Shipping container and packing cushion assembly

Abstract

A shipping assembly is described. The assembly includes a shipping container, a lower structure, and an upper structure. The lower and upper structures hold items in a spaced apart arrangement within the shipping container. A paperboard sheet is folded into three horizontal layers to form the lower structure. A first layer has openings for holding items. A second layer is spaced below and from the first layer with a substantially flat surface below the first opening. A third horizontal layer is spaced below and from the second horizontal layer. Another paperboard sheet is folded into two horizontal layers to form the upper structure. A fourth layer has another set of openings for holding items. A fifth layer is spaced above and from the fourth layer. The openings are aligned to position the items in the shipping container.

Description

[Technical field]

[0001] Shipping containers and packaging cushions may be used in logistics transportation and packaging shipments as an assembly to contain items, some of which may be destroyed as the shipping container progresses through the distribution channel. Existing packaging is often designed for bulk retail distribution on pallets and therefore lacks sufficient shock and vibration absorption or packaging cushioning to protect non-palletized shipments of fragile items. Other options include engineered protective packaging cushions, such as molded foam bottle carriers. However, engineered packaging cushions are generally custom-made to the shape of a particular product and require expensive tooling to fabricate. Summary of the Invention [Means for solving the problem]

[0002] The present disclosure relates to a shipping container and packing cushion assembly. Implementations of the disclosure include a shipping container assembly. The shipping container assembly includes a shipping container, a lower structure, and an upper structure. The lower structure holds a plurality of articles in a spaced apart arrangement within the shipping container. The lower structure includes a first paperboard sheet folded to form a first set of layers. The first set of layers includes a first horizontal layer including a plurality of first openings. Each of the first openings is sized to hold a first edge of one of the articles. The first set of layers includes a second horizontal layer below and spaced apart from the first horizontal layer. The second horizontal layer includes a substantially flat surface below the first openings. The first set of layers includes a third horizontal layer below and spaced apart from the second horizontal layer. The upper structure holds a plurality of articles in a spaced apart arrangement within the shipping container. The upper structure includes a second paperboard sheet folded to form a second set of layers. The second set of layers includes a fourth horizontal layer including a plurality of second openings. Each of the second openings is sized to hold a second end of one of the articles. Each of the second openings is aligned with one of the first openings of the lower structure when the lower structure and the upper structure are positioned in the shipping container. The second set of layers includes a fifth horizontal layer above and spaced from the fourth horizontal layer.

[0003] In some embodiments, the second opening is smaller than the first opening.

[0004] In some embodiments, the first opening and the second opening are the same shape.

[0005] In some embodiments, the first opening and the second opening are circular, square, or rectangular in shape.

[0006] In some embodiments, the lower structure, the upper structure, and the shipping container are each double wall corrugated cardboard.

[0007] In some embodiments, the substructure comprises a first sidewall connecting the first horizontal layer to the third horizontal layer and a second sidewall connecting the third horizontal layer to the second horizontal layer, the height of the first sidewall being greater than the height of the second sidewall.

[0008] In some embodiments, at least one of the second side walls includes a retention tab to create a friction fit with another of the second side walls and retain the base structure in the folded configuration.

[0009] In some embodiments, the first sidewall is sized to maintain the first horizontal layer spaced apart from the third horizontal layer.

[0010] In some embodiments, the second sidewall is sized to maintain the second horizontal layer spaced apart from the third horizontal layer.

[0011] In some embodiments, at least one of the second side walls includes at least one support tab extending between the second horizontal layer and the first horizontal layer.

[0012] In some embodiments, the height of the at least one support tab is substantially the same as the distance that the second horizontal layer is spaced from the first horizontal layer.

[0013] In some embodiments, the second sidewalls include a first pair of sidewalls and a second pair of sidewalls, the first pair of sidewalls positioned on opposing outer edges of the second horizontal layer and the second pair of sidewalls positioned approximately midway between the first pair.

[0014] In some embodiments, the second pair of side walls include retention tabs to create a friction fit between the second pair of side walls and retain the base in the folded configuration.

[0015] In some embodiments, each sidewall of both the first pair of sidewalls and the second pair of sidewalls includes at least one support tab extending between the second horizontal layer and the first horizontal layer.

[0016] In some embodiments, the upper structure comprises a third sidewall connecting the fourth horizontal layer to the fifth horizontal layer, the third sidewall being sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer.

[0017] In some embodiments, the third sidewall comprises at least four sidewalls of substantially equal height.

[0018] In some embodiments, at least one of the third side walls includes a retention tab to create a friction fit with another of the third side walls and retain the upper structure in the folded configuration.

[0019] In some embodiments, the first opening is sized to form a friction fit with the first end of the article.

[0020] In some embodiments, the second opening is sized to form a friction fit with the second end of the article.

[0021] In some embodiments, the article is a fragile vessel.

[0022] In some embodiments, the width and length of the lower structure substantially matches the inside dimensions of the shipping container, and the width and length of the upper structure substantially matches the inside dimensions of the shipping container.

[0023] A further implementation of the present disclosure includes a shipping assembly. The shipping assembly includes a shipping container, a lower works, and an upper works.

[0024] The lower structure holds a plurality of articles in a spaced apart arrangement within the shipping container. The lower structure comprises a first paperboard sheet folded to form a first set of layers. The first set of layers includes a first horizontal layer including a plurality of first openings. Each of the first openings is sized to hold a first edge of one of the articles. The first set of layers includes a second horizontal layer below and spaced apart from the first horizontal layer. The second horizontal layer includes a substantially flat surface below the first openings. The lower structure includes at least one support tab extending between the second horizontal layer and the first horizontal layer. The lower structure includes a third horizontal layer below and spaced apart from the second horizontal layer. The lower structure includes a first sidewall connecting the first horizontal layer to the third horizontal layer. The first sidewall is sized to maintain the first horizontal layer spaced apart from the third horizontal layer. The substructure includes a second sidewall connecting the third horizontal layer to the second horizontal layer, the second sidewall being sized to maintain the second horizontal layer spaced apart from the third horizontal layer.

[0025] The upper structure holds a plurality of articles in a spaced apart arrangement within the shipping container. The upper structure comprises a second paperboard sheet folded to form a second set of layers. The second set of layers includes a fourth horizontal layer including a plurality of second openings. Each second opening is sized to hold a second edge of one of the articles. Each second opening is aligned with one of the first openings of the lower structure when the lower structure and upper structure are positioned in the shipping container. The upper structure includes a fifth horizontal layer above and spaced apart from the fourth horizontal layer. The upper structure includes a third sidewall connecting the fourth horizontal layer to the third horizontal layer. The third sidewall is sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer.

[0026] A further implementation of the present disclosure includes a package for a shipping container. The package for the shipping container includes a first paperboard sheet and a second paperboard sheet.

[0027] The first paperboard sheet is folded into a base for an article to be placed in a shipping container, the first paperboard sheet including a first region, a pair of first sidewall regions, a pair of second regions, a pair of second sidewall regions, a pair of third regions, and a pair of third sidewall regions.

[0028] The first region includes a plurality of first openings. Each of the first sidewall regions is connected to an opposite side of the first region and separated from the first region by a first set of perforations. Each of the second regions is connected to a different first sidewall region of the first sidewall regions and separated from the first sidewall region by a second set of perforations. Each of the second sidewall regions is connected to a different second region of the second regions and separated from the second region by a third set of perforations. Each of the third regions is connected to a different second sidewall region of the second sidewall regions and separated from the second sidewall region by a fourth set of perforations. Each of the third sidewall regions is connected to a different third region of the third regions and separated from the third region by a fifth set of perforations.

[0029] The second paperboard sheet is folded into a superstructure for the article. The second paperboard sheet includes a fourth region, a pair of fourth sidewall regions, a pair of fifth regions, and a pair of fifth sidewall regions.

[0030] The fourth region includes a plurality of second openings. Each of the fourth sidewall regions is connected to an opposing side of the fourth region and separated from the fourth region by a sixth set of perforations. Each of the fifth regions is connected to a different one of the fourth sidewall regions and separated from the fourth region by a seventh set of perforations. Each of the fifth sidewall regions is connected to an opposing side of the fourth region and separated from the fourth region by an eighth set of perforations.

[0031] In some embodiments, the first set, the second set, the third set, the fourth set, and the fifth set of perforations each form a line between a first common edge and a second common edge, the first common edge and the second common edge being common to the first region, the second region, and the third region, respectively.

[0032] In some embodiments, the second sidewall region includes a retention tab structure formed on each of the first common edge and the second common edge.

[0033] In some embodiments, each of the sixth, seventh, and eighth sets of perforations form a line between a third common edge and a fourth common edge, the third common edge and the fourth common edge being common to the fourth region and the fifth region, respectively.

[0034] In some embodiments, the fifth sidewall region includes a retention tab structure formed on each of the third common edge and the fourth common edge.

[0035] Specific implementations of the subject matter described herein may be implemented to achieve one or more of the following advantages and address shortcomings of existing product packaging: Implementations provide shipping assemblies that use environmentally friendly, reusable, and sustainable materials to economically ship fragile consumer goods directly to consumers. For example, implementations of the present disclosure may be made from reusable paperboard for light items or from corrugated board for heavy items. Implementations may also be spread out and reused for items of different sizes / shapes. Implementations provide sufficient shock and vibration absorption or packing cushioning to prevent or minimize damage during shipping. For example, implementations are configured to include shock absorbing areas and / or hold items in fixed locations that are spaced apart from each other and away from the sides of the shipping box where the items may be bumped if the box is mishandled. Implementations may also be manufactured at a significantly lower cost than current engineered packing cushioning solutions. For example, implementations of the shipping assemblies disclosed herein do not require expensive up-front tooling that is required for engineered solutions. Instead, the implementations can be formed by simply stamping and perforating flat sheets of paperboard or corrugated board, and the packaging implementations can be stored and shipped as flat sheets, thereby making more efficient use of storage and shipping space for the shipping assembly components themselves. Because the shipping assemblies are formed from flat paperboard or corrugated board, the openings used to secure the articles can be cut to various sizes to accommodate many different sizes / shapes of articles without having to retool the manufacturing line and / or replace molding dies.

[0036] Details of one or more implementations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, drawings, and claims. [Brief description of the drawings]

[0037] [Figure 1]FIG. 2 is a perspective view of a shipping container and packing cushion assembly. [Figure 2A] FIG. 2 is a top view of the unfolded lower cushion support structure of the example of FIG. 1. [Figure 2B] FIG. 2 is a side view of the folded lower cushion support structure of the example of FIG. 1. [Figure 2C] 2A-2C are diagrams of steps for folding the lower cushion support structure of FIG. 1. [Figure 2D] 2A-2C are diagrams of steps for folding the lower cushion support structure of FIG. 1. [Figure 2E] 2A-2C are diagrams of steps for folding the lower cushion support structure of FIG. 1. [Figure 2F] 2A-2C are diagrams of steps for folding the lower cushion support structure of FIG. 1. [Figure 2G] 2A-2C are diagrams of steps for folding the lower cushion support structure of FIG. 1. [Figure 3A] FIG. 2 is a top view of the unfolded upper cushion support structure of the example of FIG. 1. [Figure 3B] FIG. 2 is a side view of the folded upper cushion support structure of the example of FIG. 1. [Figure 3C] 2A-2C are diagrams of steps for folding the upper cushion support structure of FIG. 1. [Figure 3D] 2A-2C are diagrams of steps for folding the upper cushion support structure of FIG. 1. [Figure 3E] 2A-2C are diagrams of steps for folding the upper cushion support structure of FIG. 1. [Figure 3F] 2A-2C are diagrams of steps for folding the upper cushion support structure of FIG. 1. [Figure 3G] 2A-2C are diagrams of steps for folding the upper cushion support structure of FIG. 1. [Figure 4A] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4B] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4C]2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4D] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4E] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4F] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4G] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4H] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4I] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. [Figure 4J] 2A-2C illustrate steps in a method for assembling the shipping container and packing cushion assembly of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] Like numbers and designations in the various drawings indicate like elements.

[0039] Distribution channels for sending and receiving shipments typically use shipping containers and packing cushions to protect the shipped items. The items may be fragile items. The fragile items may break, shatter, or shatter when a threshold force or repeated threshold forces are delivered to the fragile item. The fragile items may be glass. Some fragile items may be filled with liquid. When a threshold force or repeated threshold forces cause the fragile item to break, shatter, or shatter, the fragile item may break, shatter, or shatter, and the contents (e.g., liquid, powder, gas) may flow out of the fragile item and contaminate other fragile items. Also, pieces of the broken item or the contents of the broken item may injure a user.

[0040] While most shipping containers for fragile items are made from reusable cardboard, some conventional shipping containers for fragile items are made from plastic or wood, which makes it difficult and expensive to reuse the shipping containers. If not reused, these plastic or wood shipping containers will either be sent straight to landfills and end up as landfill waste, or will be dumped into the ocean where they will stay and not decompose, polluting the land or ocean. These plastic materials can also pollute the water and / or harm fish or other marine animals.

[0041] This disclosure describes shipping assemblies (e.g., packages) that can be made from flat sheets of paperboard or corrugated board that are cut and perforated according to specific patterns that allow the paperboard or corrugated board to fold on itself into upper and lower cushioned support structures that provide shock absorption for fragile items placed in the shipping container.

[0042] 1 illustrates a perspective view of an example shipping assembly 100. Shipping assembly 100 includes a shipping container 102, a lower cushion support structure 112, and an upper cushion support structure 114. One or more items 110a-110f may be placed in shipping container 102 for shipping.

[0043] The shipping container 102 can be a box. The shipping container 102 is defined by six surfaces. A first surface (not shown) is the bottom of the box. A second surface 104a, a third surface 104b, a fourth surface 104c, and a fifth surface 104d define the sides of the box. A top surface 106 of the shipping container is defined by four top panels 108a-108d that fold together to create the top surface. Two or more of the top panels 108a-108d are fastened together to seal the closed shipping container 102. For example, the top panels 108a and 108c can be folded toward the interior of the shipping container 102, and then the top panels 108b and 108d can be folded toward each other and taped together by a user with packing tape (not shown).

[0044] The shipping container 102 may be rectangular (as shown). Alternatively, the shipping container 102 may be square, triangular, or circular. The shipping container 102 may be paperboard or corrugated board. The corrugated board may be single wall or double wall. The corrugated board may be paper or plastic.

[0045] The shipping assembly 100 includes a lower cushion support structure 112 and an upper cushion support structure 114. The cushion support structures 112, 114 hold the items 110a-110f in a spaced apart arrangement within the shipping container 102 and provide shock absorption for the items 110a-110f.

[0046] 2A is a top view of the unfolded lower cushion support structure 112 of the example of FIG. 1, and FIG. 2B is a side view of the folded lower cushion support structure of the example of FIG. 1. The unfolded lower cushion support structure 112 is a paperboard sheet 202 that can be folded to form the folded lower cushion support structure 112 (e.g., as shown in FIGS. 2C-2G). Alternatively, the paperboard sheet 202 can be a corrugated sheet. The sheet 202 is formed into a plurality of regions 206, 228a, 228b, 226a, 226b, 230a, 230b, 218a, 218b, 230c, and 230d, each separated by perforations 244. The regions, when folded at the perforations 244, form a plurality of layers (e.g., a first or upper layer 206, a second or middle layer 212, and a third or lower layer 220). The central region forms the first or top layer 206. The top layer 206 includes a plurality of openings 208. A pair of sidewall regions 228a, 228b are adjacent to the central region (e.g., layer 206) on opposite sides. When folded, the sidewall regions 228a, 228b will form the outer sidewalls 228 of the lower cushion support structure 112. A second pair of regions 226a, 226b are adjacent to each of the two sidewall regions 228a, 228b. When folded, the second regions 226a, 226b will form the lower layer 220 of the lower cushion support structure 112. A second pair of sidewall regions 230a, 230b are adjacent to the second regions 226a, 226b. When folded, the second pair of sidewall regions 230a, 230b will form a first set of sidewalls 228 that support and separate the middle layer 212 from the bottom layer 220. The third pair of regions 218a, 218b are adjacent to the second set of sidewall regions 230a, 230b. When folded, the third pair of regions 218a, 218b will form the middle layer 212 of the support structure. The third pair of sidewall regions 230c, 230d are adjacent to the third regions 218a, 218b. When folded, the third pair of sidewall regions will form a second set of sidewalls 228 that support and separate the middle layer 212 from the bottom layer 220.

[0047] In some embodiments, one or both of the second and third pairs of sidewall regions 230a-230d can include support tabs 236. The support tabs 236 are sized to provide additional structural support to the bottom of the top layer 206 when the lower cushion support structure is folded. As shown in FIG. 2B, the support tabs 236 extend between the middle layer 212 and the top layer 206 and act as posts to support the top layer 206 above the middle layer 212.

[0048] In some embodiments, the second pair of sidewall regions 230a, 230b include interlocking tabs 234a-d that are used to hold the lower cushion support structure 112 in a folded configuration, for example as shown in Figures 2B and 2G.

[0049] 2C-2G illustrate steps for folding the lower cushion support structure 112 of FIG. 1. A first paperboard sheet 202 is folded to form a first set of layers 206, 212, 220. The first set of layers 206, 212, 220 includes a first horizontal layer 206. The horizontal layer 206 includes a plurality of first openings 208. Each of the first openings 208 is sized to hold a first end 210a-210f, respectively, of each of the articles 110a-110f of the shipment.

[0050] Each of the first openings 208 may be circular, square, or rectangular in shape (e.g., as shown in FIG. 2A). Each of the first openings 208 may be the same shape. Alternatively, one or more of the first openings 208 may be different shapes. Each of the first openings 208 is sized to form a friction fit with a respective first end 210a-210f of the articles 110a-110f of the shipment.

[0051] The first set of layers 206, 212, 220 includes a second horizontal layer 212. The second horizontal layer 212 is below the first horizontal layer 206. The second horizontal layer 212 is spaced from the first horizontal layer 206 by a height 216. The second horizontal layer 212 serves as a floor against which the item 110 rests when placed in the opening 208 of the lower cushion support structure 112. The second horizontal layer 212 is a substantially flat surface below the plurality of first openings 208. The second horizontal layer 212 is formed by a pair of third regions 218a and 218b.

[0052] The first set of layers 206, 212, 220 includes a third horizontal layer 220. The third horizontal layer 220 is below the second horizontal layer 212. The third horizontal layer 220 is spaced from the second horizontal layer 212 by a distance 224. This distance 224 provides separation between the item 110 and the outer packaging of the shipping box in which the item 110 is contained. The distance 224 between the layers 212 and 220 also absorbs shock and provides some protection to the item 110 against impacts to the shipping container 102. The third horizontal layer 220 is a substantially flat surface below the second horizontal layer 212. The third horizontal layer 220 is formed by a pair of second regions 226a and 226b.

[0053] The lower cushion support structure 112 includes sidewalls that connect each of the three horizontal layers 206, 212, and 220. For example, a first set of sidewalls 228 connect the first horizontal layer 206 to the third horizontal layer 220. A second set of sidewalls 230 connect each of the pairs of second regions 226a and 226b that make up the third horizontal layer 220 to each of the pairs of third regions 218a and 218b that make up the second horizontal layer 212.

[0054] The height 232 of the first sidewall 228 is greater than the height 224. The height 224 also corresponds to the height of the second sidewall 230. In the illustrated example, the first sidewall 228 is sized to keep the first horizontal layer 206 spaced apart from the third horizontal layer 220 and the second horizontal layer 212. The second sidewall 230 is sized to keep the second horizontal layer 212 spaced apart from the third horizontal layer 220.

[0055] The lower cushion support structure 112 includes a first retention tab 234a on one of the second side walls 230. The first retention tab 234a creates a friction fit with the other opposite / adjacent second side wall 230 to hold the lower cushion support structure 112 in the folded configuration. The first retention tab 234a can engage with a second retention tab 234b on the other second side wall 230 that is substantially similar to the first retention tab 234a to create a friction fit. The first retention tab 234a and the second retention tab 234b form a pair of retention tabs. Another pair of retention tabs 234c and 234d can be positioned on the opposite side of the second side wall 230 to create another friction fit to hold the lower cushion support structure 112 in the folded configuration.

[0056] The second sidewalls 230 may comprise two pairs of sidewalls 230 supporting and extending between the second horizontal layer 212 and the third horizontal layer 220. One pair of sidewalls 230 are positioned on opposite outer edges (e.g., 238a, 238b shown in FIG. 2A ) of the second horizontal layer 212, respectively. The other pair of sidewalls 230 are positioned approximately midway between the first pair of sidewalls 230. This second pair of sidewalls 230 abut one another when the lower cushion support structure 112 is in the folded configuration and may include retention tabs 234a-d.

[0057] The second pair of side walls 230 may include the pair of retention tabs 234c and 234d described above positioned on opposite sides of the second side wall 230 from the side wall 230 to create another friction fit to hold the lower cushion support structure 112 in the folded configuration.

[0058] In some cases, each sidewall 230 of both the first pair of sidewalls 230 and the second pair of sidewalls 230 includes at least one of the support tabs 236 extending between the second horizontal layer 212 and the first horizontal layer 206.

[0059] The lower cushion support structure 112 includes a support tab 236. In some examples, the support tab 236 is connected to and extends from one of the pair of third regions 218a that make up the second horizontal layer 212. The support tab 236 is connected to and extends from the other of the pair of third regions 218b that make up the second horizontal layer 212. In some examples, the support tab 236 is connected to and extends from a sidewall region (e.g., 230a-230d shown in FIG. 2A) that forms the second sidewall 230. In either example, the support tab 236 extends between the second horizontal layer 212 and the first horizontal layer 206. The support tab 236 supports the first horizontal layer 206 and separates it from the second horizontal layer 212. The height of at least one of the support tabs 236 , which is the same as the height 216 , may be substantially the same as the distance that the second horizontal layer 212 is spaced from the first horizontal layer 206 .

[0060] Each of the portions of the lower cushion support structure 112 (first horizontal layer 206, first sidewall 228, second pair of regions 226a and 226b, second sidewall 230, third pair of regions 218a and 218b, and second pair of sidewalls 230) have two common edges 246a and 246b. Referring to FIG. 2A, each of the regions of the lower cushion support structure 112 are separated from each other by perforations 244. The unfolded regions of the lower cushion support structure 112 are folded along the perforations 244 to form the folded lower cushion support structure 112. The perforations 244 extend from the common edge 246a to the common edge 246b.

[0061] 1, the shipping assembly 100 includes an upper cushion support structure 114. The upper cushion support structure 114 holds one or more shipments of items 110a-110f in a spaced apart arrangement within the shipping container 102. The upper cushion support structure 114 is generally similar to the lower cushion support structure 112 described above.

[0062] 3A is a top view of the unfolded upper cushion support structure 114 of the example of FIG. 1, and FIG. 3B is a side view of the folded upper cushion support structure 114 of the example of FIG. 1. The unfolded upper cushion support structure 114 is a paperboard sheet 200 that can be folded to form the folded upper cushion support structure 114 (e.g., as shown in FIGS. 3C-3G). The paperboard sheet 200 can be a corrugated sheet. The sheet 200 is formed into a plurality of regions 304, 322a, 322b, 320a, 320b, 322c, and 322d, each separated by a perforation 326. The regions, when folded at the perforations 326, form a plurality of layers (e.g., a fourth or lower layer 304, and a fifth or upper layer 312) and side walls. The central region forms the fourth or lower layer 304 of the upper cushion support structure 114. The lower layer 304 includes a plurality of openings 306. The pair of sidewall regions 322a, 322b are adjacent to a central region (e.g., layer 304) on opposite sides. When folded, the sidewall regions 322a, 322b will form the outer sidewalls 318 of the upper cushion support structure 114. The second pair of regions 320a, 320b are adjacent to each of the two sidewall regions 322a, 322b. When folded, the second regions 320a, 320b will form the upper layer 312 of the upper cushion support structure 114. The second pair of sidewall regions 322c, 322d are adjacent to the second regions 320a, 320b. When folded, the second pair of sidewall regions 322c, 322d will form a second set of sidewalls 318 that support the upper layer 312 and separate the upper layer 312 from the lower layer 304.

[0063] In some embodiments, the second pair of sidewall regions 322c, 322d include interlocking tabs 324a-324d that can be used to hold the upper cushion support structure 114 in a folded configuration, for example as shown in Figures 3B and 3G.

[0064] Figures 3C-3G illustrate steps for folding the upper cushion support structure of Figure 1. As described above with reference to Figure 3A, the upper cushion support structure 114 comprises a second paperboard sheet 200 that is folded to form a second set of layers 302 (shown in Figures 3D-3G) for holding one or more shipments of articles 110a-110f in a spaced apart arrangement within the shipping container 102.

[0065] 3C-3G, the second set of layers 302 includes a fourth horizontal layer 304. The fourth horizontal layer 304 includes a plurality of second openings 306. The second openings 306 are sized to hold the second ends 308a of the first shipment of articles 110a. Similarly, each of the second openings 306 is sized to hold the second ends 308b-308f of each of the articles 110b-110f, respectively. Each of the second openings 306 is aligned with one of the first openings 208 of the lower cushion support structure 112 when the lower cushion support structure 112 and the upper cushion support structure 114 are positioned in the shipping container 102.

[0066] Each of the second openings 306 may be circular, square, or rectangular in shape (e.g., as shown in FIGS. 3A-3G). Each of the second openings 306 may be the same shape. Alternatively, one or more of the second openings 306 may be different shapes. Each of the second openings 306 is sized to form a friction fit with the second ends 308a-308f of the respective articles 110a-110f of the shipment.

[0067] In some cases, the first opening 208 and the second opening 306 are the same shape. For example, as shown in Figures 2G and 3G, the shipment of articles is a round glass bottle, and both the first opening 208 and the second opening 306 are circular. In other cases, the first opening 208 and the second opening 306 are different shapes. For example, the first ends 210a-210f of the shipment of articles 110a-110f can be square (not shown), and the second ends 308a-308f of each of the shipment of articles 110a-110f are circular, such as that shown in Figure 3G with a cap 310a covering an opening (not shown) of the shipment of article 110a for pouring contents from the shipment of article 110a.

[0068] In some cases, the second opening 306 is smaller than the first opening 208. For example, the diameter 308 (shown in FIG. 3A) of the second opening 306 can be smaller than the diameter 242 (shown in FIG. 2A) of the first opening 208a. In some cases, the second opening 306 is larger than the first opening 208. For example, the diameter 308 (shown in FIG. 3A) of the second opening 306 can be larger than the diameter 242 (shown in FIG. 2A) of the first opening 208. In still other examples, the second opening 306 is the same size as the first opening 208. For example, the diameter 308 (shown in FIG. 3A) of the second opening 306 is the same as the diameter 242 (shown in FIG. 2A) of the first opening 208.

[0069] As shown in Figures 3D-3G, the second set of layers 302 includes a fifth horizontal layer 312. The fifth horizontal layer 312 overlies the fourth horizontal layer 304. The fifth horizontal layer 312 is spaced apart from the fourth horizontal layer 304 by a height 316 (shown in Figures 3E and 3G). In some cases, the fifth horizontal layer 312 includes two separate regions 320a and 320b.

[0070] The upper cushion support structure 114 includes a third sidewall 318. The third sidewall 318 connects the fourth horizontal layer 304 to the fifth horizontal layer 312. The third sidewall 318 is sized to maintain the fourth horizontal layer 304 spaced apart from the fifth horizontal layer 312. In some embodiments, the third sidewall comprises at least four sidewalls. In some cases, all of the third sidewalls 318 (e.g., sidewall regions 322a-322d) are all of substantially equal height.

[0071] The upper cushion support structure 114 includes a retention tab 324a. The retention tab 324a is mechanically coupled to the third side wall 318. The retention tab 324a creates a friction fit with the third side wall 318. The retention tab 324a holds the upper cushion support structure 114 in a folded configuration when engaged with the middle two side walls 318. The upper cushion support structure 114 includes retention tabs 324b-d that are substantially identical to the retention tab 324a. With reference to Figures 3D-E and 3G, the retention tabs 324a and 324b engage to hold the upper cushion support structure 114 in a folded configuration. Similarly, the retention tabs 324c and 324d engage to hold the upper cushion support structure 114 in a folded configuration.

[0072] 1, the width 116 and length 118 of the lower cushion support structure 112 substantially match the inner diameter of the shipping container 102. The width 120 and length 122 of the upper cushion support structure 114 substantially match the inner diameter of the shipping container 102.

[0073] Each of the portions of the upper cushion support structure 114 (the fourth horizontal layer 304, the sidewall portions 322a-322d of the third sidewall 318, and the two regions 320a and 320b of the fifth horizontal layer 312) have two common edges 328a and 328b. Referring to FIG. 3A, each of the regions of the upper cushion support structure 114 are separated from each other by perforations 326. The unfolded regions of the upper cushion support structure 114 are folded along the perforations 326 to form the folded upper cushion support structure 114. The perforations 326 extend from the common edge 328a to the common edge 328b.

[0074] 2C-2G show how the unfolded paperboard sheet lower cushion support structure 112 (shown in FIG. 2A) is folded into the folded paperboard sheet lower cushion support structure 112 (shown in FIG. 2G). FIGs. 2B-2D show step by step the second pair of side walls 230 is folded against the third pair of regions 218a and 218b, which in turn is folded against the second side walls 230 to contact the second pair of regions 226a and 226b and fully expose the support tabs 236. The folding continues until the support tabs 236 contact the first horizontal layer 206 and the first side walls 228. Finally, retention tab 234a is engaged with retention tab 234b and retention tab 234c is engaged with retention tab 234d to retain lower cushion support structure 112 in the folded configuration.

[0075] 3C-3G show how the unfolded paperboard sheet upper cushion support structure 114 (shown in FIG. 3A) is folded into the folded paperboard sheet upper cushion support structure 114 (shown in FIG. 3F). FIGS. 3B-3D show the steps of folding the first and second portions 322c and 322d (third sidewall 318) inwardly against two separate regions 320a and 320b, respectively, of the fifth horizontal layer 312. The first and second portions 322c and 322d are then folded against the third sidewalls 318a and 318b (shown in FIGS. 3D and 3E) until the sidewall regions 322c and 322d meet. Finally, in Figures 3F and 3G, retention tab 324a is engaged with retention tab 324b, and retention tab 324c is engaged with retention tab 324d to retain upper cushion support structure 114 in the folded configuration.

[0076] 4A-I illustrate steps in a method of assembling the shipping assembly of FIG. 1. For purposes of illustration, FIGS. 4A-I show a step-by-step view of shipment items 110a-110f being coupled to a folded lower cushion support structure 112 and a folded upper cushion support structure 114 without a shipping container 102. Referring to FIG. 4A, the folded lower cushion support structure 112 and the folded upper cushion support structure 114 are shown. A first opening 208 is visible in the first horizontal layer 206. A second horizontal layer 212 is visible through the first opening 208.

[0077] 4B, the items 110a-110f of the shipment are placed into the first opening 208. The items 110a-110f of the shipment are pushed through the first opening 208 until they contact the second horizontal layer 212.

[0078] 4C and 4D, the second openings 306 are disposed above and connect to the items 110a-110f of the shipment.

[0079] Figure 4E shows second ends 308e and 308f of the two shipments of articles 110e and 110f inside the upper cushion support structure 114. Figure 4F shows first ends 210e and 210f of the two shipments of articles 110e and 110f inside the lower cushion support structure 112.

[0080] 4G-4J show the stages of coupling the shipment of items 110a-110f to the folded lower cushion support structure 112 and the folded upper cushion support structure 114 to the shipping container 102. FIG. 4G shows the folded lower cushion support structure 112, the folded upper cushion support structure 114, and the shipping container 102 prepared for loading the shipment of items 110a-110f. FIG. 4H shows the folded lower cushion support structure 112 disposed inside the shipping container 102. FIG. 4I shows the shipment of items 110a-110f disposed onto the folded lower cushion support structure 112 disposed inside the shipping container 102. FIG. 4J shows the folded upper cushion support structure 114 disposed on the shipment of items 110a-110f (no longer visible) inside the shipping container 102.

[0081] Although the specification contains many specific implementation details, these should not be construed as limitations on the scope of any invention or what may be claimed, but rather as descriptions of features that may be specific to specific implementations of a particular invention. Certain features that are described in this specification in the context of another implementation may also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation may also be implemented separately in multiple implementations or in any suitable subcombination. Furthermore, although features may be described as acting in a particular combination, and even initially claimed as such, one or more features from a claimed combination may in some cases be deleted from the combination, and the claimed combination may be directed to a subcombination, or a variation of the subcombination.

[0082] Although this document contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to a particular implementation or embodiment. Certain features that are described herein in the context of another embodiment may also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described as acting in a particular combination, and even initially claimed as such, one or more features from a claimed combination may in some cases be deleted from the combination, and the claimed combination may be directed to a subcombination, or a variation of the subcombination. [Explanation of symbols]

[0083] 100 Shipping Assembly 102 Shipping container 104a Second Surface 104b Third Surface 104c Fourth Surface 104d Fifth Surface 106 Top surface 108a, 108b, 108c, 108d Upper Panel 110, 110a, 110b, 110c, 110d, 110e, 110f Articles 112 Lower cushion support structure 114 Upper cushion support structure 116 Width of lower cushion support structure 118 Length of lower cushion support structure 120 Width of upper cushion support structure 122 Length of upper cushion support structure 200 paperboard sheets 202 Paperboard Sheets 206 Area, First Layer, Upper Layer, First Horizontal Layer 208 First Opening 210a, 210b, 210c, 210d, 210e, 210f First end 212 Second layer, middle layer, second horizontal layer 216 Height, height of support tab 218a, 218b Third Region 220 Third layer, lower layer, third horizontal layer 224 Distance, height of second side wall 226a, 226b Second Area 228, 228a, 228b Sidewall region, outer sidewall, first sidewall 230, 230a, 230b, 230c, 230d Sidewall region, second sidewall 232 Height of first side wall 228 234a interlocking tab, first retention tab 234b Interlocking tab, second retention tab 234c, 234d Interlocking tabs, retention tabs 236 Support tab 238a, 238b outer edge 242 Diameter of first opening 244 Perforations 246a, 246b Common Edge 302 layers 304 area, fourth layer, lower layer, fourth horizontal layer 306 Second Opening 308 Second opening diameter 308a, 308b, 308c, 308d, 308e, 308f Second end 310a Cap 312 area, fifth layer, upper layer, fifth horizontal layer 316 Height 318 Outer side wall, third side wall 320a, 320b Second region 322a, 322b, 322c, 322d Side wall area, side wall part 324a, 324b, 324c, 324d Interlocking tabs, retention tabs 326 Perforation 328a, 328b Common Edge

Claims

1. A shipping container and, A lower structure configured to hold a plurality of articles in a spaced-apart arrangement inside the shipping container, the lower structure comprising a first cardboard sheet bent to form a first set of layers, the first set of layers being A first horizontal layer having a plurality of first openings, each of the first openings being sized to hold a first end of one of the plurality of articles, the first horizontal layer, A second horizontal layer disposed below the first horizontal layer and spaced from the first horizontal layer, the second horizontal layer having a substantially flat surface below the plurality of first openings, A third horizontal layer disposed below the second horizontal layer and spaced from the second horizontal layer, A first side wall connecting the first horizontal layer to the third horizontal layer, and A second side wall connecting the third horizontal layer to the second horizontal layer, at least one of the second side walls comprising a retaining tab configured to create a friction fit with another one of the second side walls and hold the lower structure in a folded configuration, the second side wall, The lower structure comprising, A shipping assembly comprising.

2. The shipping assembly according to claim 1, wherein the height of the first side wall is greater than the height of the second side wall.

3. The shipping assembly according to claim 2, wherein the first side wall is sized to maintain the first horizontal layer spaced from the third horizontal layer.

4. The shipping assembly according to claim 2, wherein the second side wall is sized to maintain the second horizontal layer spaced from the third horizontal layer.

5. The shipping assembly according to claim 2, wherein at least one of the second side walls comprises at least one support tab extending between the second horizontal layer and the first horizontal layer.

6. The shipping assembly according to claim 5, wherein the height of the at least one support tab is substantially the same as the distance by which the second horizontal layer is spaced from the first horizontal layer.

7. The shipping assembly according to claim 2, wherein the second side wall comprises a first pair of side walls and a second pair of side walls, the first pair being positioned at opposite outer edges of the second horizontal layer, and the second pair being positioned approximately midway between the first pair.

8. The second pair of the side walls comprises retaining tabs configured to create a friction fit between the second pair of the side walls and hold the lower structure in a folded configuration, the shipping assembly according to claim 7.

9. Each side wall of both the first pair and the second pair of the side walls comprises at least one support tab extending between the second horizontal layer and the first horizontal layer, the shipping assembly according to claim 7.

10. The shipping assembly is an upper structure configured to hold a plurality of the articles in a spaced-apart arrangement inside the shipping container, the upper structure comprising a second cardboard sheet folded to form a second set of layers, the second set of layers comprising a fourth horizontal layer comprising a plurality of second openings, each of the second openings sized to hold a second end of one of the articles, and each of the second openings aligned with one of the first openings of the lower structure when the lower structure and the upper structure are positioned inside the shipping container, the fourth horizontal layer, and a fifth horizontal layer disposed above and spaced from the fourth horizontal layer the shipping assembly according to claim 1, comprising the upper structure.

11. The upper structure comprises a third side wall connecting the fourth horizontal layer to the fifth horizontal layer, the third side wall sized to maintain the fourth horizontal layer spaced from the fifth horizontal layer, the shipping assembly according to claim 10.

12. The third side wall comprises at least four side walls of substantially equal height, at least one of the third side walls comprising a retaining tab configured to create a friction fit with another one of the third side walls and hold the upper structure in a folded configuration, the shipping assembly according to claim 11.

13. The first opening is sized to form a friction fit with the first end of the article, and the second opening is sized to form a friction fit with the second end of the article, the shipping assembly according to claim 10.

14. The width and length of the lower structure substantially match the inner dimensions of the shipping container, and the width and length of the upper structure substantially match the inner dimensions of the shipping container, the shipping assembly according to claim 10.

15. A shipping container, A lower structure configured to hold a plurality of articles in a spaced-apart arrangement inside the shipping container, the lower structure comprising a first cardboard sheet bent to form a first set of layers, the first set of layers comprising: A first horizontal layer comprising a plurality of first openings arranged in at least two parallel rows, each of the first openings sized to hold a first end of one of the articles, each of the first openings sized to hold a first end of one of the plurality of articles. A second horizontal layer disposed below the first horizontal layer and spaced apart from the first horizontal layer, the second horizontal layer comprising a substantially flat surface below the plurality of first openings and at least one support tab extending between the second horizontal layer and the first horizontal layer and aligned with a region between two rows of the first openings. A third horizontal layer disposed below the second horizontal layer and spaced apart from the second horizontal layer. A first side wall connecting the first horizontal layer to the third horizontal layer, the first side wall sized to maintain the first horizontal layer spaced apart from the third horizontal layer, and A second side wall connecting the third horizontal layer to the second horizontal layer. Comprising the lower structure. A shipping assembly comprising. **Claim 16**: The shipping assembly is An upper structure configured to hold a plurality of the articles in a spaced-apart arrangement inside the shipping container, the upper structure comprising a second cardboard sheet bent to form a second set of layers, the second set of layers comprising: A fourth horizontal layer comprising a plurality of second openings, each of the second openings sized to hold a second end of one of the articles, each of the second openings aligned with one of the first openings of the lower structure when the lower structure and the upper structure are positioned inside the shipping container. A fifth horizontal layer disposed above the fourth horizontal layer and spaced apart from the fourth horizontal layer, and A third side wall connecting the fourth horizontal layer to the third horizontal layer, the third side wall sized to maintain the fourth horizontal layer spaced apart from the fifth horizontal layer. The shipping assembly according to claim 15, comprising the upper structure and having the upper structure.

17. A shipping container and a lower structure configured to hold a plurality of articles in spaced-apart arrangement inside the shipping container, the lower structure comprising a first cardboard sheet folded to form a first set of layers, the first set of layers being a first horizontal layer having a plurality of first openings, each of the first openings being sized to hold a first end of one of the plurality of articles, the first horizontal layer a second horizontal layer disposed below and spaced from the first horizontal layer, the second horizontal layer having a substantially flat surface below the plurality of first openings a third horizontal layer disposed below and spaced from the second horizontal layer a first side wall connecting the first horizontal layer to the third horizontal layer, and a second side wall connecting the third horizontal layer to the second horizontal layer, the second side wall comprising a first pair of side walls and a second pair of side walls, the first pair being positioned at opposite outer edges of the second horizontal layer, the second pair being positioned substantially midway between the first pair, the second side wall A shipping assembly comprising.

18. The shipping assembly according to claim 17, wherein at least one of the second side walls comprises at least one support tab extending between the second horizontal layer and the first horizontal layer.

19. The shipping assembly according to claim 18, wherein at least one of the second side walls comprises a retaining tab configured to create a friction fit with another one of the second side walls and hold the lower structure in a folded configuration.

20. The shipping assembly is an upper structure configured to hold a plurality of the articles in spaced-apart arrangement inside the shipping container, the upper structure comprising a second cardboard sheet folded to form a second set of layers, the second set of layers being A fourth horizontal layer having a plurality of second openings, each of the second openings being sized to hold a second end of one of the articles, and each of the second openings being aligned with one of the first openings of the lower structure when the lower structure and the upper structure are positioned inside the shipping container; and A fifth horizontal layer disposed above the fourth horizontal layer and spaced apart from the fourth horizontal layer, The shipping assembly according to claim 17, comprising the upper structure and having the fourth and fifth horizontal layers.

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