WAVE PACKAGING ASSEMBLY, CUSHION ASSEMBLY AND PADDING ARTICLE

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application Ser. No. 63/707,485, filed Oct. 15, 2024, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

Field of Disclosure

The present teachings relate generally to product packaging and, more particularly, to product packaging having integrated support, cushioning, and reinforcement features.

Description of Related Art

Products are often wrapped in packaging to protect them from damage during transport. Traditionally, packaging often includes multiple pieces of padding, coverings, blocking, etc. to support and cushion a product in box. Packaging is often formed of molded organic materials (e.g., paper, cotton, wool, straw, etc.) or molded polymer materials (e.g., polystyrene, polyethylene, polypropylene, etc.). However, heavy products are often difficult to adequately protect with conventional molded organic packaging components. Thus, heavy items are conventionally packaged using molded polymer packaging components, which are often not biodegradable.

Therefore, it would be beneficial to have an alternative system and method for product packaging.

SUMMARY

The needs set forth herein as well as further and other needs and advantages are addressed by the present embodiments, which illustrate solutions and advantages described below.

One embodiment of a padding article according to the present teachings includes, but is not limited to, a sheet formed according to a wave pattern to include a wave crest, a wave trough connected to the wave crest, and a first plurality of dimples formed along either the wave crest or the wave trough.

In one embodiment, a padding article according to the present teachings includes a second plurality of dimples formed along the other of the wave crest or the wave trough.

In one embodiment, a padding article according to the present teachings includes a bolster defining a space, and the sheet is pivotably connected to the bolster.

In one embodiment, a padding article according to the present teachings includes the bolster including a base, and the sheet extending from an outer edge of the base.

In one embodiment, a padding article according to the present teachings includes the bolster including a side wall extending from the base, and the side wall being between the sheet and the base.

In one embodiment, a padding article according to the present teachings includes the bolster including a plurality of protrusions extending outwardly from the side wall to define a plurality of channels.

In one embodiment, a padding article according to the present teachings includes the bolster including a plurality of protrusions extending inwardly from the base into the space to define a plurality of channels.

In one embodiment, a padding article according to the present teachings includes the sheet being a first sheet, the side wall being between the first sheet and the base, and a second sheet formed according to the wave pattern being pivotably connected to the outer edge.

In one embodiment, a padding article according to the present teachings includes, in a folded configuration, the first sheet contacting the side wall, and the second sheet contacting an outer face of the base.

In one embodiment, a padding article according to the present teachings includes the second sheet extending further outwardly from the base than the first sheet.

In one embodiment, a padding article according to the present teachings includes the first plurality of dimples and the second plurality of dimples being embossed concavely inwardly toward a wave axis of the sheet.

In one embodiment, a padding article according to the present teachings includes the first plurality of dimples being spaced regularly from one another, and the second plurality of dimples being spaced regularly from one another.

In one embodiment, a padding article according to the present teachings includes the first plurality of dimples being aligned with the second plurality of dimples.

In one embodiment, a padding article according to the present teachings includes the first plurality of dimples being offset from the second plurality of dimples.

One embodiment of a cushion assembly according to the present teachings includes, but is not limited to, a bolster, and a first wing pivotably connected to the bolster, the first wing being formed according to a wave pattern to include a plurality of alternating apexes, and a plurality of dimples along the apexes.

In one embodiment, a cushion assembly according to the present teachings includes the dimples being inwardly embossed in the apexes toward a wave axis of the first wing.

In one embodiment, a cushion assembly according to the present teachings includes a second wing formed to follow the wave pattern and is pivotably connected to the bolster, and the second wing extends further from the bolster than the first wing.

In one embodiment, a cushion assembly according to the present teachings includes a plurality of end caps connected to opposite ends of the first wing.

One embodiment of a packaging assembly according to the present teachings includes, but is not limited to a box and a cushion assembly. The cushion assembly includes a bolster and a wing pivotably connected to the bolster to contact an interior surface of the box and an outer face of the bolster, the wing being formed to follow a wave pattern. The wave pattern includes a plurality of alternating apexes, and a plurality of dimples along the apexes.

In one embodiment, a packaging assembly according to the present teachings includes the dimples being inwardly embossed in the apexes toward a wave axis of the wing.

Other embodiments of the present teachings are described in detail below.

For a better understanding of the present embodiments, together with other and further aspects thereof, reference is made to the accompanying drawings and detailed description, and its scope will be pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of one embodiment of a packaging assembly according to the present teachings;

FIG. 2 is a partially exploded view of the packaging assembly of FIG. 1;

FIG. 3 is an isometric view of a cushion assembly of the packaging assembly of FIG. 1;

FIG. 4 is an exploded view of the cushion assembly of FIG. 3;

FIG. 5 is a cushion of the cushion assembly of FIG. 3;

FIG. 6 is an enlarged view of the cushion of FIG. 5 taken from region R of FIG. 5;

FIG. 7 is a side view of a wing of the cushion of FIG. 5;

FIG. 8 is an illustration of another embodiment of a packaging assembly according to the present teachings;

FIG. 9 is a partially exploded view of the packaging assembly of FIG. 8;

FIG. 10 is an illustration of a further embodiment of a packaging assembly according to the present teachings;

FIG. 11 is an isometric view of a cushion assembly of the packaging assembly of FIG. 10;

FIG. 12 is an exploded view of the cushion assembly of FIG. 11;

FIG. 13 is an isometric view of a face cushion of the cushion assembly of FIG. 12;

FIG. 14 is an isometric view of a corner cushion of the cushion assembly of FIG. 12 in an unfolded configuration;

FIG. 15 illustrates an enlarged view of a padding article according to the present teachings;

FIG. 16 illustrates an enlarged view of another embodiment of a padding article according to the present teachings; and

FIG. 17 illustrates a side view of stacked padding articles according to the present teachings.

DETAILED DESCRIPTION

The present teachings are described more fully hereinafter with reference to the accompanying drawings, in which the present embodiments are shown. The following description is presented for illustrative purposes only and the present teachings should not be limited to these embodiments. Any computer configuration and architecture satisfying the speed and interface requirements herein described may be suitable for implementing the system and method of the present embodiments.

In compliance with the statute, the present teachings have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the present teachings are not limited to the specific features shown and described, since the systems and methods herein disclosed comprise preferred forms of putting the present teachings into effect.

For purposes of explanation and not limitation, specific details are set forth such as particular architectures, interfaces, techniques, etc. in order to provide a thorough understanding. In other instances, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description with unnecessary detail.

Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to a/an/the element, apparatus, component, means, step, etc. are to be interpreted openly as referring to at least one instance of the element, apparatus, component, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated. The use of “first”, “second,” etc. for different features/components of the present disclosure are only intended to distinguish the features/components from other similar features/components and not to impart any order or hierarchy to the features/components.

To aid the Patent Office and any readers of a patent issued on this application in interpreting the claims appended hereto, it is noted that none of the appended claims or claim elements are intended to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

Recitations of numerical ranges by endpoints include all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.). Where a range of values is “greater than”, “less than”, etc., of a particular value, that value is included within the range.

Any direction referred to herein, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” “above,” below,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Many of the devices, articles, or systems described herein may be used in a number of directions and orientations.

Any citation to a reference in this disclosure or during the prosecution thereof is made out of an abundance of caution. No citation (whether in an Information Disclosure Statement or otherwise) should be construed as an admission that the cited reference qualifies as prior art or comes from an area that is analogous or directly applicable to the present teachings.

Referring now to FIG. 1, shown is a packaging assembly 100 according to an embodiment. The packaging assembly 100 includes a box 102 and a plurality of cushions 104 enveloping and supporting a product 106. In some embodiments, the box 102 is formed of corrugated cardboard. In some embodiments, the box 102 is a rectangular prism (e.g., a cube) and thus has a plurality of sides 108 and a bottom 110. The box 102 further includes a plurality of closure flaps 112, which form a top 114. One or more of the sides 108 define a cutout 116 by which the packaging assembly 100 may be grasped and moved (e.g., lifted, pulled, pushed, etc.). In operation, the closure flaps 112 are folded inwardly toward the product 106 to enclose the cushions 104 and the product 106 in the box 102. In some embodiments, the closure flaps 112 may be held closed by adhesives (e.g., glue) and/or adhesive tape (not shown). In some embodiments, the closure flaps 112 may be held closed by interlocking with one another (not shown).

Remaining with FIG. 1, in some embodiments, the box 102 and/or cushions 104 are formed of molded and bonded organic pulp (e.g., paper, wood, cellulose, plant fibers, nutshells, etc.). More specifically, in some embodiments, the organic pulp is compressed and heated in molds to reorient the fibers of the organic pulp into the three-dimensional structures of the box 102 and/or the cushions 104. Further, in some embodiments, the organic pulp is passed and/or rolled through one or more dies that compress and heat the organic pulp into the three-dimensional structures of the box 102 and/or the cushions 104. Thus, in some embodiments, the box 102 and the cushion 104 are biodegradable.

Referring again to FIG. 1, in some embodiments, box 102 and/or the cushions 104 are formed of molded polymer materials (e.g., polystyrene, polyethylene, polypropylene, etc.). More specifically, in some embodiments, the polymer materials are heated, stamped, blown, and/or injected into molds to form the box 102 and/or the cushions 104. Thus, in some embodiments, the box 102 and/or the cushions 104 are recyclable.

Turning to FIG. 2, the cushions 104 are located between the box 102 and the product 106. Additionally, the box 102 and the cushions 104 are configured to fit snugly together. More specifically, the cushions 104 are configured to engage an interior surface 120 of the box 102. The cushions 104 are slidably removable from the box 102. Thus, in operation, when the cushions 104 are slid out of the box 102, the product 106 is also removed from the box 102.

With reference to FIG. 3, in some embodiments, a cushion subassembly 130 includes four cushions 104, although not limited thereto. More specifically, two cushions 104 engage an upper portion 132 of the product 106 and two cushions 104 engage a lower portion 134 of the product 106. Further, the cushions 104 are configured to snugly engage and/or fit onto the product 106. In some embodiments, the cushions 104 are substantially identical. In some embodiments, the cushions 104 differ from one another to tightly engage the outer geometry of the product 106.

With reference to FIG. 4, the cushions 104 are configured to engage one or more corners 140 and/or one or more edges 142 of the product 106. Thus, in some embodiments, where the product 106 is generally shaped as a rectangular prism, each cushion 104 is configured to engage two corners 140 and three edges 142 of the product 106. In some embodiments, multiple cushions 104 are placed together to cover a face 144 of the product 106.

Remaining with to FIG. 4, each cushion 104 includes one or more wings 150 flexibly pivotably connected to a bolster 152, e.g., a rectilinear bolster. Thus, in a folded configuration 154, the wings 150 are folded to contact outer faces 156 of the bolster 152.

As shown in FIG. 5, in an unfolded configuration 160, the wings 150 extend outwardly from the bolster 152. The bolster 152 includes a plurality of side walls 162 connected to one another and extending from a base 164, thus forming corner brackets 166. A plurality of protrusions 168 extends from the side walls 162 and the base 164. Thus, a plurality of inner channels 170 is defined between the protrusions 168. In some embodiments, the protrusions 168 extend outwardly from the side walls 162. In some embodiments, the protrusions 168 extend inwardly from the base 164 into a space 172 defined by the bolster 152. More specifically, the wings 150 extend from an outer edge 174 of the base 164. In operation, the bolster 152 flexes via the protrusions 168. Further, because the cushion 104 may be molded, the protrusions 168 may be hollow and outer channels 176 defined within the protrusions 168 on an outer face 178 of the cushion 104, as shown in FIG. 4.

With reference to FIG. 5, the wings 150 include a first wing 180, a second wing 182, a third wing 184, and a fourth wing 186. Each wing 150 is a wave-shaped (e.g., corrugated, undulating, serpentine, etc.) sheet. In some embodiments, the second wing 182 and the third wing 184 are substantially identical. In some embodiments, the first wing 180 and the fourth wing 186 are wider along the outer edge 174 than the second wing 182 and the third wing 184. Additionally, in some embodiments, the fourth wing 186 extends further outwardly from the base 164 than the first wing 180, the second wing 182, and the third wing 184. Further, in some embodiments, each wing 150 follows a common wave pattern 188. Thus, in some embodiments, the fourth wing 186 has more undulations 190 than the first wing 180, the second wing 182, and the third wing 184. Accordingly, in some embodiments, the first wing 180, the second wing 182 and the third wing 184 are equal in undulations 190.

With reference to FIG. 4 and FIG. 5, in some embodiments, in a folded configuration 154, the first wing 180, the second wing 182, and the third wing 184 are folded to contact the side walls 162; and the fourth wing 186 is folded to contact an outer face of the base 164.

With reference to FIG. 6, following the wave pattern 188, each wing 150 has an alternating series of apexes 200 distanced from one another. Further, a series of dimples 202 are concavely embossed into the wings 150 along each apex 200. In some embodiments, the dimples 202 are spaced regularly from one another along the apexes 200. In some embodiments, the dimples 202 are aligned with one another across neighboring apexes 200. In some embodiments, the dimples 202 are offset from one another across neighboring apexes 200. In operation, the dimples 202 serve to stiffen the apexes 200. Thus, the wings 150 may be transversely stiffened by the apexes 200 and longitudinally stiffened by the dimples 202.

With reference to FIG. 7, following the wave pattern 188, the apexes 200 are distanced from one another by a wavelength λ and an amplitude A of the wing 150. The wing 150 thus includes one or more wave crests 210 connected to one or more wave troughs 212. Further, the dimples 202 are dimpled inwardly toward a wave axis W. It should be understood and appreciated that the wavelength λ, the amplitude A, a thickness t of the wing 150, and a dimpling depth d of the dimples 202 define cushioning variables and flex of the wing 150. Additionally, it should be understood and appreciated that the wavelength λ, the amplitude A, the thickness t, and the dimpling depth d may be adjusted to produce differing offsets between the product 106 (shown in FIG. 2) and the box 102 (shown in FIG. 2). More specifically, the attributes of the wing 150 may be selected to mitigate accelerations and/or shocks passing through the product 106 based on the cushioning requirements of the product 106. Thus, the wing 150 may be tailored during manufacturing to contact, interfere, cushion, and/or otherwise support the product 106 based on the cushioning requirements of the product 106. For example, a first example wing 150 with a wider, shallower wave pattern (i.e., a relatively longer wavelength λ and a relatively smaller amplitude A) would be more flexible than a second example wing 150 with a narrower, taller wave pattern (i.e., a relatively shorter wavelength λ and a relatively larger amplitude A). Consequently, the combination of the variable wavelength λ, amplitude A, thickness t, and dimpling depth d may provide a formulaic algorithm, process, matrix, system, etc. to produce customized molding and cushioning solutions.

Referring now to FIG. 8, shown is a packaging assembly 300 according to an embodiment. The packaging assembly 300 includes a box 302 that has a lid 304 and a base 306. In some embodiments, the box 302 is formed of corrugated cardboard. In some embodiments, the box 302 is a rectangular prism (e.g., a cube) and thus has a plurality of sides 308 and a bottom 310. The box 302 further includes one or more clips 312 that secure the lid 304 to the base 306 and thus keep the box 302 closed. One or more of the sides 308 define a cutout 316 by which the packaging assembly 300 may be grasped and moved (e.g., lifted, pulled, pushed, etc.).

Turning to FIG. 9, the packaging assembly 300 further includes an upper pad 320, a first trifold assembly 322, and a second trifold assembly 324. The first trifold assembly 322 and the second trifold assembly 324 are configured to nest together and snugly fit about the product 106. The upper pad 320, the first trifold assembly 322, and the second trifold assembly 324 are hollow and each include wings 150 (shown in phantom).

With reference to FIG. 9, more specifically, the upper pad 320 includes an upper sheath 330 that is hollow and is filled with one or more wings 150. In some embodiments, upper pad 320 includes four wings 150.

Remaining with FIG. 9, more specifically, the first trifold assembly 322 includes a top 340 connected to a first side 342 and a second side 344. The first side 342 and the second side 344 each include an upper side sheath 346 that is hollow and is filled with one or more wings 150. In some embodiments, the first side 342 and the second side 344 are each filled with four wings 150. Further, the top 340 defines one or more cutouts 348. In operation, the cutouts 348 provide space for protruding components of the product 106 and aid in removal of the first trifold assembly 322 from the second trifold assembly 324. The first side 342 and the second side 344 each define a cutout 350, which aligns with the cutout 316 of the lid 304.

Referring again to FIG. 9, more specifically, the second trifold assembly includes a bottom 360 connected to a third side 362 and a fourth side 364. The third side 362 and the fourth side 364 each include a lower side sheath 366 that is hollow and filled with one or more wings 150. Further, the bottom 360 includes a bottom sheath 368 that is hollow and filled with one or more wings 150. In some embodiments, the bottom 360, the third side 362 and the fourth side 364 are each filled with four wings 150. The third side 362 and the fourth side 364 each define a first clip opening 370 that receives the clip 312 (shown in FIG. 8).

Looking again at FIG. 9, the first trifold assembly 322 and the second trifold assembly 324 removably nest in the base 306. Further, the lid 304 is sized to receive the upper pad 320, the first trifold assembly 322, the second trifold assembly 324, and the base 306. The lid 304 and the base 306 define a second clip opening 380 and a third clip opening 382, respectively, which align with first clip opening 370 to receive the clip 312 (shown in FIG. 8).

Referring now to FIG. 10, shown is a packaging assembly 400 according to an embodiment. The packaging assembly 400 includes a box 402 and a plurality of face cushions 404 enveloping and supporting a product 106. In some embodiments, the box 402 is formed of corrugated cardboard. In some embodiments, the box 402 is a rectangular prism (e.g., a cube) and thus has a plurality of sides 408 and a bottom 410. The box 402 further includes a plurality of closure flaps 412, which form a top 414. One or more of the sides 408 define a cutout 416 by which the packaging assembly 400 may be grasped and moved (e.g., lifted, pulled, pushed, etc.). In operation, the closure flaps 412 are folded inwardly toward the product 106 to enclose the face cushions 404 and the product 106 in the box 402. In some embodiments, the closure flaps 412 may be held closed by adhesives (e.g., glue) and/or adhesive tape (not shown). In some embodiments, the closure flaps 412 may be held closed by interlocking with one another (not shown).

With reference to FIG. 11, in some embodiments, a cushion subassembly 420 includes a plurality of cushion blocks 422. Further, each cushion block 422 includes a plurality of the face cushions 404 connected (e.g., interlockingly) to a plurality of corner cushions 424. In some embodiments, each face cushion 404 may interlock with two corner cushions 424. Similarly, in some embodiments, each corner cushion 424 may interlock with two face cushions 404. Thus, in some embodiments, the cushion block 422 may be rectilinear. The cushions blocks 422 are configured to snugly engage and/or fit onto the product 106. In some embodiments, the face cushions 404 are substantially identical. Similarly, in some embodiments, the corner cushions 424 are substantially identical. Further, in some embodiments, the face cushions 404 and/or the corner cushions 424 respectively differ from one another to tightly engage the outer geometry of the product 106.

Referring to FIGS. 10 and 11, the cushions blocks 422 are located between the box 402 and the product 106. Additionally, the box 402 and the cushion blocks 422 are configured to fit snugly together. More specifically, the cushion blocks 422 are configured to engage an interior surface 430 of the box 402. The cushion blocks 422 are slidably removable from the box 402. Thus, in operation, when the cushion blocks 422 are slid out of the box 402, the product 106 is also removed from the box 402.

Referring to FIGS. 10 and 11, in some embodiments, the box 402 and/or the cushion blocks 422 are formed of molded and bonded organic pulp (e.g., paper, wood, cellulose, plant fibers, nutshells, etc.). More specifically, in some embodiments, the organic pulp is compressed and heated in molds to reorient the fibers of the organic pulp into the three-dimensional structures of the box 402 and cushion blocks 422. Further, in some embodiments, the organic pulp is passed and/or rolled through one or more dies that compress and heat the organic pulp into the three-dimensional structures of the box 402 and/or the cushions blocks 422. Thus, in some embodiments, the box 402 and/or the cushion blocks 422 are biodegradable.

Referring again to FIGS. 10 and 11, in some embodiments, the box 402 and/or the cushion blocks 422 are formed of molded polymer materials (e.g., polystyrene, polyethylene, polypropylene, etc.). More specifically, in some embodiments, the polymer materials are heated, stamped, blown, and/or injected into molds to form the box 402 and/or the cushion blocks 422. Thus, in some embodiments, the box 402 and/or the cushion blocks 422 are recyclable.

Referring to FIG. 11, the cushion blocks 422 are configured to engage one or more corners 140 and/or one or more edges 142 of the product 106. Thus, in some embodiments, where the product 106 is generally shaped as a rectangular prism, each cushion block 422 is configured to engage five faces 440 of the product 106. More specifically, in some embodiments, each face cushion 404 engages one face 440. Further, in some embodiments, in a folded configuration 442, each corner cushion 424 engages two orthogonally neighboring faces 440.

Turning to FIG. 12, each face cushion 404 includes a plurality of corner locking lobes 450 extending from a first support assembly 452. Further, each corner cushion 424 includes a second support assembly 454 and a third support assembly 456 pivotably and/or foldably connected to one another. Primary edge locking lobes 458 extend from the second support assembly 454. Secondary edge locking lobes 460 extend from the third support assembly 456. In some embodiments, the first support assembly 452, the second support assembly 454, and the third support assembly 456 are substantially identical. In operation, when the corner cushions 424 are in the folded configuration 442, the primary edge locking lobes 458 and the secondary edge locking lobes 460 may interlock with the corner locking lobes 450.

With reference to FIG. 13, the first support assembly 452 includes the wing 150 and a plurality of end caps 470 connected to opposite ends of the wing 150. Further, each corner locking lobe 450 includes a plurality of protrusions 474 extending from a corner flange 476, which extends from the first support assembly 452. In operation, the end caps 470 may serve to stiffen the wing 150.

Referring to FIG. 14, the corner cushion 424 is shown in an unfolded configuration 480. The second support assembly 454 and the third support assembly 456 each include the wing 150 and the end caps 470 connected to opposite ends of the wing 150. Further, the primary edge locking lobes 458 each include a plurality of the protrusions 474 extending from a primary edge flange 484, which extends from the second support assembly 454. Similarly, the secondary edge locking lobes 460 each include a plurality of the protrusions 474 extending from a secondary edge flange 486, which extends from the third support assembly 456. In some embodiments, the primary edge locking lobe 458 is longer and has more protrusions 474 than the secondary edge locking lobe 460. It should be understood that the protrusions 474 of the face cushion 404 (shown in FIG. 13) interlock with the protrusions 474 of the corner cushion 424.

Referring to FIG. 15, shown is an enlarged view of a padding article 150a according to an embodiment. The padding article 150a has an alternating series of apexes 200 distanced from one another. In the embodiment of FIG. 6, a series of dimples 202 are concavely embossed into the wings 150 along each apex 200, both at the wave crests and at the wave troughs. In contrast to the embodiment of FIG. 6, the dimples 202 are concavely embossed into the padding article 150a only along the apexes 200 at the wave crests in FIG. 15. In some embodiments, the dimples 202 are spaced regularly from one another along the apexes 200 at the wave crests. In some embodiments, the dimples 202 are aligned with one another across neighboring wave crests. In some embodiments, the dimples 202 are offset from one another across neighboring wave crests. In operation, the dimples 202 serve to stiffen the apexes 200. Thus, the padding article 150a may be transversely stiffened by the apexes 200 and longitudinally stiffened by the dimples 202.

Referring to FIG. 16, shown is an enlarged view of a padding article 150b according to an embodiment. The padding article 150b has an alternating series of apexes 200 distanced from one another. In the embodiment of FIG. 6, a series of dimples 202 are concavely embossed into the wings 150 along each apex 200, both at the wave crests and at the wave troughs. In contrast to the embodiment of FIG. 6, the dimples 202 are concavely embossed into the padding article 150b only along the apexes 200 at the wave troughs in FIG. 16. In some embodiments, the dimples 202 are spaced regularly from one another along the apexes 200 at the wave troughs. In some embodiments, the dimples 202 are aligned with one another across neighboring wave troughs. In some embodiments, the dimples 202 are offset from one another across neighboring wave troughs. In operation, the dimples 202 serve to stiffen the apexes 200. Thus, the padding article 150b may be transversely stiffened by the apexes 200 and longitudinally stiffened by the dimples 202.

In some embodiments, the wings 150 of the cushion 104 can be replaced with the padding articles 150a. In some embodiments, the wings 150 of the cushion 104 can be replaced with the padding articles 150b. The wings 150 can serve as another form of a padding article.

With reference to FIG. 9, in some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 are hollow, and each is filled with one or more padding articles 150a. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 are hollow, and each is filled with one or more padding articles 150b.

In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles 150 stacked with an approximately 180-degree phase shift. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles 150a stacked with an approximately 180-degree phase shift. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles 150b stacked with an approximately 180-degree phase shift. Such stacking provides an enhanced cushioning effect.

In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles selected from the padding articles 150, 150a, and 150b, which may be stacked in combination with an approximately 180-degree phase shift. Such stacking provides an enhanced cushioning effect.

With reference to FIG. 17, which illustrates a side view of any two of the padding articles 150, 150a, and 150b stacked with an approximately 180-degree phase shift, wherein the dimples are all omitted for clarity. Specifically, the wave troughs 212 of an upper padding article contact the wave crests 210 of a lower padding article, while the wave crests 210 of the upper padding article are spaced apart from the wave troughs 212 of the lower padding article.

With reference to FIG. 13, in some embodiments, the first support assembly 452 includes the padding articles 150a and a plurality of end caps connected to opposite ends of the padding articles 150a. In operation, the end caps may serve to stiffen the padding article 150a. In some embodiments, the first support assembly 452 includes the padding articles 150b and a plurality of end caps connected to opposite ends of the padding articles 150b. In operation, the end caps may serve to stiffen the padding article 150b.

With reference to FIG. 9 again, in some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 are hollow, and each is filled with one or more padding articles 150 with a plurality of end caps 470 connected to opposite ends of the padding articles 150. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 are hollow, and each is filled with one or more padding articles 150a with a plurality of end caps 470 connected to opposite ends of the padding articles 150a. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 are hollow, and each is filled with one or more padding articles 150b with a plurality of end caps 470 connected to opposite ends of the padding articles 150b.

In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles 150 having end caps 470 connected to opposite ends stacked with an approximately 180-degree phase shift. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles 150a having end caps 470 connected to opposite ends stacked with an approximately 180-degree phase shift. In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles 150b having end caps 470 connected to opposite ends stacked with an approximately 180-degree phase shift. Such stacking provides an enhanced cushioning effect.

In some embodiments, the upper sheath 330, the upper side sheath 346, the lower side sheath 366, and the bottom sheath 368 may include a plurality of padding articles selected from the padding articles 150, 150a, and 150b, each having end caps 470 connected to opposite ends. The plurality of padding articles may be stacked in combination with an approximately 180-degree phase shift.

While the present teachings have been described above in terms of specific embodiments, it is to be understood that they are not limited to these disclosed embodiments. Many modifications and other embodiments will come to mind to those skilled in the art to which this pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is intended that the scope of the present teachings should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.

Although it is appreciated that claims are not required in a provisional application, following are non-limiting examples of claims directed to this disclosure that the Applicant may choose to pursue.