CUSTOMIZABLE PACKAGING SYSTEMS, DEVICES, AND METHODS OF MANUFACTURE

Description

BACKGROUND

Typical foam packaging systems often use precut foam liners within a container to store and/or transport fragile items. These precut foam liners have a particular shape corresponding to a particular item. However, such containers are single-purpose because they are designated to store only the particular item with the shape matching the precut liner. In scenarios where a user stores multiple different items having different shapes and sizes, multiple containers are needed. Foam-lined containers can be large and expensive, so storing and/or transporting multiple items having different shapes is costly.

SUMMARY

Systems, methods, and devices disclosed herein can address the aforementioned issues. For instance, a packaging system can include a plurality of discrete interlockable units formed of a packaging material. The plurality of discrete interlockable units can include a first interlockable unit, which can have a first mating feature being a first protrusion extending from a first side of the first interlockable unit. The first interlockable unit can also have a second mating feature being a first recess formed into a second side of the first interlockable unit. Additionally, the packaging system can include a second interlockable unit and/or any number of interlockable units. The second interlockable unit can include a third mating feature being a second protrusion extending from a first side of the second interlockable unit. The second protrusion can be operable to mate with the first recess of the first interlockable unit. Furthermore, the second interlockable unit can include a fourth mating feature being a second recess formed into a second side of the second interlockable unit. The second recess can be operable to mate with another protrusion of another interlockable unit of the plurality of discrete interlockable units.

In some examples, the second side of the first interlockable unit can be an opposite side from the first side of the first interlockable unit. Additionally, the first recess can be an inverse of the first protrusion. Furthermore, individual interlockable units of the plurality of discrete interlockable units can have a same shape as one another, the same shape including a plurality of mating protrusions and a plurality of mating recesses shaped as inverses of the plurality of mating protrusions. Also, individual interlockable units of the plurality of discrete interlockable units can include two protrusions extending to form a 90° angle relative to each other, and/or two recesses with opening planes directed away from the two protrusions. The first protrusion of the first interlockable unit can have a same shape as the second protrusion of the second interlockable unit. Moreover, the packaging material can include a polyethylene foam.

In some instances, a packaging system can include a plurality of discrete interlockable units formed of a packaging material. Individual interlockable units of the plurality of discrete interlockable units can have a same shape as one another, and this same shape can include one or more mating protrusions and one or more mating recesses shaped as inverses of the one or more mating protrusions. As such, the plurality of discrete interlockable units can form a customizable packaging layer. Furthermore, the packaging system can include a container including a bottom base movably coupled to a lid to define an interior space. The customizable packaging layer can be disposed in the interior space of the container.

In some scenarios, the customizable packaging layer can be a first customizable packaging layer, and/or the packaging system can include a second customizable packaging layer formed of the plurality of discrete interlockable units. The second customizable packaging layer can be positioned above or below the first customizable packaging layer in the container. Also, the packaging system can include a bottom packaging layer disposed below the first customizable packaging layer and the second customizable packaging layer. The bottom packaging layer can be formed of beaded foam. Additionally, the packaging system can include a top packaging layer affixed to an interior surface of the lid. The top packaging layer can be formed of open cell compression foam. Moreover, the container can include a firearms or sporting goods case. The plurality of discrete interlockable units can also form a tessellation pattern. Furthermore, the plurality of discrete interlockable units can be removable and/or interchangeable. The customizable packaging layer can include an outer perimeter formed of the packaging material. The outer perimeter can have an outer edge shaped to align with an interior surface of the container, and/or one or more mating features directed inward towards a center of the container. Additionally, the individual interlockable units of the plurality of discrete interlockable units can have a puzzle-piece shape.

In some examples, a method of manufacturing a packaging system includes providing a sheet of packaging material. The method can also include creating a customizable packaging layer from the sheet of packaging material by forming a plurality of discrete interlockable units out of the sheet of packaging material. Individual interlockable units of the plurality of discrete interlockable units can have a same shape as one another. This same shape can include one or more mating protrusions and one or more mating recesses shaped as inverses of the one or more mating protrusions. Additionally, the method can include positioning the customizable packaging layer in an interior space of a container.

In some instances, creating the customizable packaging layer can include die cutting the sheet of packaging material into the plurality of discrete interlockable units. Also, creating the customizable packaging layer can include forming an outer perimeter of the customizable packaging layer. The outer perimeter can have flat sides operable to align with an interior surface of the container. Additionally, the sheet of packaging material can be a first sheet, and/or the customizable packaging layer can be a first customizable packaging layer. The method can also includes providing a second sheet of packaging material, creating a second customizable packaging layer from the second sheet of packaging material, and/or positioning the second customizable packaging layer above or below the first customizable packaging layer in the container.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A and 1B illustrate example packaging systems including a customizable packaging layer formed by a plurality of discrete interlockable units.

FIGS. 2A-2D illustrate example packaging systems including one or more customizable packaging layers positionable in a container.

FIG. 3 illustrates an example method of manufacturing any of the packaging systems disclosed herein regarding FIGS. 1A-2D.

DETAILED DESCRIPTION

It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the examples described herein. However, it will be understood by those of ordinary skill in the art that the examples described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the examples described herein. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features of the present disclosure. For clarity, specific dimensions, shapes, and configurations are merely illustrative and should not be construed as limiting the scope of the invention unless otherwise stated.

The systems, methods, and devices disclosed herein include a packaging system with one or more customizable packaging layers forming reconfigurable foam liner(s) in a case-style container. The customizable packaging layer(s) can be cut, via a die-cutting manufacturing procedure, into a plurality of discrete interlockable units forming a repeating tessellation pattern (e.g., a jigsaw puzzle pattern). These interlockable units can be removable, replaceable, and interchangeable such that a user can customize the liner to fit their particular need, and can reconfigure the foam liner any number of times to fit multiple, different items using the friction fit formed by the interlockable units. The reconfigurable nature of the foam liner enables precise and adaptable configurations, accommodating a variety of item shapes and sizes. Additionally, the system can be configured to accommodate non-rectangular and irregularly shaped containers, providing versatility across different storage needs. The interlockable units may also be configured for use in drawer systems, shelving systems, or other organizational structures.

In some instances, the technology disclosed herein can be incorporated into a case to store any type of items, such as fragile items or items requiring a clean, safe storage/transportation environment. For instance, the presently disclosed technology can be used for camping equipment, fishing equipment, hunting equipment, firearms, recreational equipment, other outdoor equipment, and so forth. Additionally, the packaging system(s) disclosed herein can be used for first responder storage, police or other government agency storage, emergency supply storage, electronics storage, battery storage, optics storage, glass storage, and so forth. A form factor of the customizable packaging layer(s) disclosed herein can include integration into a container or case (e.g., a clam-shell type case). That said, other form factors can be implemented, such as integration into a vehicle system (e.g., a truck bed, a trunk, a compartment), drawers, shelves, countertops, or any other surface used to hold items for storage and/or transportation.

Additional advantages of the systems, methods, and devices discussed herein will become apparent from the detailed description below.

FIGS. 1A and 1B illustrate an example packaging system 100 including a customizable packaging layer 102. The customizable packaging layer 102 can be formed by a plurality of discrete interlockable units 104 which can be cut from a sheet 106 of packaging material (e.g., polyethylene foam). The plurality of discrete interlockable units 104 can form a repeating pattern, such as a tessellation pattern 108, and can be individually removable and/or interchangeable to form one or more customizable holding spaces 110 in the customizable packaging layer 102.

In some examples, an individual interlockable unit 112 of the plurality of discrete interlockable units 104 can include one or more mating features 114 formed into one or more sides 116 of the individual interlockable unit 112. The one or more mating features 114 can include a combination of protrusions 118 and recesses 120 which, together, provide interlocking and/or interchangeable functionality with other individual units, using friction fittings. For instance, a first mating feature of the individual interlockable unit 112 can be a first protrusion 122 extending from a first side of the individual interlockable unit 112. A second mating feature of the individual interlockable unit 112 can be a first recess 126 formed into a second side of the individual interlockable unit 112. The first recess 126 can be shaped (e.g., with edges and/or contours) as an inverse of the first protrusion 122. For instance, the first protrusion 122 can have a rounded shape, in which case the first recess 126 can also have the rounded shape. The individual interlockable unit 112 can also include a second protrusion 130 extending from a third side and/or a second recess 134 formed into a fourth side. The second protrusion 130 can extend in a direction that forms a substantially 90° angle with the first protrusion 122, for instance, because the first side can form a substantially 90° angle with the third side. Additionally, the second recess 134 can define an opening plane directed (e.g., via an imaginary line perpendicular to the opening plane) at a 90° angle relative to an opening plane defined by the first recess 126. Moreover, the opening plane of the first recess 126 can be directed away from and/or in an opposite direction (e.g., at a 180° angle) from the first protrusion 122, and/or the second recess 134 can be directed away from and/or in an opposite direction (e.g., at a 180° angle) from the second protrusion 130. Furthermore, the mating features 114 disclosed herein can all be directed in a same, horizontal plane.

The first protrusion 122, the second protrusion 130, the first recess 126, the second recess 134, and/or any of the mating feature(s) 114 disclosed herein can be rounded, square, pointed, or any other shape, from a top plan view. Moreover, the first protrusion 122, the second protrusion 130, the first recess 126, the second recess 134, and/or any of the mating feature(s) 114 disclosed herein can have a height dimension which extends from a top surface 138 of the interlockable unit 112 to a bottom surface of the interlockable unit 112. Moreover, the first protrusion 122, the second protrusion 130, the first recess 126, the second recess 134, and/or any of the mating feature(s) 114 disclosed herein can have a constant and/or unchanging cross-sectional profile along the heigh dimension (e.g., from the top surface 138 of the interlockable unit 112 to the bottom surface of the interlockable unit 112). Furthermore, the plurality of discrete interlockable units 104 can each have the same, repeating shape as the individual interlockable unit 112 discussed herein. In this way, the plurality of discrete interlockable units 104, when joined together, can form a substantially planar/flat top surface 140 of the customizable packaging layer 102, which can be continuous along any portions which include interlockable units 112.

In some instances, individual interlockable unit(s) 112 can have a base shape being a square, rectangle, and/or parallelogram with four sides (e.g., the first side, the second side, the third side, and the fourth side), and with a mating feature 114 on each side. As such, the individual interlockable unit 112 can have four mating features 112 with a one-to-one correspondence of mating features-per-side. Additionally or alternatively, the individual interlockable unit(s) 112 can have a base shape being a triangular shape with three sides and three corresponding mating features 114; a pentagon shape with five sides and five corresponding mating features 114; a hexagon shape with six sides and six corresponding mating features 114; and/or an irregular shape with any number of mating features. Moreover, one or more sides may omit a mating feature 114, such that the individual interlockable unit 112 has a combination of flat sides and mating feature sides.

In some examples, the plurality of discrete interlockable units 104 can form a repeating and/or a tessellation pattern 108. For instance, the mating features 114 on one half of the individual interlockable unit 112 can be inverses of the mating features 114 on the other half of the individual interlockable unit 112, such that the array of the plurality of discrete interlockable units 104 forms the planar/flat top surface 140 with no gaps and/or no overlaps. Moreover, the mating features 114 can include rounded and/or curved protrusions 118 and recesses 120, such that the individual interlockable unit 112 can have a jigsaw puzzle-piece shape, and/or the tessellation pattern 108 can be a jigsaw puzzle pattern 142.

Furthermore, in some scenarios, one or multiple interlockable unit(s) 112 can be removed from the customizable packaging layer 102 to form the one or more customizable holding spaces 110 of any shape or size. For instance, one, two, three, four, or any number of interlockable unit(s) 112 can be removed, leaving a holding space 110 having inner wall contours shaped as an inverse of the removed interlockable units 112. The holding space(s) 110 can include a single holding space 110 formed by removing adjacent interlockable units 112, or multiple separate holding spaces 110 can be formed by removing interlockable units 112 spaced apart by one or more barrier interlockable units 112 that remain in place. Any number of holding spaces 110 defined by removing any number of interlockable units 112 can be formed to create a customized configuration corresponding to the particular item being stored with the customizable packaging layer 102 and/or the particular use-case. Furthermore, interlockable unit(s) 112 can be placed back into the holding space(s) 110 to reduce a size of the holding space(s) 110 and/or eliminate the holding space(s) 110, for instance, as part of a reconfiguration procedure of the packaging system 100.

In some instances, the customizable packaging layer 102 can be a first customizable packaging layer 143, and the packaging system 100 can include a second customizable packaging layer 144. The second customizable packaging layer 144 can be positioned above or below the first customizable packaging layer 143. The second customizable packaging layer 144 can also be formed of the plurality of discrete interlockable units 104, which can include interlockable unit(s) 112 having a same size and/or shape as the first customizable packaging layer 143. Additionally or alternatively, the second customizable packaging layer 144 can include interlockable unit(s) 112 having a different size (e.g., larger or smaller) and/or a different shape (e.g., different base shape and/or different mating feature shape) than the first customizable packaging layer 143. Also, the removed interlockable unit(s) 112 of the first customizable packaging layer 143 can vertically align with removed interlockable unit(s) 112 of the second customizable packaging layer 144, such that a depth of the holding space(s) 110 can be adjustable to include the depth of one or multiple customizable packaging layer(s) 102. Furthermore, the packaging system 100 can include a third customizable packaging layer, a fourth customizable packaging layer, or any number of customizable packaging layers 102.

As shown in FIG. 1B, the packaging system 100 can include a customizable packaging layer 102 with an outer perimeter 146, which can be shaped to align with a receptacle 148 of the customizable packaging layer 102. The receptacle 148 can be a container and/or case 150 with a bottom base 152 and a top lid 154. The top lid 154 can be moveably coupled to the bottom base 152, for instance, via one or more hinges 156 along a side 158 of the case 150.

Furthermore, in some scenarios, the bottom base 152 can have one or more sidewalls which define an interior surface 155 of the case 150. This interior surface 155 can include flat surfaces, curved surfaces, and/or various indentations which can correspond with handles, latches, or other features of the case 150. The outer perimeter 146 of the customizable packaging layer 102 can include one or more flat surfaces 157 which define an outer surface 158 of the customizable packaging layer 102. As such, the outer perimeter 146 can be shaped to abut the interior surface 155 of the bottom base 152. Furthermore, the material which forms the outer perimeter 146 can also include one or more mating features 114 directed inward, towards an interior center or middle of the case 150. The outer perimeter 146 can be formed of a continuous portion of the sheet 106 of packaging material, interlockable units 112, or combinations thereof.

FIGS. 2A-2D illustrate example packaging system(s) 100 including the customizable packaging layer 102. The packaging system 100 depicted in FIGS. 2A-2D can be manufactured for placement in the case 150, as discussed herein.

FIG. 2A depicts a plurality of packaging layers 202 of the packaging system 100 in an exploded view 204. The plurality of packaging layers 202 can include the first customizable packaging layer 143, the second customizable packaging layer 144, a bottom packaging layer 206, a top packaging layer 208, and/or any combination thereof. The first customizable packaging layer 143 and/or the second customizable packaging layer 144 can be formed of a first material, such as polyethylene. In some scenarios, the die-cutting operation can fully separate the plurality of discrete interlockable units, and they can be held together via friction fittings. Additionally or alternatively, the die cutting operation can partially separate the plurality of discrete interlockable units (e.g., with perforated seams), such that they can be pulled apart by a user to create full separation. The bottom packaging layer 206 can be formed of a second material different from the first material, such as a beaded foam. Furthermore, the top packaging layer 208 can be formed of a third material different from the first material and/or the second material, such as an open cell compression foam. Additionally, a manufacturing process can include die cutting the first customizable packaging layer 143 and/or the second customizable packaging layer 144 to form the plurality of discrete interlockable units 104 (e.g., arranged as an array or grid) out of a middle section of the sheet 106 of packaging material. The outer perimeter 146 can be formed of a continuous strip of the packaging material, not divided into discrete units, extending around a border of the plurality of discrete interlockable units 104. The outer perimeter 146 can also have outer surface(s) 158 cut via a die-cutting operation.

Additionally, in some instances, the bottom packaging layer 206 and/or the top packaging layer 208 can form continuous planar sheet(s) 210 without discrete interlockable units 112. An outer edge 212 of the bottom packaging layer 206 and/or the top packaging layer 208 can also be cut via a die-cutting operation to give the bottom packaging layer 206 and/or the top packaging layer 208 a particular shape. This particular shape can match a shape of the first customizable packaging layer 143 and/or the second customizable packaging layer 144 for placement in the container 150 or other types of receptacle 148.

Turning to FIG. 2B, the plurality of packaging layers 202 of the packaging system 100 can be in a stacked configuration 214. In the stacked configuration 214, the outer edge(s) 212 of the bottom packaging layer 206 and/or the top packaging layer 208 can align with the outer surface 158 of the first customizable packaging layer 143 and/or the second customizable packaging layer 144. The outer surface(s) 158 of the first customizable packaging layer 143 and/or the second customizable packaging layer 144 and/or the outer edge(s) 212 of the bottom packaging layer 206 and/or the top packaging layer 208 can include flat planar surfaces with one or more indents 216.

FIG. 2C depicts the plurality of packaging layers 202 separate from and/or being placed into the case 150. As shown in FIG. 2C, the interior surface 155 of the case 150 can include one or more ribs 218 and/or handle protrusions 220, which can align with and/or be positioned adjacent to the indent(s) 216 formed into the outer surface(s) 158 of the first customizable packaging layer 143, and/or the second customizable packaging layer 144 and/or the outer edge(s) 212 of the bottom packaging layer 206 and/or the top packaging layer 208.

FIG. 2D depicts the plurality of packaging layers 202 positioned in an interior space 222 of the case 150. The bottom packaging layer 206 can be affixed to a bottom inner surface 224 of the bottom base 152 (e.g., via fasteners, adhesive, tape, and the like). Additionally, the top packaging layer 208 can be affixed to a top inner surface 226 of the top lid 154. As such, the bottom packaging layer 206 and/or the top packaging layer 208 can prevent marring on the interior surface(s) 155 of the case 150 by the item being stored and/or transported in the case 150. The top lid 154 can be hingedly coupled to the bottom base 152, such that rotating the top lid 154 exposes the first customizable packaging layer 143 and/or the second customizable packaging layer 144. Additionally or alternatively, the top lid 154 can be removably coupled to the bottom base 152 via one or more latches 228, sliding mechanisms, and/or fasteners.

FIG. 3 depicts an example method 300 of manufacturing a reconfigurable packaging system, such as the packaging system(s) 100 depicted in FIGS. 1A-2D.

In some examples, at operation 302, the method 300 can provide a sheet of packaging material. At operation 304, the method 300 can create a customizable packaging layer from the sheet of packaging material by forming a plurality of discrete interlockable units out of the sheet of packaging material, individual interlockable units of the plurality of discrete interlockable units having a same shape as one another, the same shape including one or more mating protrusions and one or more mating recesses shaped as inverses of the one or more mating protrusions. In some instances, at operation 304, creating the customizable packaging layer can include die cutting the sheet of packaging material into the plurality of discrete interlockable units. Moreover, in some scenarios, at operation 304, creating the customizable packaging layer can include forming an outer perimeter of the customizable packaging layer, the outer perimeter having flat sides operable to align with an interior surface of the container. At operation 306, the method 300 can position the customizable packaging layer in an interior space of a container. Furthermore, in some example methods 300, the sheet of packaging material is a first sheet, the customizable packaging layer is a first customizable packaging layer, and/or the method 300 can further include providing a second sheet of packaging material, creating a second customizable packaging layer from the second sheet of packaging material, and/or positioning the second customizable packaging layer over the first customizable packaging layer in the container.

In some examples, to enhance user experience, the interlockable units may include visual aids like alignment markers, numbering, or color-coded features, which can assist users in reconfiguring the layout. Additionally, suction devices or edge grips may be incorporated into the system to assist users in removing or reinserting the interlockable units. The system can also be adapted to handle diverse storage environments, such as military-grade or aerospace equipment storage, where durability and reliability are crucial. Additionally, the system can offer protection for sensitive electronics, such as drones or cameras, by incorporating shock absorption or anti-static properties into the foam material.

It is to be understood that the specific order or hierarchy of steps in the methods depicted throughout this disclosure are instances of example approaches and can be rearranged while remaining within the disclosed subject matter. For instance, any of the operations discussed throughout this disclosure may be omitted, repeated, performed in parallel, performed in a different order, and/or combined with any other of the operations discussed throughout this disclosure.

While the present disclosure has been described with reference to various implementations, it will be understood that these implementations are illustrative and that the scope of the present disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, implementations in accordance with the present disclosure have been described in the context of particular implementations. Functionality may be separated or combined differently in various implementations of the disclosure or described with different terminology. Any component or feature of one example can be combined with any component or feature of any other example. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.