is provided with kick plate means for holding the two vertical walls against the interior of two walls of the tray member.

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Description

This patent application is a continuation in part of U.S. patent application Ser. No. 12/570,755, filed Sep. 30, 2009, which application claims the benefit of provisional patent application 61/194,663, filed Sep. 30, 2008, and having the title “Suspension Packaging”, the disclosures of which are incorporated herein by reference, as though recited in full.

BACKGROUND

1. Field of Invention

The present invention relates generally to a collapsible shipping container utilizing standard box making equipment manufactured from material such as paper, corrugated board, and corrugated plastic, and in particular, to a package that employs a tensioned film system, that retains a product between a film layer and a wall of the package.

2. Brief Description of Prior Art

The prior art includes numerous variations of boxes that employ a stretch film to hold a product within the box. However, there is still a need to design a box that provides the combination of low cost, ease of manufacture, ease of transport to an end user, ease of use from the end user's standpoint, and which provides a required level of cushioning.

SUMMARY

The present invention relates to a container formed from a pair of end caps or trays and having an internal object retention member. In accordance with a first broad aspect of the invention, a packaging structure for holding an object securely against a rigid backing includes a retention member, a flexible film material, a tray member, and an end cap member. The retention member has a substantially rigid panel with a pair of longitudinal folding side panels and a pair of latitudinal folding side panels separated from a base panel by fold lines. The base panel has an upper side and a lower side. The longitudinal folding side panels are folded to a position where the longitudinal folding side panels are under and parallel to the base panel, and the latitudinal side panels are vertical relative to a horizontal orientation of the base panel. The tray member has two latitudinal vertical side panels, two longitudinal vertical side panels, and a tray base panel. The film extends across the pair of longitudinal folding side panels and the upper side of the base panel and is and fixed at each of two opposing ends to one of the pair of longitudinal folding side panels. Means is provided for securing the flexible film to the pair of longitudinal folding side panels. the retention member is positioned within the tray member, and the tray member is positioned within the end cap member. The end cap member has two longitudinal vertical end cap side panels, two latitudinal vertical end cap side panels, and an end cap base panel.

In accordance with another embodiment of the invention the end cap member has kick plate means that has peripheral dimensions to form at least a pair of parallel channels. The channels are dimensioned to receive and retain the retention member latitudinal side panels.

In accordance with a further embodiment of the invention, the end cap member has kick plate means which has peripheral dimensions to form two pairs of parallel channels. One pair of the channels is dimensioned to receive and retain at least the retention member latitudinal side panels and the other pair of the channels is dimensioned to receive and retain the tray member longitudinal vertical side panels.

In accordance with an additional embodiment of the invention, the end cap member has kick plate means which has peripheral dimensions to form two pairs of parallel channels. One pair of the channels is dimensioned to receive and retain at least the retention member latitudinal side panels and the tray member latitudinal vertical side panels, and the other pair of the channels is dimensioned to receive and retain the tray member longitudinal vertical side panels.

In accordance with still another embodiment of the invention, the end cap has two vertical side panels, each two each of which includes a first vertical section and a second vertical section. The first vertical section is contiguous with the end cap base panel, and the second vertical section is contiguous with the first vertical section. The second vertical section is folded to a position overlying and interior of the first vertical section. The end caps vertical sections further includes a first horizontal section and a second horizontal section. The first horizontal section is contiguous with the second vertical section and overlies the end cap base panel. The second horizontal section is folded to a position overlying the first horizontal section and has a peripheral edge substantially parallel to the second vertical section and spaced there from to form one channel of at least one pair of parallel channels. Each of the at least one pair of parallel channels is dimensioned to receive and retain one of the retention member latitudinal side panels.

In accordance with still another embodiment of the invention, the end cap has two vertical side panels, each two each of which includes a first vertical section and a second vertical section. The first vertical section is contiguous with the end cap base panel, and the second vertical section is contiguous with the first vertical section. The second vertical section is folded to a position overlying and interior of the first vertical section. The end caps vertical sections further includes a first horizontal section and a second horizontal section. The first horizontal section is contiguous with the second vertical section and overlies the end cap base panel. The second horizontal section is folded to a position overlying the first horizontal section and has a peripheral edge substantially parallel to the second vertical section and spaced there from to form one channel of at least one pair of parallel channels. Each of the at least one pair of parallel channels is dimensioned to receive and retain one of the retention member latitudinal side panels and a tray member latitudinal side panel.

In accordance with a further embodiment of the invention, each of the second horizontal sections has a pair of peripheral edges substantially parallel to two of the end cap vertical end cap side panels and spaced there from to form longitudinal channels between the of the second horizontal section's peripheral edges and an end cap member longitudinal side panel, and each of the longitudinal channels is dimensioned to receive and retain one of the tray member longitudinal side panels.

In accordance with a further embodiment of the invention, a method is provided for assembling and filling a package and retaining an object securely against a rigid backing within the package. The package includes a retention member that has a substantially rigid panel with a pair of longitudinal folding side panels and a pair of latitudinal folding side panels separated from a base panel by fold lines. The base panel has an upper side and a lower side, and a flexible film material extends across the pair of longitudinal folding side panels and the upper side of the base panel and is fixed at each of two ends to one of the pair of longitudinal folding side panels. The package further includes a tray member that has two latitudinal vertical side panels, two longitudinal vertical side panels, and a tray base panel. The package further includes an end cap member that has two longitudinal vertical end cap side panels, two latitudinal vertical end cap side panels, and an end cap base panel. The steps of the method include inserting an object between the flexible film and the retention member base panel, folding the pair of longitudinal folding side panels to a position where the the longitudinal folding side panels are under and parallel to the base panel, the base panel and the longitudinal folding side panels, folding the latitudinal side panels vertically relative to a horizontal orientation of the base panel, positioning the retention member within the tray member, and positioning the tray member within the end cap member.

In accordance with an additional embodiment of the invention, the package end cap member has kick plate means that have peripheral dimensions to form at least a pair of parallel channels. The channels are dimensioned to receive and retain the retention member latitudinal side panels, comprising the step of positioning the tray within the end cap with the retention member latitudinal side panels in the channels.

In accordance with another embodiment of the invention, each of the at least one pair of parallel channels is dimensioned to receive and retain one of the retention member latitudinal side panels and a tray member latitudinal side panel and the method further includes positioning one of the retention member latitudinal side panels and a tray member latitudinal side panel in a channel.

In accordance with another embodiment of the invention, each of the second horizontal sections has a pair of peripheral edges substantially parallel to two of the end cap vertical end cap side panels and spaced there from to form longitudinal channels between the of the second horizontal section's peripheral edges and an end cap member longitudinal side panel, and each of the longitudinal channels is dimensioned to receive and retain one of the tray member longitudinal side panels. The method further includes the step of positioning one of the tray member longitudinal side panels in each of the longitudinal channels.

In accordance with an additional embodiment of the invention the packaging structure further comprises each two of the end cap vertical end cap side panels having a first vertical section and a second vertical section. The first vertical section is contiguous with the end cap base panel, and the second vertical section is contiguous with the first vertical section. The structure further includes a first horizontal section and a second horizontal section, wherein the first horizontal section is contiguous with the second vertical section. The method further includes the steps of folding the first horizontal section to a position overlying the end cap base panel, folding the second vertical section to a position overlying and interior of the first vertical section; folding the second horizontal section to a position overlying the first horizontal section such that it has a peripheral edge substantially parallel to the second vertical section and spaced there from to form one channel of the at least one pairs of parallel channels. Each of the at least one pair of parallel channels is dimensioned to receive and retain one of the retention member latitudinal side panels.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be described with the accompanying drawings, in which:

FIG. 1 is an isometric view of an interior support for a retention pack.

FIG. 2 is an isometric view of the retention pack support member, with two walls folded vertically, and two walls being rotated toward a position underlying a center panel of the support member.

FIG. 3 is a cross section of the retention pack with two opposing walls completely folded under into an abutting relationship with the center panel and an object secured between the film and the center panel.

FIG. 4 is a plan view of the blank used for the formation of the two channel kick plate.

FIG. 5 is a cross sectional side view of the folded kick plate of FIG. 4.

FIG. 6 is a cross section of the retention pack of FIG. 3 with the retention pack in a tray and the tray inserted into an end cap having a kick plate structure for retaining vertical walls of the support member.

FIG. 7 a cross-sectional plan view of the retention pack within a tray.

FIG. 8 is a cross-sectional plan view of an end cap with a fold over kick plate panel corresponding to the kick plate of FIG. 4 and FIG. 5.

FIG. 9 is a top cross-sectional plan view of alternate embodiment of an end cap with a panel type of kick plate fixed to the inner side of the end cap.

FIG. 10 is a plan view of an end cap/kick plate structure that provides four channels.

FIG. 11 is an isometric view of the end cap of FIG. 10, shown partly assembled.

 DETAILED DESCRIPTION Definitions

It is advantageous to define several terms before describing the invention. It should be appreciated that the following definitions are used throughout this application. Where the definition of terms departs from the commonly used meaning of the term, applicant intends to utilize the definitions provided below, unless specifically indicated.

For the purposes of the present invention, the term “box” refers to an enclosure of any size and shape formed from a single or multiple bonded corrugated sheet that has the appropriate score lines, as well known in the art. The terms package and container are used herein interchangeable with the term “box”.

For the purposes of the present invention, the term “clearance space” as used herein, refers to the space between flap side edges and an adjacent side wall, when the box is in its erected configuration.

For the purposes of the present invention, the term “kick plate” as used herein refers to a structure that butts up against a side wall member and prevents the side wall member from moving inward.

For the purposes of the present invention, the term “end cap” as used herein refers to a tray structure that includes a planar base and four side walls contiguous with, and at a right angle to the planar base.

For the purposes of the present invention, “longitudinal” and “latitudinal” are used to refer to two series of sides of a square or rectangle. Longitudinal refers to one set of parallel sides, while latitudinal refers to the other set of parallel sides. Longitudinal and latitudinal sides may be switched.

For the purposes of the present invention, “vertical” and “horizontal” as used herein refer to a spatial configuration in which the center panel of the support member, and the base of the tray into which the support member is inserted, are horizontal. The terms are used to signify relative positions of various components, rather than a spatial position relative to the earth, the floor of a building, etc. The vertical walls 411 and 421 of the end cap 400 form side walls of the end cap.

For the purposes of the present invention, the terms “corrugated paper”, “corrugated plastic”, and the term “corrugated board” are used interchangeably, and are inclusive of single, double and triple wall corrugated materials for shipping boxes, as well known in the art.

For the purposes of the present invention, the term “double wall” refers to a corrugated material that has two corrugated layers separated by a flat sheet and having two outer flat sheets. Containers of the present invention preferably are formed, at least in part, from double wall corrugated.

For the purposes of the present invention, the term “fold line” as used herein refers to a juncture between two adjacent panels about which the panels are folded. Fold lines are typically formed by crushing or otherwise scoring the corrugated board, as well known in the art.

For the purposes of the present invention, the term “narrower” as used herein refers to a dimension of a first panel that is less than the dimension of another panel, where both panels are measured in the same direction.

For the purposes of the present invention, the term “score lines” may also be referred to as “fold lines” or “crush lines”. Forming fold lines in blanks from which boxes are made is well known in the art, and any desired one of the well known techniques can be used.

For the purposes of the present invention, the term “score” refers to the manufacturing method that linearly crushes the corrugated sheet to enable a fold line to be formed, as well known in the art.

For the purposes of the present invention, the terms “side panels” the side wall panels of a rectangular box, as for example, 111, 113, 413, and 415 of FIGS. 1, 2 and 5. In the case of a square box, two opposing sidewalls of the four sidewalls are referred to as end panels and the other two opposing side walls are referred to as side panels.

The terms “end panels” and “side panels” are terms of convenience and are used to identify a first pair of opposing side walls and a second pair of opposing side walls. For the purposes of the present invention, the term “flap” and/or “flaps” may be used when referring to end panels.

For the purpose of the present invention, the term “retention” refers to the combination of a film structure that attaches to a paneled member for securing objects during shipping. The term “retention pack” is used interchangeably with “support member”, to indicate a retention structure that holds an object in place within a package and supports the object within the package.

For the purpose of the present invention, the term “pouch” refers to a film structure that in combination with a support panel encloses and forms a region for retaining an object, as seen for example, in FIGS. 3 and 4 in side view and in FIG. 5 in a top view.

For the purpose of the present invention, the term “film”, refers to structure that can be an anti-static/static dissipating material, and is preferably a material that will hold a product under tension when stretched. The material tends to return to its un-stretched form rather than to deform or elongated to a longer dimension, and thus, will hold a product firmly, and under tension. The product is accordingly not free to move, or rattle around in the box. The film is resilient and returns to its original shape when after being subjected to a vibration or jarring action. The film thus cushions and cradles the object being transported. The method in which films are joined to the walls of the box can include, by way of example, welding, heat activated adhesives, co-adhesives, pressure sensitive tapes, and hot melt glues. Epoxies and silicone adhesive can be used. Pressure sensitive tapes for the pouch structure are provided with a release film which is removed when the pouch is to be sealed closed.

For the purpose of the present invention, the terms “fixing” and “securing”, refers to the attaching of a panel of one blank to a panel of another blank, or the attaching of a retaining or support member such 100 to a tray, or attaching a film to a panel. Means for attaching of two members together can by any of the well known means, such as adhesives, including for example, a hot melt glue, heat activated adhesives, co-adhesives, or pressure sensitive adhesives, and by other known means such as staples, adhesive tapes and the like.

The term “substantially” as referred to herein indicates a near, close to relationship, not significantly departing from a particular quality. For example, while 50% would not be substantially 100%, but a value that provides the desired result though not exactly equal to the ideal or optimum value, would be considered to be substantially the exact, ideal, or optimum value. A substantially vertical article could depart from the perpendicular relationship with a horizontal plane, but would not depart to the extent that it begins to lose its stability or requires an external support to be self supporting.

Description

There are multiple advantages to the suspension packaging system of the present invention. The product provides exceptional cushioning and vibration protection while greatly reducing warehouse space by eliminating the need for inner cushioning materials which in turn saves labor, and reduces material and storage costs.

The support film of the present invention is preferably a plastic that stretches up to about 40% with high load retention, that is, without distorting or deforming, or exceeding its yield point. The films can be any that meet the criteria set forth herein, including but not limited to anti-static/static dissipative films.

The film advantageous to most embodiments is a transparent urethane approximately 3 mils thick. The urethane film's unique properties of stretch ability and memory enable the film to return to its original dimensions. This enables the film to absorb repeated shock and vibration encountered during handling and shipping.

The packaging structure according to the present invention includes a substantially rigid panel 100, as shown in FIG. 1. The panel 100 may be formed of any substantially stiff but foldable material such as paperboard, cardboard, or plastic. It will be appreciated that, although denominated as rigid, the chosen material preferably can have a certain amount of flexibility in the cases of extreme physical impact and that the use of very rigid materials, such as metals, would only be desirable in a few applications. One preferred material is a single wall corrugated cardboard such as B-flute or E-flute corrugated cardboard. Another preferred material is double wall corrugated.

The substantially rigid panel 100 includes fold lines 101, usually scored, crimped or perforated, which are generally parallel the side edges of the panel. These fold lines 101 thus define longitudinal folding side panels 113, latitudinal folding side panels 111 and a center panel 121.

A flexible film material 131 is superimposed on the surface of the rigid panel 100, and extends over the longitudinal folding side panels 113 and center panel 121. This flexible film material 131 is preferably a transparent and elastomeric polymer such as PVC (polyvinyl chloride) or polyurethane ester.

The flexible film 131 is secured to the longitudinal folding side panels 113, preferably on the underside of the side panels 113, by means of an adhesive, staples or the like, as well known in the art. The flexible film 131 remains unsecured to the base or center panel 121, enabling the object 301 (FIG. 3) to be packaged to be inserted between the film 131 and the center panel 121. Once the object 301 is inserted between the film 131 and the center panel 121, the longitudinal folding side panels 113 are bent downwardly to be parallel with the center panel 121. The latitudinal folding side panels 111 are positioned upwardly perpendicular at a 90 degree angle to the center panel 121 towards the object 301. For convenience, the side panels are referred to as being vertical.

When the longitudinal folding side panels 113 are folded adjacent to the underside of the center panel 121, as illustrated in FIG. 3 they pull against those portions of the flexible film 131 that extend past the fold lines 101. This causes the film to stretch slightly towards the longitudinal folding side panels 113, increasing the film's tension and grip on the object 301. This feature thus provides improved retention of the packaged object 301 against the base panel 121.

To prevent the latitudinal folding side panels 111 from collapsing inward toward the center panel 121 and to provide structural reinforcement, the retention pack 140 is mated with an end cap 400, having a kick plate type of structure 418 as illustrated in FIGS. 4 and 5. The end cap and its integral kick plate structure 418 is formed from corrugated that has been scored and folded to create channels 431 as seen in FIGS. 5 and 6, between the kick plate structure 418 and the tray side wall 415 to receive the latitudinal flaps 111. It should be noted that as the two ends are mirror images, only one will be described in detail.

The blank for the kick plate 400 is illustrated in FIG. 4 shows the center panel 401 that has a periphery slightly greater than that of the exterior periphery of the tray 410 (FIG. 6), and the folds of the latitudinal portion 420 of the kick plate structure 418. As seen in FIG. 5, the latitudinal portion 420 is folded at fold line 428 to place the interior base wall 427 adjacent to the channel panel 429. As the channel panel 429 is shorter than the interior base wall 427, a channel 431 is formed between the end of the interior base wall 429 and the interior vertical support 425. The interior vertical support 425 is adjacent to the exterior vertical support 421 by way of fold 423. The dimensions of channels 431 must be such that they can receive the latitudinal folding side panels 111 of the retention member 140 and optionally, the longitudinal side walls 413 of the tray 410 without damaging friction or excessive movement while bracing the latitudinal folding side panels 111 and tray side walls 413.

The folded retention pack 140 of FIG. 3 is placed within a tray 410, as illustrated in FIG. 6. The tray 410 is an open structure having two tray side walls 413, two tray side walls 415, a base 411 and a interior periphery dimensioned to receive the folded retention pack 140.The retention pack 140 is positioned so that the longitudinal folding side panels 113 which are folded in the downward position rest against the base 401 of the retention pack and against the base panel 417 of the tray 410. The latitudinal folding side panels 111 are in a parallel plane with and abuts against the latitudinal tray walls 413. Both can be of approximately the same height, or preferably, the side panels 111 can extend slightly above the side panels 413, as shown in FIG. 6

In a preferred embodiment, the retention pack 140 is used with the two channel end cap 400. The latitudinal folding side panels 111 and latitudinal tray walls 413 mate with the kick plate channel 431 such that the latitudinal folding side panels 111 and latitudinal tray walls 413 are between the outer kick plate wall 429 and the inner base wall 425. The inner base wall 429 can have additional layers to create a deeper channel if required to meet a specific application. The latitudinal folding side panels 111 and latitudinal tray walls 413 fit snuggly within the channel 431 between the inner base wall 429 and the inner base wall 425 so that it cannot move, effectively locking the retention pack and tray 410 in place. When using a two channel end cap 400 the longitudinal tray walls 415 are not as tall as the latitudinal folding side panels 111 and latitudinal tray walls 413, so that the longitudinal tray walls 415 do not interfere with the kick plate 400 when mated with the retention pack 140 and tray 410.

The retention pack is illustrated from a top view within the tray 410 in FIG. 7, clearly showing the construction of the tray 410. The latitudinal tray walls 413 are U shaped with the legs 450 of the U shape dimensioned to receive the retention pack 140. The legs 450 are overlain by the longitudinal tray walls 415 which are secured to the legs 450 to form the tray 410. Optionally, the legs or flaps 450 can be exterior of the tray, rather interior of the tray.

In FIG. 8 a top view of an embodiment of an end cap 800 is illustrated from the top. The center plate 801 is illustrated with the kick plate portion 818 folded and secured to the center kick plate section 819 which in turn is secured to center panel 801. This, as illustrated heretofore, forms channels 831 with interior side wall 825 of the tray. In this embodiment the exterior side wall 829 has side flaps 830 that are optionally secured exterior of the longitudinal walls 832.

In an alternative embodiment, the retention pack is used with a four channel end cap 900 is illustrated in FIG. 9. When an end cap 900 with four channels is used, both the longitudinal tray walls 415 and the latitudinal tray walls 413 will be mated. In this embodiment, the longitudinal tray walls 415 are approximately the same height as the latitudinal folding side panels 111 and latitudinal tray walls 413, so that all walls are mated within the channel 902 of the end cap 900. The channel 902 is formed from U shaped outer walls 908 and center kick plate panel 904. The center panel 904 has a depth approximately equal to the kick plate portion 418 as illustrated heretofore and is formed by adhering additional material to the center panel 910 of the end cap 900. In this embodiment, the flutes of the kick plate panel 904 are at a right angle to the flutes of the center or base panel 910.

In another alternative embodiment of a four channel end cap 1000, the retention pack is used with a four channel folded kick plate that includes folding sections 1027 and 1029. When a kick plate with four channels is used, both the longitudinal tray walls 415 and the latitudinal tray walls 413 will be mated. In this embodiment, the longitudinal tray walls 415 can optionally be approximately the same height as the latitudinal folding side panels 111 and latitudinal tray walls 413, so that all walls are mated with the folded kick plate containing end cap 1000. This alternative embodiment is similar to the two channel embodiment illustrated in FIG. 8.

The blank for an alternate end cap 1000 and perspective, partially folded view of the end cap 1000 are illustrated in FIGS. 10 and 11. As can be seen from these views, the base 1001 has longitudinal folding sides 1011 with end flaps 1030. The kick plate is formed from folding 1021 at fold lines 1023, 1025 and 1028 with interior wall 1029 ending adjacent to, but spaced from panel 1024. The formation of the kick plate is as described heretofore with FIG. 4, however in this embodiment the end flaps 1030 are placed on the interior, adjacent to interior panel 1025 rather than on the exterior of the panel as described heretofore. A second pair of channels is formed between the edges of panel 1029 and the side walls 1029. Optionally, the edges of panel 1027 can also be spaced from the side wall 1028 to form a double depth channel, rather than a single layer channel such as channel the channel between the panel 1029 and the side wall 1024.

Although the present invention has been fully described in conjunction with several embodiments thereof with reference to the accompanying drawings, it is to be understood that various changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as described by the appended claims, unless they depart there from.

Broad Scope of the Invention

While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” In this disclosure and during the prosecution of this application, means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects and embodiments), and should not be improperly interpreted as limiting the scope of the application or claims. In this disclosure and during the prosecution of this application, the terminology “embodiment” can be used to describe any aspect, feature, process or step, any combination thereof, and/or any portion thereof, etc. In some examples, various embodiments may include overlapping features. In this disclosure, the following abbreviated terminology may be employed: “e.g.” which means “for example.”

Claims

1- A packaging structure for holding an object securely against a rigid backing, said packaging structure comprising:

a retention member, comprising a substantially rigid panel with a pair of longitudinal folding side panels and a pair of latitudinal folding side panels separated from a base panel by fold lines,
said base panel having an upper side and a lower side,
a flexible film material extending across said pair of longitudinal folding side panels and the upper side of said base panel and fixed at each of two opposing ends to one of said pair of longitudinal folding side panels,
means for securing said flexible film to said pair of longitudinal folding side panels,
said pair of longitudinal folding side panels being folded to a position where the said longitudinal folding side panels are under and parallel to said base panel,
said latitudinal side panels being vertical relative to a horizontal orientation of said base panel,
a tray member, said tray member having two latitudinal vertical side panels, two longitudinal vertical side panels, and a tray base panel,
said retention member being positioned within said tray member,
an end cap member, said end cap member having two longitudinal vertical end cap side panels, two latitudinal vertical end cap side panels, and an end cap base panel,
said tray member being positioned within said end cap member.

2- The packaging structure of claim 1, further comprising said end cap member having kick plate means, said kick plate means having peripheral dimensions to form at least a pair of parallel channels, said channels being dimensioned to receive and retain said retention member latitudinal side panels.

3- The packaging structure of claim 1, further comprising said end cap member having kick plate means, said kick plate means having peripheral dimensions to form two pairs of parallel channels, one pair of said channels being dimensioned to receive and retain at least said retention member latitudinal side panels and the other pair of said channels being dimensioned to receive and retain said tray member longitudinal vertical side panels.

4- The packaging structure of claim 1, further comprising said end cap member having kick plate means, said kick plate means having peripheral dimensions to form two pairs of parallel channels, one pair of said channels being dimensioned to receive and retain at least said retention member latitudinal side panels and said tray member latitudinal vertical side panels, and the other pair of said channels being dimensioned to receive and retain said tray member longitudinal vertical side panels.

5- The packaging structure of claim 1, further comprising,

each of said end cap latitudinal vertical end cap side panels comprising a first vertical section and a second vertical section,
said first vertical section being contiguous with said end cap base panel, and
said second vertical section being contiguous with said first vertical section,
said second vertical section being folded to a position overlying and interior of said first vertical section,
a first horizontal section and a second horizontal section,
said first horizontal section being contiguous with said second vertical section and overlying said end cap base panel,
said second horizontal section being folded to a position overlying said first horizontal section and having a peripheral edge substantially parallel to said second vertical section and spaced there from to form one channel of said at least one pair of parallel channels,
each of said at least one pair of parallel channels being dimensioned to receive and retain one of said retention member latitudinal side panels.

6- The packaging structure of claim 5, each of said at least one pair of parallel channels being dimensioned to receive and retain one of said retention member latitudinal side panels and a tray member latitudinal side panel.

7- The packaging structure of claim 4, further comprising, each of said second horizontal sections having a pair of peripheral edges substantially parallel to two of said end cap vertical end cap side panels and spaced there from to form longitudinal channels between said of said second horizontal section's peripheral edges and an end cap member longitudinal side panel, each of said longitudinal channels being dimensioned to receive and retain one of said tray member longitudinal side panels.

8- The method of assembling and filling a package and retaining an object securely against a rigid backing within the package, the package comprising:

a retention member having a substantially rigid panel with a pair of longitudinal folding side panels and a pair of latitudinal folding side panels separated from a base panel by fold lines,
said base panel having an upper side and a lower side,
a flexible film material extending across said pair of longitudinal folding side panels and the upper side of said base panel and fixed at each of two ends to one of said pair of longitudinal folding side panels,
a tray member, said tray member having two latitudinal vertical side panels, two longitudinal vertical side panels, and a tray base panel, and
an end cap member, said end cap member having two longitudinal vertical end cap side panels, two latitudinal vertical end cap side panels, and an end cap base panel,
comprising the steps of:
inserting an object between said flexible film and said retention member base panel,
folding said pair of longitudinal folding side panels to a position where the said longitudinal folding side panels are under and parallel to said base panel, said base panel and said longitudinal folding side panels,
folding said latitudinal side panels vertically relative to a horizontal orientation of said base panel,
positioning said retention member within said tray member,
and positioning said tray member within said end cap member.

9- The method of claim 8, wherein said package end cap member has kick plate means, said kick plate means having peripheral dimensions to form at least a pair of parallel channels, said channels being dimensioned to receive and retain said retention member latitudinal side panels, comprising the step of positioning said tray within said end cap with said retention member latitudinal side panels in said channels.

10- The of method of claim 8, wherein said package end cap member has kick plate means, said kick plate means having peripheral dimensions to form two pairs of parallel channels, one pair of said channels being dimensioned to receive and retain at least said retention member latitudinal side panels and the other pair of said channels being dimensioned to receive and retain said, and comprising the steps of positioning said tray within said end cap with said retention member latitudinal side panels in said one pair channels and positioning said tray member longitudinal vertical side panels in said other pair of said channels.

11- The of method of claim 8, wherein said package end cap member has kick plate means, said kick plate means having peripheral dimensions to form two pairs of parallel channels, one pair of said channels being dimensioned to receive and retain at least said retention member latitudinal side panels and the other pair of said channels being dimensioned to receive and retain said, and comprising the steps of positioning said tray within said end cap with said retention member latitudinal side panels and said tray member latitudinal vertical side panels in said one pair channels and positioning said tray member longitudinal vertical side panels in said other pair of said channels.

12- The method of claim 8, the packaging structure further comprising,

each two of said end cap vertical end cap side panels comprising a first vertical section and a second vertical section,
said first vertical section being contiguous with said end cap base panel, and
said second vertical section being contiguous with said first vertical section,
a first horizontal section and a second horizontal section,
said first horizontal section being contiguous with said second vertical section
folding said first horizontal section to a position overlying said end cap base panel,
folding said second vertical section to a position overlying and interior of said first vertical section,
folding said second horizontal section to a position overlying said first horizontal section and having a peripheral edge substantially parallel to said second vertical section and spaced there from to form one channel of at least one pair of parallel channels,
each of said at least one pair of parallel channels being dimensioned to receive and retain one of said retention member latitudinal side panels.

13- The method of claim 12, further comprising each of said at least two pairs of parallel channels being dimensioned to receive and retain one of said retention member latitudinal side panels and a tray member latitudinal side panel and comprising the step of positioning one of said retention member latitudinal side panels and a tray member latitudinal side panel in a channel.

14- The method of claim 12, each of said second horizontal sections having a pair of peripheral edges substantially parallel to two of said end cap vertical end cap side panels and spaced there from to form longitudinal channels between said of said second horizontal section's peripheral edges and an end cap member longitudinal side panel, each of said longitudinal channels being dimensioned to receive and retain one of said tray member longitudinal side panels and comprising the step of positioning one of said tray member longitudinal side panels in each of said longitudinal channels.

15- A packaging structure comprising:

an end cap member, said end cap member having two longitudinal vertical end cap side panels, two latitudinal vertical end cap side panels, and an end cap base panel,
a base member, said base member having a pair of latitudinal side panels and a pair of longitudinal side panels,
each of said end cap latitudinal vertical end cap side panels comprising a first vertical section and a second vertical section,
said first vertical section being contiguous with said end cap base panel, and
said second vertical section being contiguous with said first vertical section,
said second vertical section being folded to a position abutting and interior of said first vertical section,
a first horizontal section and a second horizontal section,
said first horizontal section being contiguous with said second vertical section and overlying said end cap base panel,
said second horizontal section being folded to a position overlying said first horizontal section and having a peripheral edge substantially parallel to said second vertical section and spaced there from to form one channel of said at least one pair of parallel channels,
each of said at least one pair of parallel channels being dimensioned to receive and retain one of said base member latitudinal side panels.

16- The packaging structure of claim 15, further comprising, each of said second horizontal sections having a pair of peripheral edges substantially parallel to two of said end cap vertical end cap side panels and spaced there from to form longitudinal channels between said of said second horizontal section's peripheral edges and an end cap member longitudinal side panel, each of said longitudinal channels being dimensioned to receive and retain one of said base member longitudinal side panels.

17- The packaging structure of claim 15, further comprising said first horizontal section being fixed to said second horizontal section and said end cap base panel.

Patent History
Publication number: 20110108448
Type: Application
Filed: Dec 29, 2010
Publication Date: May 12, 2011
Inventor: David Goodrich (Newton, CT)
Application Number: 12/981,187
Classifications
Current U.S. Class: Article Housing Attached To Panel (206/461); Forming Or Partial Forming A Receptacle And Subsequent Filling (53/452); Folding (220/6)
International Classification: B65D 6/00 (20060101); B65D 73/00 (20060101);