Integrated Shipping Containers

Description

RELATED APPLICATION(S)

The present application claims the benefit of and priority to a U.S. Provisional Patent Application Ser. No. 63/686,099, filed Aug. 22, 2024, which is hereby incorporated by reference in its entirety into the present application.

BACKGROUND

The present invention relates to shipping containers and packaging systems. More particularly, it relates to corrugated cardboard containers configured for the secure shipment of personal electronic devices, such as cell phones, tablet computers, and similar portable consumer electronics.

The safe shipment of personal electronic devices presents unique challenges due to their fragile components, high value, and susceptibility to impact damage. Traditional corrugated cardboard shipping containers are widely used for packaging a variety of consumer goods. However, such conventional containers rely on additional protective materials, such as molded plastic inserts, bubble wrap, foam pads, or separate cushioning layers, in order to provide adequate protection for delicate electronic products. This reliance on secondary protective elements increases material costs, assembly time, and environmental waste.

Existing container systems typically utilize multiple separate pieces of material for cushioning and security that are manually combined during packaging. These approaches complicate manufacturing and increase the potential for packaging errors. In addition, many current designs fail to provide adequate shock absorption along all sides of the product, leaving sensitive electronic devices vulnerable to damage during drops or rough handling.

There remains a need in the art for improved shipping containers that are formed from a single piece of corrugated cardboard, yet provide both structural support and built-in cushioning features. Such a design would reduce reliance on secondary packaging materials, simplify assembly, reduce costs, reduce waste, and improve the protection of personal electronic devices during transport.

SUMMARY

The present disclosure is directed to integrated shipping containers, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a diagram of an exemplary integrated shipping container, according to one embodiment of the present disclosure;

FIG. 2 shows a diagram of a blank for folding the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure;

FIG. 3 shows a cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure;

FIG. 4 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure;

FIG. 5 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure;

FIG. 6 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure;

FIG. 7 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure;

FIG. 8 shows a cross-section of an exemplary integrated shipping container, according to one embodiment of the present disclosure;

FIG. 9 shows another cross-section of the exemplary integrated shipping container of FIG. 8, according to one embodiment of the present disclosure;

FIG. 10 shows another cross-section of the exemplary integrated shipping container of FIG. 8, according to one embodiment of the present disclosure; and

FIG. 11 shows another cross-section of the exemplary integrated shipping container of FIG. 8, according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

The following description contains specific information pertaining to embodiments in the present disclosure. The drawings in the present application and their accompanying detailed description are directed to merely exemplary embodiments. Unless noted otherwise, like or corresponding elements among the figures may be indicated by like or corresponding reference numerals. Moreover, the drawings and illustrations in the present application are generally not to scale and are not intended to correspond to actual relative dimensions.

FIG. 1 shows a diagram of an exemplary integrated shipping container, according to one embodiment of the present disclosure. The integrated shipping container includes outer container 1, comprising outer container base 2, outer container sidewall 3, outer container sidewall 4, outer container end 5, outer container end 6, and outer container top 7. The integrated shipping container may be a shipping or storage container for personal electronic devices, such as mobile phones, tablet computers, smart watches, and laptop computers. As shown in FIG. 1, outer container 1 includes tear-away strip 8 included in outer container top 7. Tear-away strip 8 may be perforated to allow for easy removal of tear-away strip 8 to open the integrated shipping container. As shown in FIG. 1, end 5 is open. In other embodiments, end 5 may include an outer container end wall enclosing end 5 of outer container 1. outer container end 6, obscured form view in FIG. 1, may be open or include outer container end wall.

FIG. 2 shows a diagram of a blank for folding the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure. The blank may be cut from a single piece of integrated shipping container material, such as corrugated cardboard, paper board, flexible plastics, foamed plastics, rigid plastics, corrugated plastics, or any combination thereof. The blank includes a plurality of folds where the blank may be folded to build the integrated shipping container. As shown in FIG. 2, the blank includes product compartment top 9, product compartment front wall 10, product compartment base 11, product compartment rear wall 12, outer container top (inner layer) 7a, outer container sidewall 3, outer container base 2, outer container sidewall 4, and outer container top (outer layer) 7b. In some embodiments, the integrated shipping container may include adhesive strip 13 for affixing outer container top layer 7b to outer container top layer 7a to seal the integrated shipping container when the integrated shipping container is in a close configuration and sealed to contain a product. As shown in FIG. 2, product compartment top 9 may include cushion tab 14 and product compartment base 11 may include cushion tabs 15 and 16. Cushion tabs 14, 15, and 16 may be in place to maintain an air cushion gap between product compartment front wall 10 and outer container sidewall 3 when the blank is folded to build the integrated shipping container.

As shown in FIG. 2, the blank includes supports 17 and 18, extending from product compartment top 9, and connected to suspension elements 19 and 20. When the blank is folded into the integrated shipping container, suspension element 19 and 20 extend into the product compartment. In some embodiments, suspension element 19 and 20 each may extend through a portion of the length of the product compartment. In some embodiments, suspension element 19 and 20 may each extend through a length that is less than half the length product compartment top 9. Supported at the outer end by supports 17 and 18, suspension elements 19 and 20 may provide a retention force on a product placed in the product compartment and provide suspension support between the product and product compartment top 9.

As shown in FIG. 2, the blank includes supports 21 and 22, extending from product compartment base 11, and connected to suspension elements 23 and 24. When the blank is folded into the integrated shipping container, suspension element 23 and 24 extend into the product compartment. In some embodiments, suspension element 23 and 24 each may extend through a portion of the length of the product compartment. In some embodiments, suspension element 23 and 24 may each extend through a length that is less than half the length product compartment base 11. Supported at the outer end by suspension support elements 21 and 22, suspension elements 23 and 24 may provide a retention force on a product placed in the product compartment and provide suspension support between the product and product compartment base 11.

As shown in FIG. 2, the integrated shipping container includes product compartment end wall 25 and end wall securing element 26 and product compartment end wall 27 and end wall securing element 28 extending from the ends of outer container top 7. When the blank is folded into the integrated shipping container, end walls 25 and 27 may fold over the ends of the product compartment to enclose a product inserted therein. End wall securing elements 26 and 28 may be secured between product compartment base 11 and outer container base 2.

FIG. 3 shows a cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure. As shown in FIG. 3, the integrated shipping container is formed from one blank folded to form the product compartment contained in the outer container. The folding of the product compartment creates an air gap between the product compartment front wall 10 and outer container sidewall 3, an air gap between product compartment base 11 and outer container base 2, and an air gap between product compartment rear wall 12 and outer container sidewall 4. A product space is shown between suspension elements 20 and 24. A product that is inserted in the integrated shipping container may be cushioned by the suspension elements in the product compartment. The product may also be protected by the air gaps around the product compartment. The cross-section shown in FIG. 3 crosses through cushion tab 14, extending from product compartment front wall 10 and outer container sidewall 3.

FIG. 4 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure. As shown in FIG. 4, the cross section passes through cushion tab 16, extending from product compartment front wall 10 and outer container sidewall 3. Additionally, the cross-section passes through suspension elements 20 and 24, clearly showing the product space defined therebetween.

FIG. 5 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure. The cross-section shows the air gap created between product compartment front wall 10 and outer container sidewall 3. As shown in FIG. 5, cushion tabs 14, 15, and 16 extend from the product compartment towards outer container sidewall 3 (not shown). FIG. 6 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure. The cross section shows product compartment top 9, supports 17, 18, 21, and 22, with suspension elements 19, 20, 23, and 24 extending therefrom, respectively. In some embodiments, suspension elements 19, 20, 23, and 24 may provide a cushion for a product in the integrated shipping container. The cushions above and below the product that are formed and maintained by suspension elements 19, 20, 23, and 24 may be a variable cushion because the cushion and suspension force may change with the weight of the product, the orientation of the integrated shipping container, and with any external forces applied due to movement, transportation, or falling. In some embodiments, the open ends of the outer container may provide a cushion effect by deformation in the event of a fall or impact.

End wall 25 extends from the end of outer container top 7 and product compartment end wall securing element is inserted between product compartment base 11 and outer container base 2. The air cushion formed by the outer container extension beyond the end walls of the product compartment is clearly shown. FIG. 7 shows another cross-section of the exemplary integrated shipping container of FIG. 1, according to one embodiment of the present disclosure. As shown in FIG. 7, the air cushion maintained by the extension of product compartment end walls 25 and 27, as well as product compartment end wall securing elements 26 and 28, is shown.

FIG. 8 shows a cross-section of an exemplary integrated shipping container, according to one embodiment of the present disclosure. The cross-section shows product compartment end wall securing elements 26 and 28 is inserted between product compartment base 11 and outer container base 2 (not shown). FIG. 9 shows another cross-section of the exemplary integrated shipping container of FIG. 8, according to one embodiment of the present disclosure. As shown in FIG. 9, product compartment base 11 does not fill the width of outer container 1, leaving an air gap between outer container sidewall 4 and product compartment rear wall 12 (not visible). The air gap between product compartment front wall 10 and outer container sidewall 3 and maintained by cushion tabs 15 and 16 is visible.

FIG. 10 shows another cross-section of the exemplary integrated shipping container of FIG. 8, according to one embodiment of the present disclosure. The cross-section shows the inside of the product compartment and the product space formed by the suspension elements. FIG. 11 shows another cross-section of the exemplary integrated shipping container of FIG. 8, according to one embodiment of the present disclosure. The cross-section shows the cushion space above the suspension elements and cushion tab 14 maintaining the air cushion between product compartment front wall 10 and outer container sidewall 3.

In other embodiments, the integrated shipping container may be used as an insert in a larger shipping container. In some embodiments, the integrated shipping container may be used as one of a plurality of inserts in a larger shipping container.

From the above description, it is manifest that various techniques can be used for implementing the concepts described in the present application without departing from the scope of those concepts. Moreover, while the concepts have been described with specific reference to certain embodiments, a person having ordinary skill in the art would recognize that changes can be made in form and detail without departing from the scope of those concepts. As such, the embodiments described are to be considered in all respects as illustrative and not restrictive. It should also be understood that the present application is not limited to the particular embodiments described above, but many rearrangements, modifications, and substitutions are possible without departing from the scope of the present disclosure.