Lightweight, shock-absorbing package   

The present invention relates to a lightweight, shock-absorbing package for shipping or mailing fragile items, and more specifically, to a new configuration for a mailable package which contains an article that must be cushioned so as to sustain certain shock loads that can be expected to occur during transit.

It is an inescapable fact that the need often arises to mail or otherwise ship fragile articles. There are several reasons for this. The explosive growth of the catalog mail-order business has prompted the shipping of all sorts of delicate, impact-sensitive products from centralized warehouses to consumers' residences. Manufacturing or product development firms also often need to ship fragile items, such as computer chips or other components, from a parts supplier to a final assembly point or to some location where the component can be tested after integration into some larger system. Physicians' offices and medical laboratories also ship fragile articles in the form of containers, often made of glass, that contain samples of biological material.

Several concepts have been introduced in an attempt to adequately protect delicate items being shipped through the postal service. U.S. Pat. No. 2,646,876 to Sparks discloses a mailable display package designed to hold an article for shipment wherein the structure is formed of thick boxboard and is sealed by a series of flaps. One disadvantage of the Sparks package is the increased weight that results from the use of the thick boxboard that increases the weight of the shipping container. The size of the package required to enclose a given volume is also increased by the boxboard's thickness, with the attendant increase in material costs and reduction in the amount of boxes that can be ferried by any particular mode of transportation. Additional drawbacks of Sparks' use of boxboard includes the increased difficulty in forming the specified cut-outs, creases and flaps in the boxboard, which of course leads to increased production costs.

U.S. Pat. No. 5,119,952 to Warriner, Jr. discloses a postcard-type package for flowable substances such as would be contained in a sample container of biological fluid. A flat sheet is folded approximately in half forming first and second sections, with a slotted opening cut in the second section. A cradle is inserted into the slotted opening, said cradle being secured by a flange to the second section.

Despite these known methods and devices, there still is a need for an improved shipping package that is lightweight while still providing ample protection from impact loads that inevitably occur during shipping. The present invention discloses such shipping packages which avoid the disadvantages of the prior art.

The invention now provides a new and improved lightweight, shock-absorbing package for shipping fragile articles via the postal service. Such a package avoids the use of heavier-stock boxboard and forms a package for shipping fragile articles which is easy and inexpensive to produce and assemble. The size and configuration of the package enables fragile articles to be shipped by the postal service which involves minimum shipping costs due to the size and weight of the shipping package. The invention also relates to a new and improved lightweight, shock-absorbing package for shipping fragile articles which visibly displays the article when the package is sealed.

To achieve these advantages, the present package comprises first and second relatively stiff substantially flat sheet portions each having a front and a back face, and at least one shock-absorbing resilient member made of lightweight, flexible material and placed between the sheet portions to form an assembly, wherein the resilient material includes open areas that are configured and dimensioned to receive one or more of the articles between the sheet portions. The resilient member also can have cut out or open areas which are configured and dimensioned to receive or conform to the shape (s) of the articles(s) to be shipped.

The sheet portions and resilient member may be maintained in the desired orientation by being adhered together after the one or more articles are placed in the package. Thereafter, the sheet portions and resilient member may be maintained in the desired orientation by being surrounded by a polymer film after the one or more articles are placed in the package. The polymer film preferably has a shrink wrap properties.

Alternatively, the package may further comprise cooperating engaging elements formed on the flat sheet for the purpose of providing a releasable connection between the first and sheet portions. These cooperating adhesive elements are hook-and-loop fasteners.

In addition, the package can include cooperating engaging elements formed on the flat sheet and the resilient member for the purpose of providing a releasable connection between the first section and the resilient member. Again, these cooperating adhesive elements may be hook-and-loop fasteners. Furthermore, the resilient member is preferably a resilient foam that is present as a sheet with cut out portions to receive the articles or as an edge member that is positioned along at least 3 or in some cases all four edges of the sheet portions or sheets to form an internal chamber in the package that receives the articles to be shipped.

In another embodiment, the package comprises a relatively stiff substantially flat sheet, preferably of single-ply cardboard, having front and back sides that is divided by two creased fold lines into three sections. The first section and second section are of equal size, while the spine section is considerably narrower, with a width equal to the desired thickness of the package. When forming the advantageous package, the first and second sections are folded back toward one another about the spine section, so that the back sides of the first and second sections are brought into a facing arrangement.

One or more shock-absorbing resilient edge members are provided that are preferably fashioned of a solid, flexible foam. This will provide an advantageous shock-absorbing quality when the package undergoes the gyrations and impacts that inevitably occur during shipping. The resilient edge member can be bonded proximally to three edges of the back face of the second section by means of adhesive or fasteners such as staples. The edges are those that are opposite from and perpendicular to the spine section.

In an alternative embodiment, the first section can have at least one cut-out which, when combined with a transparent film affixed to the back side of first section, forms a viewing window that allows an article being shipped to be visualized when the package is sealed. Any desired quantity and shape of cut-out can be chosen based on the type of article being shipped, and its likely orientation when placed in the package.

The advantageous package of the present invention is also capable of being sealed once the fragile article is placed within. A releasably sealed connection can be formed between the first section and the edge members, either by means of a Velcro-type hook and loop fastener connection or by an adhesive chosen for its combination of strength and tendency to yield under appropriate application of force by a recipient of the package. Alternatively, the flat sheet can be designed to form a releasable tongue-and-groove type of connection between the first and second sections, or between the first section and one or both of the second section and resilient edge members.

The invention will be better understood in relation to the attached drawings illustrating preferred embodiments, wherein:

FIG. 1 is a plan view of a preferred embodiment of the present invention, prior to folding of the substantially flat sheet;

FIG. 2 is a perspective view of the embodiment of FIG. 1, prior to folding of the substantially flat sheet;

FIG. 3 is a side view of the embodiment of FIG. 1, prior to folding of the substantially flat sheet;

FIG. 4 is a side view of the embodiment of FIG. 1, subsequent to folding of the substantially flat sheet;

FIG. 5 is a plan view of an alternative embodiment of the present invention having a film window, prior to folding of the substantially flat sheet; and

FIG. 6 is a perspective view of the embodiment of FIG. 5, subsequent to folding of the substantially flat sheet; and

FIG. 7 is an exploded perspective view of an embodiment comprised of two substantially flat sheets.

Referring now more particularly to FIGS. 1, 2, 3 and 4 of the accompanying drawings, there is illustrated a lightweight, shock-absorbent package constructed in accordance with the preferred embodiments of the present invention.

The present invention 100 shown in plan view in FIG. 1 includes a relatively stiff substantially flat sheet 112 having front and back sides that is divided by two creased fold lines 114,116 advantageously into three sections, namely, first section 118, spine section 120, and second section 122. First section 118 and second section 122 are of equal size, while the spine section 120 is considerably smaller, with a height equal to that of sections 118,122 but a width that is equal to the desired thickness of the package. When forming the advantageous package, first and second sections 118,122 are folded back along fold lines 114,116 toward one another about spine section 120, so that the back sides of the first and second sections are brought into a facing arrangement. A typical size for such a package would be 5″×6″×0.75″, though a package of any size which conforms to postal service regulations can be formed.

According to a preferred embodiment, the relatively stiff substantially flat sheet 112 is made up of a single-ply cardboard, sometimes referred to as card stock. This material is desirable because it provides more than sufficient structural stability to withstand being shipped through the post, while being of very low weight per unit area relative to corrugated boxboard. It is also a suitable choice because single-ply cardboard is also more easily cut into properly-sized pieces and scored to produce the desired fold lines 114,116. Other types of commonly used cardboard or shipboard are also suitable materials for the flat sheet.

One or more shock-absorbing resilient members 124 are provided that are preferably fashioned of a solid, flexible foam. Several different types of foam can be advantageously used. In a preferred embodiment, either open cell or closed cell foam can be used, depending on the application. This will provide an advantageous shock-absorbing quality when the package undergoes the gyrations and impacts that inevitably occur during shipping. The resilient member can be bonded proximally to three edges of the back face of the second section 122 by means of adhesive or fasteners such as staples. The edges are those that are opposite from and perpendicular to the spine section 120, as can be seen in FIG. 1.

FIG. 3 is a side view of the preferred embodiment of the present invention, showing the substantially flat sheet 112 prior to folding. The resilient member can consist of a single cord of foam that is bent to conform to the desired three edges of the second section, or can be comprised of a plurality of resilient members arrayed so as to seal the desired three edges. When first and second sections 118,122 are folded back along fold lines 114,116 toward one another about spine section 120, such that the back sides of the first and second sections 118,122 are brought into a facing arrangement, the resilient member 124 serves to form a closed, sealed package that fully contains a fragile article disposed therein. This is shown in FIG. 4.

FIGS. 5 and 6 illustrate a further advantageous arrangement for a lightweight, shock-absorbent package containing sections 218, 220 and 222. This alternative embodiment of the present invention 200, which is shown in plan view in FIG. 1, includes the relatively stiff substantially flat sheet 212 having front and back sides that is divided as in the preferred embodiment by two creased fold lines 214,216 into three sections 218, 220, and 222. However, first section 218 now has at least one cut-out 226 which, when combined with a transparent film affixed to the back side of first section 218, forms a viewing window that allows an article being shipped to be visualized when the package is sealed. Any desired quantity and shape of cut-out can be chosen based on the type of article being shipped, and its likely orientation when placed in the package. As with the previous embodiment, the first and second sections 218,222 are folded back along fold lines 214,216 toward one another about spine section 220, so that the back sides of the first and second sections are brought into a facing arrangement.

The advantageous package of the present invention is also capable of being sealed once the fragile article is placed within. This can be done by forming a releasably sealed connection between first section 218 and resilient members 224, either by means of a Velcro-type hook and loop connection or an adhesive chosen for its combination of strength and tendency to yield under appropriate application of force by a recipient of the package. Alternatively, the flat sheet 212 can be designed such that a releasable tongue-and-groove type of connection is formed between first and second sections 218,222, or between the first section and one or both of the second section and resilient members 224. FIG. 5 shows possible arrangements of a releasably adhesive connection. Adhesive elements 226 can take the form of respective hook and loop pads, or can be points of application of an appropriate adhesive. It is to be understood that many possible arrangements of the chosen adhesive elements 226 about the resilient members can be made. FIG. 5 also shows a possible arrangement of engaging elements 228 comprised of tongue and groove cut-outs formed on the first section and the resilient member, respectively. It is to be understood that many possible arrangements of engaging elements can be made, including between the first and second sections 218,222, or between all three sections.

Additional means for the finishing and preparation for shipping of a package according to the present invention include the application of a polymer film 230 about the entire exterior of the package. The polymer film can take the form of shrink wrap polymer film. The shrink wrap film is typically made of polypropylene or polyethylene, and can be applied in lieu of or in addition to any adhesive elements or engaging elements that are used.

As noted above and shown in FIG. 7, in a basic embodiment 300, two sheets 318,322 of a relatively stiff material can be placed in vertical alignment with a resilient member 324 placed therebetween. The resilient member, preferably a foam, can include open areas in the center to receive the articles to be shipped. The open areas can be configured in the shape of the article(s) to be shipped. The resilient member can also be placed adjacent the edges of the sheets to provide an open area in the center of the package to receive the articles to be shipped. Additionally, the resilient member 324, which is sandwiched between the two sheets 318, 322 of relatively stiff material, can extend around the edges of the sheets where the foam resilient member is pre-glued. The foam is first applied to one sheet, the article is placed in the open area and then the top surface of the foam is adhered to the opposite sheet.

To secure the package, the resilient member can be adhered to the sheets or sheet portions after the articles are placed therein. Alternatively, the package can be provided with a polymer film such as shrink wrap that holds the components together with the article(s) therebetween.

The preferred sizes for the products of the invention are set forth in US Post Office Standard for C800 Automation-Compatible Mail entitled “C820 Flats” (see http://pe.usps.gov/archive/html/dmmarchive0810/C820.htm#Rba33587), the entire standard is expressly incorporated herein by reference thereto. In particular, each flat-size piece is rectangular and the preferred shape and size requirements would be:

For height, no more than 12 inches and no less than 5 inches high.

For length, no more than 15 inches and no less than 6 inches long.

For thickness, no more than 0.75 inch and no less than 0.009 inch thick.

The maximum weight limits are as follows:

For First-Class Mail, 13 ounces.

For Standard Mail, less than 16 ounces.

Also, the package meets certain turning ability and deflection criteria, including:

Turning Ability. The mailpiece must fit between two concentric arcs drawn on a horizontal flat surface, one with a radius of 15.72 inches and the other with a radius of 16.72 inches, in one of the following ways:

The piece must be flexible enough to bend between the two arcs when positioned vertically, with (if applicable) the bound, folded, or final folded edge perpendicular to the surface where the arcs are drawn.

For a rigid construction (i.e., the package constructed of or containing inflexible materials), the piece must be small enough to allow its longest edge to be placed between the two arcs without touching the lines of the arcs.

Deflection. A flat-size mailpiece meeting the AFSM 100 dimensions must be rigid enough so that, when placed flat on a surface to extend unsupported 5 inches off that surface, no part of the edge of the piece that is opposite the bound, folded, or final folded edge (as applicable) deflects more than 1¾ inches (if the piece is less than ⅛ inch thick) or more than 2⅜ inches (if the piece is from ⅛ to ¾ inch thick).

Testing for compliance with the above standards can be done with a flat mail machinability tester constructed to USPS specification USPS-STD-28 and following the instructions for use of that device.

As noted, the present invention is capable of meeting the aforementioned criteria.

To the extent not already indicated, it also will be understood by those of ordinary skill in the art that any one of the various specific embodiments herein described and illustrated may be further modified to incorporate features shown in other of the specific embodiments, as desired.