Packaging Assembly

Provided herein is, among other things, a packaging assembly comprising a substantially rigid panel having a pair of side edges; a pair of end edges; a center portion; a pair of proximal segments, each connected respectively to the right side and left side of the center portion; a pair of distal segments, each connected to one of the proximal segments opposite to the center portion; a first pair of substantially parallel fold lines; a second pair of substantially parallel fold lines; and a flexible film material secured on the rigid panel, wherein an object to be packaged is held securely between the flexible film material and the rigid panel. Also provided herein is a method of packaging an object using the packaging assembly disclosed herein.

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Description
FIELD OF THE INVENTION

Provided herein is a packaging assembly comprising a substantially rigid panel and a film material secured on the rigid panel, wherein an object to be packaged is held securely between the film material and the rigid panel. Also provided herein is a method of packaging an object using the packaging assembly disclosed herein.

BACKGROUND OF THE INVENTION

Packaging assemblies have long been used to secure an object to be packaged which requires protection from physical shock, dust, dirt and other contaminants. For example, when shipping objects which is comparatively fragile or sensitive, it is often desirable to secure the object inside a box to protect the object from physical shocks, dust, dirt and other contaminants which may occur during loading, transit and unloading.

Many packaging assemblies include a rigid panel, a flexible film material and additional structures to keep an object and the packaging assembly within a box from moving uncontrollably in the box. Such additional structures generally include a pair of folding side flaps and a pair of folding end flaps around a center portion of the rigid panel. An object is inserted between the flexible film material and the center portion and is secured when the folding side flaps are folded away from the flexible film material to tighten the flexible film material against the object. The folding end flaps are then folded in the same or opposite direction to the folding side flaps. The rigid panel in its folded condition is then placed in a box having interior dimensions which correspond to the peripheral dimensions of the folded rigid panel. The major problem with this type of packaging assembly is that it is difficult to keep the packaging assembly in the folded condition by one assembler. It is because while the pair of folding side flaps are folded in order to tighten the flexible film material against the object, the tension created on the flexible film material means that the pair of folding side flaps would rebound to an unfolded condition. Thus, the flexible film material would remain relaxed over the object unless an assembler continuously holds onto the pair of folding side flaps with both hands. With both hands being occupied, the assembler could not fold the pair of folding end flaps without the assistance of an additional assembler. Without fixing both pairs of folding side flaps and folding end flaps to their respective folded positions, the rigid panel could not be smoothly fitted into a box having interior dimensions which correspond to the peripheral dimensions of the folded rigid panel.

Therefore, there is a need for a packaging assembly that can successfully secure objects against a substantially rigid panel and prevent uncontrolled movement of the objects when the rigid panel and the objects are packaged within a box. There is also a need for a packaging assembly that can be easily operated and fitted into a box by a single assembler.

SUMMARY OF THE INVENTION

Provided herein is a packaging assembly that can successfully secure an object against a substantially rigid panel and prevent uncontrolled movement of the objects when the rigid panel and the object is packaged within a box. Also provided herein is a packaging assembly that can be easily operated and fitted into a box by a single assembler.

In one aspect, provided herein is a packaging assembly comprising:

    • a) a substantially rigid panel having:
      • (i) a pair of side edges and a pair of end edges;
      • (ii) a center portion around the center of the rigid panel;
      • (iii) a pair of proximal segments, each connected respectively to the right side and left side of the center portion;
      • (iv) a pair of distal segments, each respectively connected to one of the proximal segments; and
    • (v) a first pair of substantially parallel fold lines and a second pair of substantially parallel fold lines,
      • wherein the first pair of fold lines and the second pair of fold lines are substantially parallel with each other,
      • wherein the first pair of fold lines and the pair of side edges define the center portion,
      • wherein the first pair of fold lines, the second pair of fold lines and the pair of side edges define the proximal segments,
      • wherein the second pair of fold lines, the pair of side edges and the pair of end edges define the distal segments, and
      • wherein the width of the pair of distal segments is greater than the width of the pair of proximal segments; and
    • b) a film material having opposed ends superimposed on one surface of the rigid panel, extending over the center portion and passing the first pair of fold lines onto the proximal segments, wherein each of the opposed ends is secured respectively to each of the proximal segments by one or more stitch lines.

In some embodiments, the packaging assembly further comprises a pair of unsecured edge portions of the film material substantially adjacent to the side edges.

In certain embodiments, the rigid panel has an unfolded condition in which the proximal segments and the distal segments are substantially coplanar with the center portion and has a folded condition in which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion.

In some embodiments, the packaging assembly further comprises a box adapted to receive the rigid panel in the folded condition, the box having interior dimensions corresponding to the peripheral dimensions of the rigid panel when folded so that the rigid panel is securely held within the box.

In certain embodiments, one or more of the stitch lines extend from one of the side edges to the other side edge. In one embodiment, each stitch line comprises a plurality of stitch line segments having unsecured portions of film therebetween.

In some embodiments, the packaging assembly further comprises at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge.

In certain embodiments, the packaging assembly further comprises at least one cutout along each of the end edges.

In another aspect, provided herein is a packaging assembly comprising:

    • a) a substantially rigid panel having:
      • (i) a pair of side edges and a pair of end edges;
      • (ii) a center portion around the center of the rigid panel;
      • (iii) a pair of proximal segments, each connected respectively to the right side and left side of the center portion;
      • (iv) a pair of distal segments, each respectively connected to one of the proximal segments; and
      • (v) a first pair of substantially parallel fold lines and a second pair of substantially parallel fold lines,
      • wherein the first pair of fold lines and the second pair of fold lines are substantially parallel with each other,
      • wherein the first pair of fold lines and the pair of side edges define the center portion,
      • wherein the first pair of fold lines, the second pair of fold lines and the pair of side edges define the proximal segments,
      • wherein the second pair of fold lines, the pair of side edges and the pair of end edges define the distal segments, and
      • wherein the width of the pair of distal segments is greater than the width of the pair of proximal segments;
    • b) a film material having opposed ends superimposed on one surface of the rigid panel, extending over the center portion and passing the first pair of fold lines onto the proximal segments, wherein each of the opposed ends is secured respectively to each of the proximal segments by one or more stitch lines; and
    • c) a box adapted to receive the rigid panel in the folded condition, the box having interior dimensions corresponding to the peripheral dimensions of the rigid panel when folded so that the rigid panel is securely held within the box.

In certain embodiments, the packaging assembly further comprises a pair of unsecured edge portions of the film material substantially adjacent to the side edges.

In some embodiments, a height of the box from a bottom end to a top end thereof is substantially equal to the width of the distal segments, and a width of the box from a side to the opposite side thereof is substantially equal to the width of the center portion.

In certain embodiments, the rigid panel has an unfolded condition in which the proximal segments and the distal segments are substantially coplanar with the center portion and has a folded condition in which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion.

In certain embodiments, one or more of the stitch lines extend from one of the side edges to the other side edge. In one embodiment, each stitch line comprises a plurality of stitch line segments having unsecured portions of film therebetween.

In some embodiments, the packaging assembly further comprises at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge.

In certain embodiments, the packaging assembly further comprises at least one cutout along each of the end edges.

In another aspect, provided herein is a method for packaging an object in the packaging assembly disclosed herein, wherein the method comprises the steps of:

    • a) folding the pair of proximal segments in a direction towards the film material;
    • b) inserting at least a portion of the object into the packaging assembly through an opening defined by an unsecured edge portion of the film material and the rigid panel;
    • c) folding each of the distal segments towards the film material and folding the pair of proximal segments together with the pair of distal segments in a direction away from the film material in which the film material is tightened against at least a portion of the object and the pair of proximal segments and the pair of distal segments are substantially transverse to the center portion and the end edges are above the film material; and
    • d) placing the folded panel with the object into a box having interior dimensions corresponding to the peripheral dimensions of the folded panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a plan view of an embodiment of the packaging assembly disclosed herein in an unfolded condition,

FIG. 2 depicts a perspective view of the embodiment of the packaging assembly as shown in FIG. 1 to illustrate the insertion of an object.

FIG. 3 depicts a perspective view of the embodiment of the packaging assembly as shown in FIG. 1 to illustrate the direction in which the proximal segments and the distal segments are folded.

FIG. 4 depicts a perspective view of the embodiment of the packaging assembly as shown in FIG. 1 in a folded condition.

FIG. 5 depicts a perspective view of the embodiment of the packaging assembly as shown in FIG. 1 illustrating the way in which the packaging assembly fits inside a box.

FIG. 6 depicts a plan view of another embodiment of the packaging assembly disclosed herein.

FIG. 7 depicts a perspective view of the embodiment of the packaging assembly as shown in FIG. 6 illustrating the way in which the cutouts allow the lid side portions of a box to be easily inserted into the space between the distal segments and the box side portions when the box lid is being closed.

 DETAILED DESCRIPTION OF THE INVENTION Definitions

The term “rigid panel” refers to a panel which is formed of any substantially rigid material and is substantially rectangular in shape. In certain embodiments, the substantially rigid material can hold a load of at least about 0.5 kg, at least about 1 kg, at least about 2 kg, at least about 3 kg, at least about 4 kg, at least about 6 kg, at least about 8 kg or at least about 10 kg per 400 cm2 of the substantially rigid material.

The term “film material” refers to a generally flexible material that is secured to the rigid panel in the corresponding proximal segments to secure an object against the rigid panel and prevent uncontrolled movement of the object to be packaged.

The term “object” includes any consumer goods that are generally categorized as merchandise and/or other item of common daily use, and/or industrial goods that are generally categorized as equipment, machinery, materials and/or other goods or component parts for use and/or consumption by other industries and/or firms.

The term “substantially rectangular shape” includes rectangular shapes with rounded or sloped corners. In some embodiments, the term “substantially rectangular shape” includes openings anywhere and cutouts along the edges of the rectangular shape. In further embodiments, the term “substantially rectangular shape” includes any irregular shapes that has a substantial portion of its outer edges touching the boundaries of a rectangle.

The term “edge” of the rigid panel disclosed herein refers to a line or border at which a surface on the rigid panel terminates. The line or border can be curved, straight or substantially straight.

The term “side edges” of the rigid panel disclosed herein refer to a longer pair of edges of the rigid panel as seen by an observer when the rigid panel lies flat on a surface. In some embodiments, the side edges are substantially perpendicular to the first pair of fold lines or the second pair of fold lines.

The term “end edges” of the rigid panel disclosed herein refer to a shorter pair of edges of the rigid panel as seen by an observer when the rigid panel lies flat on a surface. In some embodiments, the end edges are substantially parallel to the first pair of fold lines or the second pair of fold lines.

The term “center portion” refers to a portion on the rigid panel that is defined by a pair of first fold lines and a pair of side edges. In some embodiments, the center portion is in the center of the rigid panel. In certain embodiments, the center portion is around the center of the rigid panel. In certain embodiments, the center portion is near the center of the rigid panel.

The term “proximal segment” refers to a segment that is connected to either the right side or the left side of the center portion as seen by an observer when the rigid panel lies flat on a surface.

The term “distal segment” refers to a segment that is connected to a proximal segment opposite to the center portion. In some embodiments, the width of the distal segment is greater than the width of the proximal segment by at least 20%, at least 40%, at least 60%, at least 80%, at least 100%, at least 150%, or at least 200%. In certain embodiments, the width of the distal segment is greater than the width of the proximal segment by about 20% to about 200%.

The term “width of the proximal segment” refers to the longest distance between a first fold line and the closest second fold line. The distance is measured by the length of a line perpendicularly to the first fold line and extending from the first fold line to the second fold line.

The term “width of the distal segment” refers to the longest distance between a second fold line and the closest end edge. The distance is measured by the length of a line perpendicularly to the second fold line and extending from the second fold line to the end edge.

The term “fold line” refers to a line along which the panel may be creased, crimped, embossed, perforated, scored, or otherwise weakened so as to enhance the foldability of the panel.

The term “first fold line” refers to a fold line extending from a side edge to the opposed side edge along which the proximal segment is connected to the center portion.

The term “second fold line” refers to a fold line extending from a side edge to the opposed side edge along which the distal segment is connected to the proximal segment.

The term “substantially parallel lines” refers to any two or more lines having a general orientation accepting moderate ranges of deviation from absolute parallel that are commonly acceptable within the meaning of parallel within the container-folding field. In some embodiments, when the lines intersect, the interior angle of intersection is about 0.5°, about 1°, about 1.5°, about 2°, about 2.5°, about 3°, about 5°, about 6°, about 8°, about 9° or about 10°. In certain embodiments, the corresponding angle of intersection is from about 0.5° to about 10°.

The term “substantially transverse segments or portions” refers to any set of segments or portions having a slight departure from an absolute perpendicular arrangement. In some embodiments, when the two segments or portions intersect, the interior angle of intersection is 85°, 86°, 87°, 88°, 89°, 90°, 91°, 92°, 93°, 94° or 95°. In certain embodiments, the interior angle of intersection is from about 85° to about 95°.

The term “substantially coplanar segments or portions” refers to any set of segments or portions having a slight departure from lying absolutely on the same plane. In some embodiments, a set of segments or portions are substantially coplanar when the interior angle between the set of segments or portions is 170°, 171°, 172°, 173°, 174°, 175°, 176°, 177°, 178°, 179°, 180°, 181°, 182°, 183°, 184°, 185°, 186°, 187°, 188°, 189° or 190°. In certain embodiments, a set of segments or portions are substantially coplanar when the interior angle between the set of segments or portions is from about 170° to about 190°

The term “substantially 0 degree” refers to 0°, 1°, 2°, 3°, 4° or 5°.

The term “transparent” refers to polymeric material with a transparency value of about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 99% or about 99.9% as measured in accordance with ASTM D1746.

The term “translucent” refers to polymeric material with a transparency value of about 35%, about 40%, about 45%, about 50%, about 55% or about 60% as measured in accordance with ASTM D1746.

The term “opaque” refers to polymeric material with a transparency value of about 5%, about 10%, about 15%, about 20%, about 25% or about 30% as measured in accordance with ASTM D1746.

The term “stich” refers to a single loop of thread that is passed through a piece of material. In some embodiments, the thread is made of cotton. In certain embodiments, the thread is made of natural fiber. In some embodiments, the thread is made of animal fiber. In certain embodiments, the thread is made of synthetic fiber. In some embodiments, the thread is made of polyester. In certain embodiments, the thread is made of fusible. In some embodiments, the thread is made of linen. In certain embodiments, the thread is made of metal. In some embodiments, the thread is made of nylon. In certain embodiments, the thread is made of rayon. In some embodiments, the thread is made of silk. In certain embodiments, the thread is made of wool. In some embodiments, the thread cannot be made of water-soluble. Of course, it will be understood that a number of materials are suitable for the thread and can be selected, or custom designed, by those familiar with such materials without undue experimentation.

The term “unfolded condition” refers to the condition which the proximal segments and the distal segments are substantially coplanar with the center portion. Of course, it will be understood that the unfolded condition of the rigid panel is in a state which the rigid panel is ready to accept an object to be secured.

The term “folded condition” refers to the condition which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion. Of course, it will be understood that the folded condition of the rigid panel is a state which the rigid panel has secured an object to be packaged.

The term “copolymer” refers to a polymer derived from two or more types of monomers, including terpolymers.

The terms “unsecured portion” and “unsecured edge portion” refer to the space between the film material and the rigid panel whereby the film material and the rigid panel are not sealed, attached, connected and/or secured to each other by any physical, chemical, and/or mechanical means.

Provided herein are packaging assemblies that can successfully secure objects against a substantially rigid panel and prevent uncontrolled movement of the objects when the rigid panel and the objects are packaged within a box. In some embodiments, the packaging assemblies can be easily operated and fitted into a box by a single assembler. It will be understood that many of the features of the embodiments discussed below may be used in combination with the features of the other various embodiments.

In one aspect, provided herein is a packaging assembly comprising:

    • a) a substantially rigid panel having:
      • (i) a pair of side edges and a pair of end edges;
      • (ii) a center portion around the center of the rigid panel;
      • (iii) a pair of proximal segments, each connected respectively to the right side and left side of the center portion;
      • (iv) a pair of distal segments, each respectively connected to one of the proximal segments; and
      • (v) a first pair of substantially parallel fold lines and a second pair of substantially parallel fold lines,
      • wherein the first pair of fold lines and the second pair of fold lines are substantially parallel with each other,
      • wherein the first pair of fold lines and the pair of side edges define the center portion,
      • wherein the first pair of fold lines, the second pair of fold lines and the pair of side edges define the proximal segments,
      • wherein the second pair of fold lines, the pair of side edges and the pair of end edges define the distal segments, and
      • wherein the width of the pair of distal segments is greater than the width of the pair of proximal segments; and
    • b) a film material having opposed ends superimposed on one surface of the rigid panel, extending over the center portion and passing the first pair of fold lines onto the proximal segments, wherein each of the opposed ends is secured to the proximal segments by one or more stitch lines.

In some embodiments, the packaging assembly further comprises a pair of unsecured edge portions of the film material substantially adjacent to the side edges.

In certain embodiments, the rigid panel has an unfolded condition in which the proximal segments and the distal segments are substantially coplanar with the center portion and has a folded condition in which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion.

In some embodiments, the packaging assembly further comprises a box adapted to receive the rigid panel in the folded condition, the box having interior dimensions corresponding to the peripheral dimensions of the rigid panel when folded so that the rigid panel is securely held within the box.

In certain embodiments, one or more of the stitch lines extend from one of the side edges to the other side edge. In one embodiment, each stitch line comprises a plurality of stitch line segments having unsecured portions of film therebetween.

In some embodiments, the packaging assembly further comprises at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge.

In certain embodiments, the packaging assembly further comprises at least one cutout along each of the end edges.

In another aspect, provided herein is a packaging assembly comprising:

    • a) a substantially rigid panel having:
      • (i) a pair of side edges and a pair of end edges;
      • (ii) a center portion around the center of the rigid panel;
      • (iii) a pair of proximal segments, each connected respectively to the right side and left side of the center portion;
      • (iv) a pair of distal segments, each respectively connected to one of the proximal segments; and
      • (v) a first pair of substantially parallel fold lines and a second pair of substantially parallel fold lines,
      • wherein the first pair of fold lines and the second pair of fold lines are substantially parallel with each other,
      • wherein the first pair of fold lines and the pair of side edges define the center portion,
      • wherein the first pair of fold lines, the second pair of fold lines and the pair of side edges define the proximal segments,
      • wherein the second pair of fold lines, the pair of side edges and the pair of end edges define the distal segments, and
      • wherein the width of the pair of distal segments is greater than the width of the pair of proximal segments;
    • b) a film material having opposed ends superimposed on one surface of the rigid panel, extending over the center portion and passing the first pair of fold lines onto the proximal segments, wherein each of the opposed ends is secured respectively to each of the proximal segments by one or more stitch lines; and
    • c) a box adapted to receive the rigid panel in the folded condition, the box having interior dimensions corresponding to the peripheral dimensions of the rigid panel when folded so that the rigid panel is securely held within the box.

In certain embodiments, the packaging assembly further comprises a pair of unsecured edge portions of the film material substantially adjacent to the side edges.

In some embodiments, a height of the box from a bottom end to a top end thereof is substantially equal to the width of the distal segments, and a width of the box from a side to the opposite side thereof is substantially equal to the width of the center portion.

In certain embodiments, the rigid panel has an unfolded condition in which the proximal segments and the distal segments are substantially coplanar with the center portion and has a folded condition in which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion.

In certain embodiments, one or more of the stitch lines extend from one of the side edges to the other side edge. In one embodiment, each stitch line comprises a plurality of stitch line segments having unsecured portions of film therebetween.

In some embodiments, the packaging assembly further comprises at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge.

In certain embodiments, the packaging assembly further comprises at least one cutout along each of the end edges.

The rigid panel disclosed herein can be in any shape and size suitable to be used for securing objects. In some embodiments, the rigid panel is substantially rectangular in shape. The rigid panel disclosed herein is formed of any substantially rigid material.

In some embodiments, the substantially rigid material is a corrugated cardboard. In certain embodiments, the corrugated cardboard is an A-Flute, B-Flute, C-Flute, E-Flute or F-Flute corrugated cardboard. In some embodiments, the substantially rigid material is a paperboard or a laminate. In other embodiments, the substantially rigid material is a plastic. In certain embodiments, the substantially rigid material is not a corrugated cardboard, a paperboard, a laminate or a plastic. In certain embodiments, the rigid panel is substantially continuous. In some embodiments, the rigid panel comprises one or more openings or cutouts on its surface or along its edges.

In certain embodiments, the rigid panel has an average thickness of at most about 0.75 mm, at most about 1.50 mm, at most about 3.00 mm, at most about 4.50 mm, at most about 6.00 mm, at most about 7.50 mm, at most about 10.00 mm or at most about 12.50 mm. In some embodiments, the rigid panel has an average thickness of at least about 0.075 mm, at least about 0.15 mm, at least about 0.30 mm, at least about 0.45 mm, at least about 0.60 mm, at least about 0.75 mm, at least about 1.00 mm or at least about 1.25 mm.

In certain embodiments, the pair of first fold lines and the pair of second fold lines are scored, crimped or perforated. In some embodiments, the pair of side edges, particularly the sections along the center portion, are not connected to any further features or materials. In certain embodiments, the pair of side edges along the center portion are not connected to any further features or materials.

The film material disclosed herein includes generally a thin continuous polymeric material, which can be transparent, translucent, opaque or colored. In certain embodiments, the film material comprises any material that is suitable for packaging known to a person of ordinary skill in the art. Non-limiting examples of suitable materials include one or more fabrics, such as wovens, knits, nonwovens, openwork meshes, spandex, including Lycra® brand spandex and elastic fabrics. In some embodiments, the film material has a thickness of at most about 0.2 mm, at most about 0.15 mm, at most about 0.13 mm, at most about 0.10 mm, at most about 0.08 mm, at most about 0.05 mm, at most about 0.04 mm, or at most about 0.03 mm. In certain embodiments, the film material has a thickness of at least about 0.03 mm, at least about 0.04 mm, at least about 0.05 mm, or at least about 0.08 mm.

The film material disclosed herein is generally an elastic polymeric material. In some embodiments, the film material has an elastic recovery in the transverse direction and/or longitudinal direction of at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95% or at least about 100% measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time. In certain embodiments, the film material has a Young's modulus of at least about 13,700 KPa, at least about 17,200 KPa, at least about 20,600 KPa, at least about 24,100 KPa, or at least about 27,500 KPa and/or at most about 55,100 KPa, at most about 68,900 KPa, at most about 103,400 KPa, at most about 137,800 KPa, or at most about 275,700 KPa as measured in accordance with ASTM D882 at a temperature of 73° F. In certain embodiments, the film material has an ultimate elongation value of at least about 100%, at least about 200%, at least about 300%, at least about 400%, or at least about 500%, as measured in accordance with ASTM D412. In certain embodiments, the film material has a low speed puncture maximum load of about 17 newton, about 20 newton, about 22 newton, about 24 newton, about 26 newton, about 28 newton or about 31 newton, measured according to ASTM F1306 using a crosshead speed of 127 mm per minute.

The elastic polymeric material can be an elastomer or a thermoplastic. In certain embodiments, the elastic polymeric material disclosed herein can comprise at least one additive for the purposes of improving and/or controlling the processibility, appearance, physical, chemical, and/or mechanical properties of the elastic polymeric material. Non-limiting examples of suitable additives include colorants or pigments, UV stabilizers, plasticizers, antioxidants, fillers, lubricants, antifogging agents, flow aids, coupling agents, cross-linking agents, nucleating agents, surfactants, slip agents, anti-blocking agents, solvents, flame retardants, antistatic agents, and combinations thereof. The total amount of the additives can range from about greater than 0 to about 80 wt. %, from about 0.001 wt. % to about 70 wt. %, from about 0.01 wt. % to about 60 wt. %, from about 0.1 wt. % to about 50 wt. %, from about 1 wt. % to about 40 wt. %, or from about 10 wt. % to about 50 wt. % of the total weight of the elastic polymeric material. Some polymer additives have been described in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition (2001), which is incorporated herein by reference in its entirety.

In some embodiments, the elastic polymeric material is an elastomer. In certain embodiments, the elastomer includes natural or synthetic rubber (e.g., styrene-butadiene rubber, polybutadiene, neoprene rubber, polyisoprene rubber, ethylene-propylene diene monomer (EPDM) rubber, polysiloxane, nitrile rubber, and butyl rubber), and polyurethanes (e.g., polyether polyurethanes, polyester polyurethane, polycarbonate polyurethanes, and thermoplastic polyurethane elastomers). In some embodiments, the polymeric material is thermoplastic polyolefin elastomers (TPOs), which are two-component elastomer systems comprising an elastomer (such as EPDM) finely dispersed in a thermoplastic polyolefin (such as polypropylene or polyethylene).

In certain embodiments, the elastic polymeric material is a thermoplastic polyurethane elastomer. In certain embodiments, the thermoplastic polyurethane elastomer is ELASTOLLAN®, commercially available from the BASF company, Florham Park, USA.

In some embodiments, the elastic polymeric material is a thermoplastic modified with one or more additives for improving and/or controlling elasticity and/or appearance of the thermoplastic for the film material disclosed herein. In some embodiments, the thermoplastic includes polyolefins, polyethylene homopolymers (e.g., low density polyethylene), polyethylene copolymers (e.g., ethylene/alpha-olefin copolymers (“EAOs”), ethylene/unsaturated ester copolymers, and ethylene/(meth)acrylic acid), polypropylene homopolymers, polypropylene copolymers, and polyvinyl chloride.

In some embodiments, the elastic polymeric material disclosed herein can comprise a plasticizer or tackifier. In general, a plasticizer is a chemical that can increase the flexibility and lower the glass transition temperature of polymers. Any plasticizer disclosed herein can used for the elastic polymeric material. Non-limiting examples of plasticizers include mineral oils, abietates, adipates, alkyl sulfonates, azelates, benzoates, chlorinated paraffins, citrates, epoxides, glycol ethers and their esters, glutarates, hydrocarbon oils, isobutyrates, oleates, pentaerythritol derivatives, phosphates, phthalates, esters, polybutenes, ricinoleates, sebacates, sulfonamides, tri- and pyromellitates, biphenyl derivatives, stearates, difuran diesters, fluorine-containing plasticizers, hydroxybenzoic acid esters, isocyanate adducts, multi-ring aromatic compounds, natural product derivatives, nitriles, siloxane-based lamination agents, tar-based products, thioeters and combinations thereof. Where used, the amount of the plasticizer in the elastic polymeric material can be from greater than 0 to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 5 wt. % of the total weight of the elastic polymeric material. Some plasticizers have been described in George Wypych, “Handbook of Plasticizers,” ChemTec Publishing, Toronto-Scarborough, Ontario (2004), which is incorporated herein by reference.

In certain embodiments, the elastic polymeric material disclosed herein can comprise a tackifier. In general, a tackifier is a chemical that can increase the tack and lower the glass transition temperature of polymers. Any tackifier disclosed herein can used for the elastic polymeric material. Non-limiting examples of tackifiers include rosins and their derivatives, terpenes and modified terpenes, aliphatic, cycloaliphatic and aromatic resins (e.g., C5 aliphatic resins, C9 aromatic resins, and C5/C9 aliphatic/aromatic resins), hydrogenated hydrocarbon resins, and their mixtures, and terpene-phenol resins. Where used, the amount of the tackifier in the elastic polymeric material can be from greater than 0 to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, or from about 1 wt. % to about 5 wt. % of the total weight of the elastic polymeric material.

In some embodiments, the elastic polymeric material disclosed herein optionally comprise a colorant or pigment that can change the look of the elastic polymeric material to human eyes. Any colorant or pigment known to a person of ordinary skill in the art may be added to the elastic polymeric material disclosed herein. Non-limiting examples of suitable colorants or pigments include inorganic pigments such as metal oxides such as iron oxide, zinc oxide, and titanium dioxide, mixed metal oxides, carbon black, organic pigments such as anthraquinones, anthanthrones, azo and monoazo compounds, arylamides, benzimidazolones, BONA lakes, diketopyrrolo-pyrroles, dioxazines, disazo compounds, diarylide compounds, flavanthrones, indanthrones, isoindolinones, isoindolines, metal complexes, monoazo salts, naphthols, b-naphthols, naphthol AS, naphthol lakes, perylenes, perinones, phthalocyanines, pyranthrones, quinacridones, and quinophthalones, and combinations thereof. Where used, the amount of the colorant or pigment in the elastic polymeric material can be from about greater than 0 to about 10 wt. %, from about 0.1 wt. % to about 5 wt. %, or from about 0.25 wt. % to about 2 wt. % of the total weight of the elastic polymeric material. Some colorants have been described in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition, Chapter 15, pages 813-882 (2001), which is incorporated herein by reference.

In certain embodiments, the elastic polymeric material disclosed herein optionally comprise an UV stabilizer that may prevent or reduce the degradation of the elastic polymeric material by UV radiations. Any UV stabilizer known to a person of ordinary skill in the art may be added to the elastic polymeric material disclosed herein. Non-limiting examples of suitable UV stabilizers include benzophenones, benzotriazoles, aryl esters, oxanilides, acrylic esters, formamidines, carbon black, hindered amines, nickel quenchers, hindered amines, phenolic antioxidants, metallic salts, zinc compounds and combinations thereof. Where used, the amount of the UV stabilizer in the elastic polymeric material can be from about greater than 0 to about 5 wt. %, from about 0.01 to about 3 wt. %, from about 0.1 wt. % to about 2 wt. %, or from about 0.1 wt. % to about 1 wt. % of the total weight of the elastic polymeric material. Some UV stabilizers have been described in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition, Chapter 2, pages 141-426 (2001), which is incorporated herein by reference.

In certain embodiments, the elastic polymeric material disclosed herein can comprise a lubricant. In general, the lubricant can be used, inter alia, to modify the rheology of the molten elastic polymeric material, to improve the surface finish of molded articles, and/or to facilitate the dispersion of fillers or pigments. Any lubricant known to a person of ordinary skill in the art may be added to the elastic polymeric material disclosed herein. Non-limiting examples of suitable lubricants include fatty alcohols and their dicarboxylic acid esters, fatty acid esters of short-chain alcohols, fatty acids, fatty acid amides, metal soaps, oligomeric fatty acid esters, fatty acid esters of long-chain alcohols, montan waxes, polyethylene waxes, polypropylene waxes, natural and synthetic paraffin waxes, fluoropolymers and combinations thereof. Where used, the amount of the lubricant in the elastic polymeric material can be from about greater than 0 to about 5 wt. %, from about 0.1 wt. % to about 4 wt. %, or from about 0.1 wt. % to about 3 wt. % of the total weight of the elastic polymeric material. Some suitable lubricants have been disclosed in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition, Chapter 5, pages 511-552 (2001), both of which are incorporated herein by reference.

Optionally, the elastic polymeric material disclosed herein can comprise an antistatic agent. Generally, the antistatic agent can increase the conductivity of the elastic polymeric material and to prevent static charge accumulation. Any antistatic agent known to a person of ordinary skill in the art may be added to the elastic polymeric material disclosed herein. Non-limiting examples of suitable antistatic agents include conductive fillers (e.g., carbon black, metal particles and other conductive particles), fatty acid esters (e.g., glycerol monostearate), ethoxylated alkylamines, diethanolamides, ethoxylated alcohols, alkylsulfonates, alkylphosphates, quaternary ammonium salts, alkylbetaines and combinations thereof. Where used, the amount of the antistatic agent in the elastic polymeric material can be from about greater than 0 to about 5 wt. %, from about 0.01 wt. % to about 3 wt. %, or from about 0.1 wt. % to about 2 wt. % of the total weight of the elastic polymeric material. Some suitable antistatic agents have been disclosed in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition, Chapter 10, pages 627-646 (2001), both of which are incorporated herein by reference.

In some embodiments, the elastic polymeric material disclosed herein comprise a slip agent. In other embodiments, the elastic polymeric material disclosed herein do not comprise a slip agent. Slip is the sliding of film surfaces over each other or over some other substrates. The slip performance of films can be measured by ASTM D 1894, Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting, which is incorporated herein by reference. In general, the slip agent can convey slip properties by modifying the surface properties of films; and reducing the friction between layers of the films and between the films and other surfaces with which they come into contact.

Any slip agent known to a person of ordinary skill in the art may be added to the elastic polymeric material disclosed herein. Non-limiting examples of the slip agents include primary amides having about 12 to about 40 carbon atoms (e.g., erucamide, oleamide, stearamide and behenamide); secondary amides having about 18 to about 80 carbon atoms (e.g., stearyl erucamide, behenyl erucamide, methyl erucamide and ethyl erucamide); secondary-bis-amides having about 18 to about 80 carbon atoms (e.g., ethylene-bis-stearamide and ethylene-bis-oleamide); and combinations thereof.

In certain embodiments, the slip agent is a primary amide with a saturated aliphatic group having between 18 and about 40 carbon atoms (e.g., stearamide and behenamide). In other embodiments, the slip agent is a primary amide with an unsaturated aliphatic group containing at least one carbon-carbon double bond and between 18 and about 40 carbon atoms (e.g., erucamide and oleamide). In further embodiments, the slip agent is a primary amide having at least 20 carbon atoms. In further embodiments, the slip agent is erucamide, oleamide, stearamide, behenamide, ethylene-bis-stearamide, ethylene-bis-oleamide, stearyl erucamide, behenyl erucamide or a combination thereof. In a particular embodiment, the slip agent is erucamide. In further embodiments, the slip agent is commercially available having a trade name such as ATMER™ SA from Uniqema, Everberg, Belgium; ARMOSLIP® from Akzo Nobel Polymer Chemicals, Chicago, Ill.; KEMAMIDE® from Witco, Greenwich, Conn.; and CRODAMIDE® from Croda, Edison, N.J. Where used, the amount of the slip agent in the elastic polymeric material can be from about greater than 0 to about 3 wt. %, from about 0.0001 wt. % to about 2 wt. %, from about 0.001 wt. % to about 1 wt. %, from about 0.001 wt. % to about 0.5 wt. % or from about 0.05 wt. % to about 0.25 wt. % of the total weight of the elastic polymeric material. Some slip agents have been described in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition, Chapter 8, pages 601-608 (2001), which is incorporated herein by reference.

In some embodiments, the elastic polymeric material disclosed herein can comprise an anti-blocking agent. In some embodiments, the elastic polymeric material disclosed herein do not comprise an anti-blocking agent. The anti-blocking agent can be used to prevent the undesirable adhesion between touching layers of articles made from the elastic polymeric material, particularly under moderate pressure and heat during storage, manufacture or use. Any anti-blocking agent known to a person of ordinary skill in the art may be added to the elastic polymeric material disclosed herein. Non-limiting examples of anti-blocking agents include minerals (e.g., clays, chalk, and calcium carbonate), synthetic silica gel (e.g., SYLOBLOC® from Grace Davison, Columbia, Md.), natural silica (e.g., SUPER FLOSS® from Celite Corporation, Santa Barbara, Calif.), talc (e.g., OPTIBLOC® from Luzenac, Centennial, Colo.), zeolites (e.g., SIPERNAT® from Degussa, Parsippany, N.J.), aluminosilicates (e.g., SILTON® from Mizusawa Industrial Chemicals, Tokyo, Japan), limestone (e.g., CARBOREX® from Omya, Atlanta, Ga.), spherical polymeric particles (e.g., EPOSTAR®, poly(methyl methacrylate) particles from Nippon Shokubai, Tokyo, Japan and TOSPEARL®, silicone particles from GE Silicones, Wilton, Conn.), waxes, amides (e.g. erucamide, oleamide, stearamide, behenamide, ethylene-bis-stearamide, ethylene-bis-oleamide, stearyl erucamide and other slip agents), molecular sieves, and combinations thereof. The mineral particles can lower blocking by creating a physical gap between articles, while the organic anti-blocking agents can migrate to the surface to limit surface adhesion. Where used, the amount of the anti-blocking agent in the elastic polymeric material can be from about greater than 0 to about 3 wt. %, from about 0.0001 wt. % to about 2 wt. %, from about 0.001 wt. % to about 1 wt. %, or from about 0.001 wt. % to about 0.5 wt. % of the total weight of the elastic polymeric material. Some anti-blocking agents have been described in Zweifel Hans et al., “Plastics Additives Handbook,” Hanser Gardner Publications, Cincinnati, Ohio, 5th edition, Chapter 7, pages 585-600 (2001), which is incorporated herein by reference.

The packaging assembly disclosed herein includes means for securing the film material to the proximal segments, which is of mechanical or chemical nature. In some embodiments, the means constitutes a pair of stitch lines extending from one of the side edges to the other side edge. In certain embodiments, the means cannot constitute of glue strips or glue dots. The stitch lines define two unsecured edge portions of the film substantially adjacent to the side edges through which an object to be packaged is inserted between the film material and the center portion.

In certain embodiments, the stitch lines cooperate with the proximal segments to tighten the film material against an object between the film material and the center portion when the proximal segments are folded downwardly (i.e. away from the film material). A hand is inserted through one of the unsecured edge portions of the film material to loosen the film material relative to the center portion. The object to be secured is then inserted more easily through one of the unsecured edge portions. Each of the distal segments are then folded towards each of the connecting proximal segments until the angle between the connecting distal segment and proximal segment are substantially 0 degree, and folding the pair of proximal segments and the pair of distal segments downwardly (i.e. away from the film material) until the pair of proximal segments and the pair of distal segments are substantially transverse to the center portion and the end edges are above the film material. When the rigid panel is in its folded condition, the film material must extend over a slightly greater distance than it would when the rigid panel is in its unfolded condition, i.e., when the proximal segments and the distal segments are substantially coplanar with the center portion. This increased distance tends to encourage the film material to stretch slightly towards the proximal segments. It will be easily understood that the strain on the film material in turn increases the film material's tension and grip on the object to be secured.

In some embodiments, the folded rigid panel is then inserted into a box having inner dimensions corresponding to the peripheral dimensions of the folded rigid panel. Thus, when placed in the box, the proximal segments and the distal segments are restrained from unfolding by the inner sides of the box. In addition, the proximal segments and the distal segments space the center portion from the bottom of the box. Thus, the object, when placed in the box, is maintained out of direct contact with the box in all three axes, which can further reduce the risk of physical impact damage.

In certain embodiments, the stitch line disclosed herein comprises a plurality of stitch line segments having unsecured portions of the film material therebetween. These embodiment is particularly useful for securing taller objects, i.e., objects that extend further upwardly away from the rigid panel when being secured. When the rigid panel is folded as discussed above, the unsecured portions of the film material between the stitch line segments give slightly, which reduces the tension against a taller object. The length of the unsecured portions may be adjusted depending upon the height and width of the object being secured.

In some embodiments, the rigid panel disclosed herein comprises at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge. In certain embodiments, the opening is to accommodate a part for fixing an object to a particular position on the center portion. In some embodiments, when the rigid panel is folded and placed in a box as discussed above, materials such as instruction manuals are inserted through the cutout and are packaged together with the object. Of course, it will be understood that a number of materials can be inserted through the cutout and can be packaged together with an object. It will also be understood that the size or shape of the cutout can be custom made to accommodate the size or shape of the material to be packaged together with an object.

In certain embodiments, the distal segments disclosed herein comprise at least one cutout along each of the end edges. In some embodiments, when the rigid panel is folded and placed in a box as discussed above, the cutouts allow the lid side portions to be easily inserted into the space between the distal segments and the box side portions when the box lid is being closed. Of course, it will be understood that the size, shape or the position of the cutout depends on the corresponding position of the lid side portions when the box lid is being closed.

In an exemplary embodiment, the packaging assembly disclosed herein is easier to operate comparing to a prior art packaging assembly which generally comprises a pair of folding side flaps and a pair of folding end flaps around a center portion of a rigid panel. An object is inserted between a flexible film material and the center portion and is secured when the folding side flaps are folded away from the flexible film material to tighten the flexible film material against the object. The folding end flaps are then folded in the same or opposite direction to the folding side flaps. The rigid panel in its folded condition is then placed in a box having interior dimensions which correspond to the peripheral dimensions of the folded rigid panel. The major problem with the typical packaging assembly is that it is difficult to keep the typical packaging assembly in the folded condition by one assembler. This is because while the pair of folding side flaps are folded in order to tighten the flexible film material against an object, the tension created on the flexible film material causes the pair of folding side flaps to rebound to an unfolded condition. Accordingly, the flexible film material would remain relaxed over the object unless the assembler continuously holds onto the pair of folding side flaps with both hands. With both hands being occupied, the assembler could not fold the pair of folding end flaps without the assistance of an additional assembler. Without fixing both pairs of folding side flaps and folding end flaps to their respective folded positions, the rigid panel could not be smoothly fitted into a box having interior dimensions which correspond to the peripheral dimensions of the folded rigid panel. The typical packaging assembly would require more cost, time and labor to secure an object to be packaged as compared to the exemplary packaging assembly.

In another aspect, provided herein is a method for packaging an object in the packaging assembly disclosed herein, wherein the method comprises the steps of:

    • a) folding the pair of proximal segments in a direction towards the film material;
    • b) inserting at least a portion of the object into the packaging assembly through an opening defined by an unsecured edge portion of the film material and the rigid panel;
    • c) folding each of the distal segments towards the film material and folding the pair of proximal segments together with the pair of distal segments in a direction away from the film material in which the film material is tightened against at least a portion of the object and the pair of proximal segments and the pair of distal segments are substantially transverse to the center portion and the end edges are above the film material; and
    • d) placing the folded panel with the object into a box having interior dimensions corresponding to the peripheral dimensions of the folded panel.

FIG. 1 depicts a plan view of an embodiment of the packaging assembly (1) disclosed herein in an unfolded condition comprising a pair of end edges (2), a pair of side edges (3), a center portion (4) around the center of the rigid panel (14); a pair of proximal segments (7), each connected respectively to the right side and left side of the center portion (4); a pair of distal segments (8), each respectively connected to one of the proximal segments (7); and a first pair of substantially parallel fold lines (5) and a second pair of substantially parallel fold lines (6), wherein the first pair of fold lines (5) and the second pair of fold lines (6) are substantially parallel with each other, wherein the first pair of fold lines (5) and the pair of side edges (3) define the center portion (4), wherein the first pair of fold lines (5), the second pair of fold lines (6) and the pair of side edges (3) define the proximal segments (7), wherein the second pair of fold lines (6), the pair of side edges (3) and the pair of end edges (2) define the distal segments (8), and wherein the width of the pair of distal segments (8) is greater than the width of the pair of proximal segments (7); and a film material (10) having opposed ends superimposed on one surface of the rigid panel (14), extending over the center portion (4) and passing the first pair of fold lines (5) onto the proximal segments (7), wherein each of the opposed ends is secured respectively to each of the proximal segments (7) by one or more stitch lines (9), and a pair of unsecured edge portions (23) of the film material (10) substantially adjacent to the side edges (3).

FIG. 2 depicts a perspective view of the embodiment of the packaging assembly (1) as shown in FIG. 1 to illustrate the insertion of an object; the embodiment comprises a pair of end edges (2), a pair of side edges (3), a center portion (4) around the center of the rigid panel (14); a pair of proximal segments (7), each connected respectively to the right side and left side of the center portion (4); a pair of distal segments (8), each respectively connected to one of the proximal segments (7); a first pair of substantially parallel fold lines (5) and a second pair of substantially parallel fold lines (6); a film material (10) having opposed ends superimposed on one surface of the rigid panel (14), extending over the center portion (4) and passing the first pair of fold lines (5) onto the proximal segments (7), wherein each of the opposed ends is secured respectively to each of the proximal segments (7) by one or more stitch lines (9); and a pair of unsecured edge portions (23) of the film material (10) substantially adjacent to the side edges (3), wherein an object (100) to be secured is inserted through one of the unsecured edge portions (23) of the packaging assembly (1).

FIG. 3 depicts a perspective view of the embodiment of the packaging assembly (1) as shown in FIG. 1 to illustrate the direction in which the proximal segments (7) and the distal segments (8) are folded; the embodiment comprises a pair of end edges (2), a pair of side edges (3), a center portion (4) around the center of the rigid panel (14); a pair of proximal segments (7), each connected respectively to the right side and left side of the center portion (4); a pair of distal segments (8), each respectively connected to one of the proximal segments (7); and a first pair of substantially parallel fold lines (5) and a second pair of substantially parallel fold lines (6), wherein the first pair of fold lines (5) and the second pair of fold lines (6) are substantially parallel with each other, wherein the first pair of fold lines (5) and the pair of side edges (3) define the center portion (4); a film material (10) having opposed ends superimposed on one surface of the rigid panel (14), extending over the center portion (4) and passing the first pair of fold lines (5) onto the proximal segments (7); and an object (100) being secured in between the center portion (4) and the film material (10), wherein each of the opposed ends is secured respectively to each of the proximal segments (7) by one or more stitch lines (9), wherein each of the distal segments (8) are folded towards each of the connecting proximal segments (7) until the angle between the connecting distal segment (8) and proximal segment (7) are substantially 0 degree, and folding the pair of proximal segments (7) and the pair of distal segments (8) downwardly (i.e. away from the film material (10)).

FIG. 4 depicts a perspective view of the embodiment of the packaging assembly (1) as shown in FIG. 1 in a folded condition comprising a pair of end edges (2), a pair of side edges (3), a center portion (4) around the center of the rigid panel (14); a pair of proximal segments (7), each connected respectively to the right side and left side of the center portion (4); a pair of distal segments (8), each respectively connected to one of the proximal segments (7); and a first pair of substantially parallel fold lines (5) and a second pair of substantially parallel fold lines (6), wherein the first pair of fold lines (5) and the second pair of fold lines (6) are substantially parallel with each other, wherein the first pair of fold lines (5) and the pair of side edges (3) define the center portion (4); a film material (10) having opposed ends superimposed on one surface of the rigid panel (14), extending over the center portion (4) and passing the first pair of fold lines (5) onto the proximal segments (7); and an object (0) being secured in between the center portion (4) and the film material (10), wherein the pair of proximal segments (7) and the pair of distal segments (8) are substantially transverse to the center portion (4) and the end edges (2) are above the film material (10). When the rigid panel (14) is in the folded condition, the film material (10) must extend over a slightly greater distance than it would when the rigid panel (14) is in the unfolded condition, i.e., when the proximal segments (7) and the distal segments (8) are substantially coplanar with the center portion (4). This increased distance tends to encourage the film material (10) to stretch slightly towards the proximal segments (7). It will be easily understood that the strain on the film material (10) in turn increases the film material's (10) tension and grip on the object (100) to be secured.

FIG. 5 depicts a perspective view of the embodiment of the packaging assembly (1) as shown in FIG. 1 illustrating the way in which the packaging assembly (1) fits inside a box (31); the embodiment comprises a rigid panel (14) in the folded condition comprising a pair of end edges (2), a pair of side edges (3), a center portion (4) around the center of the rigid panel (14); a pair of proximal segments (7), each connected respectively to the right side and left side of the center portion (4); a pair of distal segments (8), each respectively connected to one of the proximal segments (7); and a first pair of substantially parallel fold lines (5) and a second pair of substantially parallel fold lines (6), wherein the first pair of fold lines (5) and the second pair of fold lines (6) are substantially parallel with each other, wherein the first pair of fold lines (5) and the pair of side edges (3) define the center portion (4); a film material (10) having opposed ends superimposed on one surface of the rigid panel (14), extending over the center portion (4) and passing the first pair of fold lines (5) onto the proximal segments (7); an object (100) being secured in between the center portion (4) and the film material (10); and a box (31) comprising a box lid (41); a pair of lid side portions (42) each connected respectively to the right side and left side of the box lid (41); and a pair of box side portions (43), wherein the rigid panel (14) in the folded condition is inserted into the box (31) having inner dimensions corresponding to the peripheral dimensions of the folded rigid panel (14). Thus, when placed in the box (31), the proximal segments (7) and the distal segments (8) are restrained from unfolding by the inner sides of the box (31). In addition, the proximal segments (7) and the distal segments (8) space the center portion (4) from the bottom of the box (31). Thus, the object (100), when placed in the box (31), is maintained out of direct contact with the box (31) in all three axes, which can further reduce the risk of physical impact damage.

FIG. 6 depicts a plan view of another embodiment of the packaging assembly (51) disclosed herein comprising a pair of end edges (52), a pair of side edges (53), a center portion (54) around the center of the rigid panel (64); a pair of proximal segments (57), each connected respectively to the right side and left side of the center portion (54); a pair of distal segments (58), each respectively connected to one of the proximal segments (57); and a first pair of substantially parallel fold lines (55) and a second pair of substantially parallel fold lines (56), wherein the first pair of fold lines (55) and the second pair of fold lines (56) are substantially parallel with each other, wherein the first pair of fold lines (55) and the pair of side edges (53) define the center portion (54), wherein the first pair of fold lines (55), the second pair of fold lines (56) and the pair of side edges (53) define the proximal segments (57), wherein the second pair of fold lines (56), the pair of side edges (53) and the pair of end edges (52) define the distal segments (58), and wherein the width of the pair of distal segments (58) is greater than the width of the pair of proximal segments (57); and a film material (60) having opposed ends superimposed on one surface of the rigid panel (64), extending over the center portion (54) and passing the first pair of fold lines (55) onto the proximal segments (57), wherein each of the opposed ends is secured respectively to each of the proximal segments (57) by a plurality of stich line segments (19) having unsecured portions (15) of the film material (60) therebetween; a pair of unsecured edge portions (73) of the film material (60) substantially adjacent to the side edges (53); an opening (12) in the center portion (54) adjacent to a side edge (53); a cutout (11) along the opposite side edge (53); and a cutout (13) along each of the side edges.

FIG. 7 depicts a perspective view of the embodiment of the packaging assembly (51) as shown in FIG. 6 illustrating the way in which the cutouts (13) allow the lid side portions (42) of a box (31) to be easily inserted into the space between the distal segments (58) and the box side portions (43) when the box lid (41) is being closed.

FIGS. 1-7 depicts just two non-limiting embodiments of the packaging assembly disclosed herein. Variations and modifications from the embodiment exist.

As demonstrated above, embodiments of the invention provide packaging assemblies that can successfully secure objects against a substantially rigid panel and prevent uncontrolled movement of the objects when the rigid panel and the objects are packaged within a box. While the invention has been described with respect to a limited number of embodiments, the specific features on one embodiment should not be attributed to other embodiments of the invention. No single embodiment is representative of all aspects of the invention. Variations and modifications from the described embodiments exist. The appended claims intend to cover all such variations and modifications as falling within the scope of the invention.

All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. Although the foregoing invention has been described in some detail by way of illustration and example for purpose of clarity of understanding, it will be readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.

Claims

1. A packaging assembly comprising:

a) a substantially rigid panel having: (i) a pair of side edges and a pair of end edges; (ii) a center portion around the center of the rigid panel; (iii) a pair of proximal segments, each connected respectively to the right side and left side of the center portion; (iv) a pair of distal segments, each respectively connected to one of the proximal segments; and (v) a first pair of substantially parallel fold lines and a second pair of substantially parallel fold lines, wherein the first pair of fold lines and the second pair of fold lines are substantially parallel with each other, wherein the first pair of fold lines and the pair of side edges define the center portion, wherein the first pair of fold lines, the second pair of fold lines and the pair of side edges define the proximal segments, wherein the second pair of fold lines, the pair of side edges and the pair of end edges define the distal segments, and wherein the width of the pair of distal segments is greater than the width of the pair of proximal segments; and
b) a film material having opposed ends superimposed on one surface of the rigid panel, extending over the center portion and passing the first pair of fold lines onto the proximal segments, wherein each of the opposed ends is secured respectively to each of the proximal segments by one or more stitch lines.

2. The packaging assembly of claim 1 further comprises a pair of unsecured edge portions of the film material substantially adjacent to the side edges.

3. The packaging assembly of claim 1, wherein the rigid panel has an unfolded condition in which the proximal segments and the distal segments are substantially coplanar with the center portion and has a folded condition in which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion.

4. The packaging assembly of claim 1 further comprising a box adapted to receive the rigid panel in the folded condition, the box having interior dimensions corresponding to the peripheral dimensions of the rigid panel when folded so that the rigid panel is securely held within the box.

5. The packaging assembly of claim 1, wherein one or more of the stitch lines extend from one of the side edges to the other side edge.

6. The packaging assembly of claim 4, wherein each stitch line comprises a plurality of stitch line segments having unsecured portions of film therebetween.

7. The packaging assembly of claim 1 further comprising at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge.

8. The packaging assembly of claim 1 further comprising at least one cutout along each of the end edges.

9. A packaging assembly comprising:

a) a substantially rigid panel having: (i) a pair of side edges and a pair of end edges; (ii) a center portion around the center of the rigid panel; (iii) a pair of proximal segments, each connected respectively to the right side and left side of the center portion; (iv) a pair of distal segments, each respectively connected to one of the proximal segments; and (v) a first pair of substantially parallel fold lines and a second pair of substantially parallel fold lines, wherein the first pair of fold lines and the second pair of fold lines are substantially parallel with each other, wherein the first pair of fold lines and the pair of side edges define the center portion, wherein the first pair of fold lines, the second pair of fold lines and the pair of side edges define the proximal segments, wherein the second pair of fold lines, the pair of side edges and the pair of end edges define the distal segments, and wherein the width of the pair of distal segments is greater than the width of the pair of proximal segments;
b) a film material having opposed ends superimposed on one surface of the rigid panel, extending over the center portion and passing the first pair of fold lines onto the proximal segments, wherein each of the opposed ends is secured respectively to each of the proximal segments by one or more stitch lines; and
c) a box adapted to receive the rigid panel in the folded condition, the box having interior dimensions corresponding to the peripheral dimensions of the rigid panel when folded so that the rigid panel is securely held within the box.

10. The packaging assembly of claim 9 further comprises a pair of unsecured edge portions of the film material substantially adjacent to the side edges.

11. A packaging assembly of claim 8, wherein a height of the box from a bottom end to a top end thereof is substantially equal to the width of the distal segments, and wherein a width of the box from a side to the opposite side thereof is substantially equal to the width of the center portion.

12. A packaging assembly of claim 8, wherein the rigid panel has an unfolded condition in which the proximal segments and the distal segments are substantially coplanar with the center portion and has a folded condition in which the proximal segments are folded away from the film material and are substantially transverse to the center portion, and the distal segments are folded towards the film material and are substantially transverse to the center portion.

13. The packaging assembly of claim 8, wherein one or more of the stitch lines extend from one of the side edges to the other side edge.

14. The packaging assembly of claim 11, wherein each stitch line comprises a plurality of stitch line segments having unsecured portions of film therebetween.

15. The packaging assembly of claim 8 further comprising at least one opening in the center portion adjacent to one of the side edges and at least one cutout along the opposite side edge.

16. The packaging assembly of claim 8 further comprising at least one cutout along each of the end edges.

17. A method for packaging an object in the packaging assembly of claim 1, wherein the method comprises the steps of:

a) folding the pair of proximal segments in a direction towards the film material;
b) inserting at least a portion of the object into the packaging assembly through an opening defined by an unsecured edge portion of the film material and the rigid panel;
c) folding each of the distal segments towards the film material and folding the pair of proximal segments together with the pair of distal segments in a direction away from the film material in which the film material is tightened against at least a portion of the object and the pair of proximal segments and the pair of distal segments are substantially transverse to the center portion and the end edges are above the film material; and
d) placing the folded panel with the object into a box having interior dimensions corresponding to the peripheral dimensions of the folded panel.
Patent History
Publication number: 20180229883
Type: Application
Filed: Feb 14, 2017
Publication Date: Aug 16, 2018
Applicant: E - pac Packaging Services Co. Ltd. (Hong Kong)
Inventors: Tin Yeu Terence Lun (Hong Kong), Zhong Zhu Luo (DongGuan), Shi Hu Zhou (DongGuan)
Application Number: 15/432,912
Classifications
International Classification: B65D 5/50 (20060101); B65B 11/50 (20060101); B65B 61/20 (20060101); B65D 5/42 (20060101); B65D 5/66 (20060101); B65D 81/05 (20060101);