Customizable Cushioning Grid

Abstract

A protective system includes a housing defining an interior and a bottom panel positioned within the interior of the housing. The bottom panel is formed of a first material and defines a plurality of apertures. A plurality of cushioning elements are supported on the bottom panel, with each cushioning element including a body formed of a second material and a dowel extending in an axial direction from the body. The dowel of each cushioning element is receivable within a respective aperture of the bottom panel to releasably secure the cushioning element to the bottom panel, thereby enabling configurable positioning of the cushioning elements within the housing.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63 / 747,799 filed Jan. 21, 2025, and U.S. Provisional Patent Application Ser. No. 63 / 801,800 filed May 7, 2025, each of which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] This disclosure relates to protective systems or cases and more particularly to systems and methods for customizing voids formed in the cushioning material of protective systems or cases.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. The dimensions of the various features may be arbitrarily expanded or reduced for clarity.

[0004] FIG. 1 is a perspective view of one implementation of a protective system in a closed configuration.

[0005] FIG. 2A is a top cross-sectional view of one implementation of a protective system.

[0006] FIG. 2B is a side cross-sectional view of the protective system of FIG. 2A.

[0007] FIG. 3 is a partial, cut-away, isometric view of one implementation of a protective system.

[0008] FIG. 4 is a partial, cut-away, isometric view of another implementation of a protective system.

[0009] FIG. 5 is a top plan view of a portion of one implementation of a grid with square apertures for receiving cushioning elements with square cross-sections.

[0010] FIG. 6 is a side view of one implementation of a dual grid arrangement where the grids are shifted with respect to one another to pinch, and thereby secure in place, the various cushioning elements.

[0011] FIG. 7 is a side view of one implementation of a cushioning element with cavities formed therein.

[0012] FIG. 8 is a side view of another implementation of a dual grid arrangement where the grids are shifted with respect to one another to engage cavities formed in the cushioning elements and secure the cushioning elements in place.

[0013] FIG. 9 is a side view of another implementation of a dual grid arrangement where the grids are shifted with respect to one another to engage cavities formed in the cushioning elements and secure some of the cushioning elements in an extended position and others in a retracted position.

[0014] FIG. 10 is a partial, cut-away, isometric view of another implementation of a protective system.

[0015] FIG. 11 is a partial, cut-away, isometric view of another implementation of a protective system.

[0016] FIG. 12A is an isometric view of an individual cushioning element comprising a dowel suitable for insertion into a corresponding aperture in a bottom panel.

[0017] FIG. 12B is a partial isometric view of three individual cushioning elements comprising dowels aligned with respect to each other and for insertion into corresponding apertures in a bottom panel.

[0018] FIG. 13A is a top cross-sectional view of one implementation of a protective system employing the dowel-based engagement of FIG. 12B.

[0019] FIG. 13B is a side cross-sectional view of the protective system of FIG. 13A.

[0020] FIG. 14A is a top plan view of one implementation of an intermediate panel comprising multiple partially separated cushioning elements.

[0021] FIG. 14B is a side cross-sectional view of the intermediate panel of FIG. 14A.

[0022] FIG. 15 is a top cross-sectional view of another implementation of an intermediate panel comprising multiple partially separated cushioning elements.DETAILED DESCRIPTION

[0023] Referring to FIG. 1, a protective system 100 may be described with reference to an orthogonal coordinate system 101 to aid in clarity and consistency of description. For example, the protective system 100 may have a length that extends in a longitudinal direction 101a, a width that extends in a lateral direction 101b, and a thickness or height that extends in a transverse direction 101c. The longitudinal direction 101a, lateral direction 101b, and transverse direction 101c may extend substantially orthogonal to one another. This coordinate reference system may be provided for descriptive purposes and is not intended to limit the orientation of the protective system 100 during use.

[0024] In selected implementations, the protective system 100 may include a housing 102 comprising or forming an exterior shell. The housing 102 may be formed of a rigid or substantially rigid material, such as a polymeric compound, metal, or composite, thereby providing structural integrity and bending resistance. The housing 102 may include one or more latches 104, hinges, seals, or the like to create a watertight or dust-tight enclosure, depending on the requirements of the application. The housing 102 may include one or more handles 106 to facilitate manual transport of the protective system 100. In some implementations, the housing 102 may incorporate design features like molded ridges or internal channels to further reinforce its shape, prevent unwanted flexing or bending, or the like.

[0025] In certain implementations, a housing 102 may include a first portion 108a and a second portion 108b. The first portion 108a and the second portion 108b may be designed to combine and form an enclosure. For example, the first portion 108a may be configured to form the top of the enclosure, while the second portion 108b may form the bottom of the enclosure. In certain implementations, the first portion 108a and the second portion 108b may be pivotally connected to one another. Such a pivotal connection may allow the two portions to open and close relative to one another, providing access to the enclosure while maintaining structural integrity when closed. The one or more latches 104 may selectively secure the first portion 108a and the second portion 108b in a closed position with respect to one another.

[0026] In some implementations, the housing 102 may be configured as a drawer or as part of a drawer system rather than as a clamshell style enclosure. In such implementations, the housing 102 may be slidably receivable within a box, cabinet, rack, workstation, or other supporting structure and may be movable between an open position and a closed position along the longitudinal direction 101a or the lateral direction 101b. The housing 102 may include or engage with rails, slides, rollers, or other guide features that facilitate smooth insertion and removal of the housing 102 relative to the supporting structure. Access to the interior of the housing 102 may be provided when the housing 102 is moved to the open position, while the housing 102 may be retained in a protected and stowed configuration when moved to the closed position. In these implementations, the cushioning components positioned within the housing 102 may function in the same manner as described herein to support and protect items stored within the drawer.

[0027] Referring to FIGS. 2A and 2B, a housing 102 may contain cushioning material 200. The housing 102 and cushioning material 200 may work together to safeguard various devices or instruments placed inside. The cushioning material 200 may comprise foam, gel, rubber, or other compressible or resiliently compressible materials that effectively absorb and dissipate vibrations, shocks, or impacts. The cushioning material 200 may be shaped or contoured to conform to the dimensions of specific devices, items, or instruments placed within the protective system 100.

[0028] Structurally, the housing 102 and cushioning material 200 may combine to form a protective case that encloses the stored items. The housing 102 may act as a robust outer shell, shielding the contents from external hazards, such as drops, collisions, or environmental stressors. Meanwhile, the cushioning material 200 may provide internal support by cradling the stored items and reducing motion inside the housing 102. This dual-protection approach may help ensure that sensitive or valuable items (e.g., electronic devices, laboratory instruments, firearms, or the like) remain secure and protected even when subjected to rough handling or transport.

[0029] The cushioning material 200, or selected portions thereof, may be secured within the housing 102 by adhering or mechanically fastening it to the interior surfaces of the first portion 108a or the second portion 108b. For example, certain portions of the cushioning material 200 may be bonded to one or more interior surfaces of the housing 102 using industrial adhesives that ensure a fixed position during transport. Alternatively, the housing 102 may include molded or recessed features, such as ridges, slots, or clips, designed to interlock with the shape of certain portions of the cushioning material 200, thereby preventing displacement or relative movement of those portions of the cushioning material 200 with respect to a respective portion of the housing 102. In some embodiments, hook-and-loop fasteners or snap-in retention structures may be used to allow the cushioning material 200 to be removable and / or replaceable, offering flexibility for accommodating different contents or cleaning.

[0030] In certain implementations, the cushioning material 200 may be customizable (e.g., customizable by an end user). The cushioning material 200 may be strategically segmented or layered (e.g., strategically arranged by an end user) to form one or more voids 202 (e.g., one or more compartments, open areas, pockets, or channels) offering an organized layout for receiving one or more items therewithin and preventing those items from colliding with each other or against the housing 102. Thus, the protective system 100 may be tailored for specific items or collections of items.

[0031] In selected implementations, the cushioning material 200 may include cushioning elements 204. These cushioning elements 204 may be shaped or configured as dowels, pegs, or similar structures formed of or comprising foam, gel, rubber, or other resiliently compressible materials that effectively absorb and dissipate vibrations, shocks, or impacts. The cushioning elements 204 may have various cross-sectional shapes. For instance, the cross-section may be square or rectangular in some implementations. Alternatively, the cross-section may be circular, triangular, or polygonal. The specific shape of the cushioning elements 204 may be selected to suit the intended purpose or application.

[0032] The cushioning elements 204 may be arranged in a grid pattern (e.g., a rectangular grid) or two-dimensional array within the housing 102 to define one or more voids 202 (e.g., a first void 202a and a second void 202b). These voids 202 may serve specific purposes, such as providing additional flexibility, enhancing energy absorption, or allowing space for the placement of specific items. The size and arrangement of the cushioning elements 204 may vary to create voids 202 of different shapes and dimensions.

[0033] For example, the cushioning elements 204 may be provided in different sizes, such as long cushioning elements 204a and short cushioning elements 204b. When positioned together, these cushioning elements 204 may define one or more voids 202. The variation in size among the cushioning elements 204 may allow for a more customized configuration, which may be tailored to the requirements of the protective system 100 and the item or items it is designed to safeguard.

[0034] In certain implementations, the cushioning material 200 may include a top panel 206 that may be positioned and / or secured within the first portion 108a of the housing 102. The longitudinal direction 101a and lateral direction 101b may generally define a plane of the top panel 206, while the transverse direction 101c may extend generally perpendicular to that plane. The top panel 206 may cooperate with one or more cushioning elements 204 that may be positioned within the second portion 108b of the housing 102. Together, the top panel 206 and the cushioning elements 204 may define the top, sides, and bottom of one or more voids 202. Accordingly, one or more items placed within the voids 202 may be protected on multiple sides.

[0035] In selected implementations, the cushioning elements 204 may provide protection along the sides and bottom of the voids 202, while the top panel 206 may protect the items from above. This arrangement may enhance the overall protective characteristics of the protective system 100. It may ensure that items placed within the voids 202 are safeguarded from potential impacts, vibrations, or other forces that may act upon the protective system 100.

[0036] In certain implementations, the short cushioning elements 204b may support an item from below, the long cushioning elements 204a may provide lateral support along at least one side, opposing sides, or all sides of the item, and the top panel 206 may overlay the cushioning elements 204 (and potentially contact the long cushioning elements 204a) to define a top boundary of the voids 202. Thus, the top panel206, the short cushioning elements 204b, and the long cushioning elements 204a may cooperate to substantially surround the item within the housing 102 and provide cushioning in the longitudinal direction 101a, lateral direction 101b, and transverse direction 101c.

[0037] Referring to FIG. 3, an isometric view of a cutaway section of one embodiment of a protective system 100 is illustrated. In certain implementations, the cushioning material 200 may include a bottom panel 300 positioned beneath the cushioning elements 204. The longitudinal direction 101a and lateral direction 101b may generally define a plane of the bottom panel 300, while the transverse direction 101c may extend generally perpendicular to that plane. This configuration may enhance the protective characteristics of the protective system 100. The cushioning elements 204 may provide protection along the sides of the voids 202, while the top panel 206 may protect one or more items within the voids 202 from above and the bottom panel 300 may protect the items from below. Together, these components may create a protective enclosure that mitigates impacts or other forces from multiple directions.

[0038] In selected implementations, each cushioning element 204 may include an attachment mechanism 302 that may allow for selective or releasable connection to one or more adjacent cushioning elements 204. For example, each cushioning element 204 may have a hook material on one side and a loop material on the other. This configuration may enable the cushioning elements 204 to be linked together to form long strips or other arrangements. Specific cushioning elements 204 may be removed or rearranged to create one or more voids 202. These voids may be tailored to have a size and shape that may accommodate one or more items securely.

[0039] In other implementations, the attachment mechanisms 302 may include magnets, magnetic material, water-soluble glue, or other mechanisms. These mechanisms (like the hook and loop arrangement discussed above) may facilitate selective connection between the cushioning elements 204. Such configurations may allow the cushioning elements to be secured in a desired arrangement. The arrangement may define one or more voids 202 that may protect one or more items placed within them. Additionally, these attachment mechanisms 302 may enable the cushioning elements 204 to be repositioned to fit other items. For example, the cushioning elements 204 in their connected state may be placed in a water bath or water rinse to dissolve or break down the water-soluble glue. Thereafter, the cushioning elements 204 may be removed from the water bath or rinse, dried, and then be reassembled in a new arrangement.

[0040] In certain implementations, one or more attachment mechanisms 302 may be used to secure the cushioning elements 204 to each other, the bottom panel 300, an interior surface of the housing 102, or other components of the protective system 100, or combinations or sub-combinations thereof. These attachment mechanisms 302 may ensure that the cushioning elements 204 remain in place while allowing for flexibility in configuring the arrangement to suit specific applications. A combination or sub-combination of the attachment mechanisms 302 may be employed to achieve the desired level of protection and adaptability.

[0041] Referring to FIG. 4, an isometric view of a cutaway section of one embodiment of a protective system 100 is illustrated. In certain implementations, one or more cushioning elements 204 may be positioned within one or more grids 400. A grid 400, or a combination of multiple grids 400, may be used to hold two or more cushioning elements 204 in a desired relationship with respect to each other. This arrangement may help maintain the positioning of the cushioning elements 204 while allowing for flexibility in customizing their configuration.

[0042] In selected implementations, the protective system 100 may include a first grid 400a and a second grid 400b. When the first grid 400a and the second grid 400b are aligned with each other, they may provide little to no resistance to the cushioning elements 204 as they slide through the grids. This alignment may allow a user to selectively position the cushioning elements 204 as desired to define one or more voids 202. For example, some cushioning elements 204 may be placed in an extended position 402, while others may be placed in a retracted position 404. The retracted position 404 may include a fully retracted or a partially retracted state. The voids 202 may be formed in the spaces above the cushioning elements 204 that are in the retracted position 404.

[0043] Once the cushioning elements 204 have been positioned and the voids 202 have been defined as desired, the user may shift or misalign the second grid 400b with respect to the first grid 400a, or vice versa. This shifting or misalignment may pinch or compress the cushioning elements 204. As a result, the cushioning elements 204 may be prevented from inadvertently sliding through the grids. In the aligned state, the first grid 400a and the second grid 400b may provide little to no sliding resistance to the cushioning elements 204. However, in the shifted or misaligned state, the grids may create sufficient resistance to secure the cushioning elements 204. This configuration may prevent the cushioning elements 204 in the extended position 402 from slipping into a cavity below the grids, such as the space below the first grid 400a and the second grid 400b.

[0044] By selectively or releasably locking the first grid 400a and the second grid 400b in the shifted or misaligned arrangement, the user may secure the cushioning elements 204 in a desired configuration. Conversely, by removing the shift or misalignment, the cushioning elements 204 may be free to move within the grids 400. This feature may enable the user to manipulate and customize the arrangement of the cushioning elements 204 and the voids 202 as often as desired. This level of customization may enhance the adaptability and utility of the protective system 100 for a wide range of applications.

[0045] Referring to FIG. 5, a grid 400 may include one or more walls 500 that may define one or more apertures 502. The apertures 502 may be configured to correspond to the cross-sectional shape of the cushioning elements 204. For example, if the cushioning elements 204 have a square cross-section, the apertures 502 may have a square shape. This matching of shapes may facilitate the proper alignment and positioning of the cushioning elements 204 within the grid 400.

[0046] In selected implementations, the dimensions of the apertures 502 may be slightly smaller than the corresponding dimensions of the cushioning elements 204. This size difference may create an interference fit. Such an interference fit may introduce resistance, such as a slight resistance, to the sliding of the cushioning elements 204 within the grid 400. This resistance may help to prevent inadvertent movement of the cushioning elements 204, such as gravity-induced slipping, through the apertures 502 of the grid 400.

[0047] The interference fit may also contribute to the stability and reliability of the cushioning elements 204 within the grid 400. This configuration may ensure that the cushioning elements 204 remain securely in place, even when external forces (e.g., forces associated with normal use) act upon the protective system 100. At the same time, the interference fit may allow the user to manually adjust the positioning of the cushioning elements 204 within the grid 400 as needed. This adjustability may enhance the versatility and adaptability of the protective system 100 for various applications.

[0048] Referring to FIG. 6, the compressible and / or resilient nature of the cushioning material 200 that forms the cushioning elements 204 may enable or enhance the pinching effect created by shifting or misaligning the second grid 400b relative to the first grid 400a. This compressibility or resilience may allow the cushioning elements 204 to deform slightly under pressure when the grids are misaligned. As a result, the pinching effect may securely hold the cushioning elements 204 in place by increasing the resistance to their movement through the grids.

[0049] This characteristic of the cushioning material 200 may improve the overall functionality and reliability of the protective system 100. The ability of the cushioning elements 204 to adapt to the shifted grid arrangement may ensure that the desired configuration of voids 202 and cushioning elements 204 remains stable under various conditions. At the same time, the resilient nature of the cushioning material 200 may allow the user to easily release the pinching effect by realigning the grids. This may enable quick and repeated customization of the arrangement without compromising the integrity of the protective system 100.

[0050] Referring to FIG. 7, in certain implementations, one or more cushioning elements 204 may include one or more cavities 700 formed within them. For example, a cushioning element 204 may include an upper cavity 700a and a lower cavity 700b. The upper cavity 700a may enable the cushioning element 204 to be selectively or releasably secured or locked in a retracted position 404. Conversely, the lower cavity 700b may enable the cushioning element 204 to be selectively or releasably secured or locked in an extended position 402. These cavities may interact with other components of the protective system 100 to enhance its functionality and versatility.

[0051] Referring to FIG. 8, the cushioning elements 204 are shown in the extended position 402. In this position, the walls 500 of the second grid 400b may engage with the lower cavities 700b of the cushioning elements 204. This mechanical engagement may selectively or releasably secure or lock the cushioning elements 204 in the extended position 402. Such an arrangement may ensure that the cushioning elements 204 remain stable and properly positioned (e.g., do not inadvertently move) while in use.

[0052] Referring to FIG. 9, some of the cushioning elements 204 are shown in the extended position 402, while others are shown in the retracted position 404. For the cushioning elements 204 in the extended position 402, the walls 500 of the second grid 400b may engage with the lower cavities 700b of the cushioning elements 204. For the cushioning elements 204 in the retracted position 404, the walls 500 of the second grid 400b may engage with the upper cavities 700a of the cushioning elements 204. This mechanical engagement may selectively or releasably secure or lock the cushioning elements 204 in the desired position, whether extended or retracted.

[0053] The configuration of the upper cavities 700a and lower cavities 700b within the cushioning elements 204 may allow the user to customize the arrangement of the voids 202 as needed. This flexibility may enhance the adaptability of the protective system 100 for various applications. The ability to selectively secure or release the cushioning elements 204 in the retracted or extended positions may enable repeated reconfiguration without compromising the stability or reliability of the protective system 100.

[0054] Referring to FIG. 10, in certain implementations, each of the cushioning elements 204 may include an attachment mechanism 302 that may secure the cushioning element 204 to a portion of a housing 102 located below it. The attachment mechanism 302 may be, or may include, a hook-and-loop engagement, water-soluble glue, a magnetic arrangement, or other similar mechanisms. For example, in the illustrated implementation, a bottom surface of each cushioning element 204 may have a magnet 1000 secured thereto. An interior surface of the housing 102 may include a ferrous material 1002 secured thereto. Alternatively, a bottom surface of each cushioning element 204 may have a ferrous material secured to it, and an interior surface of the housing 102 may include a magnet secured to it. In still other implementations, both the bottom surface of each cushioning element 204 and the interior surface of the housing 102 may include a magnet secured to it. In these configurations, magnetic attraction may selectively and releasably secure each cushioning element 204 in place.

[0055] In such an arrangement, side-to-side abutment between adjacent cushioning elements 204 may provide additional stability. This stability may prevent the cushioning elements 204 from tipping or folding over, ensuring that they remain upright and in the desired configuration. The cushioning elements 204 may include both long cushioning elements 204a and short cushioning elements 204b. The space above the short cushioning elements 204b may define one or more voids 202.

[0056] A user may customize the configuration of the protective system 100 by replacing one or more long cushioning elements 204a with one or more short cushioning elements 204b, or vice versa. This replacement process may allow the user to create or define one or more voids 202 as needed. The ability to selectively adjust the type and arrangement of the cushioning elements 204 may enhance the adaptability and functionality of the protective system 100. This flexibility may make the protective system 100 suitable for a variety of applications where specific configurations of voids 202 are required to securely accommodate and protect devices or other items placed within the protective system 100.

[0057] Referring to FIG. 11, in selected implementations, a grid 400 may be configured to selectively and releasably secure one or more cushioning elements 204 in place. Side-to-side abutment between adjacent cushioning elements 204 may provide additional stability. This stability, combined with the support provided by the grid 400, may prevent the cushioning elements 204 from tipping or folding over. This arrangement may ensure that the cushioning elements 204 remain upright and maintain their desired configuration. The cushioning elements 204 may include both long cushioning elements 204a and short cushioning elements 204b. The space above the short cushioning elements 204b may define one or more voids 202.

[0058] A user may customize the configuration of the protective system 100 by replacing one or more long cushioning elements 204a with one or more short cushioning elements 204b, or vice versa. This replacement process may allow the user to create or define one or more voids 202 as required. The ability to adjust the type and arrangement of the cushioning elements 204 may enhance the flexibility and functionality of the protective system 100. This adaptability may make the protective system 100 suitable for various applications where specific configurations of voids 202 are needed to securely accommodate and protect devices or other items within the protective system 100.

[0059] The dimensions of the apertures 502 in the grid 400 may be slightly smaller than the corresponding dimensions of the cushioning elements 204. This size difference may create an interference fit between the cushioning elements 204 and the apertures 502. The interference fit may introduce resistance to the sliding motion of the cushioning elements 204 within the grid 400. This resistance may contribute to the stability and reliability of the cushioning elements 204 when positioned within the grid 400. For example, the resistance may help ensure that the cushioning elements 204 remain securely in place, even when external forces associated with normal use act upon the protective system 100. At the same time, the interference fit may allow the user to manually adjust the positioning of the cushioning elements 204 within the grid 400 as needed. For example, a user may pull out long cushioning elements 204a and replace them with short cushioning elements 204b, or vice versa. This adjustability may enhance the versatility of the protective system 100 and allow for customization across a wide range of applications.

[0060] Referring to FIGS. 12A, 12B, 13A, and 13B, in selected implementations, the protective system 100 may include a bottom panel 300. The bottom panel 300 may define a planar or substantially planar base that supports an arrangement of cushioning elements 204. In certain implementations, the bottom panel 300 may include an array of apertures 1200 (e.g., a two-dimensional array of apertures 1200, a plurality of apertures 1200 distributed in a rectangular grid pattern, or the like) formed therein. Each of the apertures 1200 formed in the bottom panel 300 may extend in the transverse direction 101c at least partially through (e.g., halfway through, completely through) the bottom panel 300, such that the apertures 1200 open through a surface (e.g., a top surface) of the bottom panel 300 facing the cushioning elements 204. The apertures 1200 may be arranged (e.g., distributed in the longitudinal direction 101a and the lateral direction 101b) in a regular pattern. The array may extend across the entire surface of the bottom panel 300 or may be localized to selected regions. The regular pattern of the apertures 1200 may facilitate systematic placement and repositioning of cushioning elements 204 across the bottom panel 300.

[0061] For example, in selected implementations, each cushioning element 204 may include a dowel 1202, pin, extension, or the like that may extend downward from the cushioning material 200 forming part of the cushioning element 204. The dowel 1202 may be shaped and dimensioned to be insertable into one or more of the apertures 1200 formed in the bottom panel 300. Thus, the engagement between the dowel 1202 and the corresponding aperture 1200 in the bottom panel 300 may form or be an attachment mechanism 302.

[0062] In selected implementations, the dowel 1202 may be integrally formed with the cushioning material 200 of the cushioning element 204. In other implementations, the dowel 1202 may be secured to the cushioning material 200. For example, the dowel 1202 may have one end glued within an aperture of the cushioning material 200 of the cushioning element 204. The other end of the dowel 1202 may extend from the cushioning material 200 of the cushioning element 204 to engage an aperture 1200.

[0063] The dowel 1202 may engage with the aperture 1200 through an interference fit or a frictional engagement that may releasably secure the cushioning element 204 to the bottom panel 300. The insertion of the dowels 1202 into the apertures 1200 may also help to maintain the upright orientation and spacing of the cushioning elements 204 during use, contributing to the stability and reliability of the protective system 100. In certain implementations, the dowel 1202 may be formed of a substantially rigid material (e.g., wood, a polymeric material, a more rigid foam than that which forms the cushioning material 200, or the like) and form a supporting backbone within the cushioning element 204.

[0064] The user may adjust the configuration of the protective system 100 by selecting specific apertures 1200 and inserting the dowels 1202 of selected cushioning elements 204 into the selected apertures 1200. By inserting or removing the dowels 1202 from the apertures 1200, the user may alter the arrangement of the cushioning elements 204 within the bottom panel 300. This adjustability may allow the user to define voids 202 of varying size, shape, and location within the protective system 100. Accordingly, the voids 202 may serve to accommodate the contours of specific devices or instruments intended to be stored within the protective system 100.

[0065] This configuration may allow for repeatable, user-defined customization of the voids 202 without requiring permanent modification of the bottom panel 300 or the cushioning elements 204. The dowel-based engagement may provide a balance between secure attachment and reconfigurability, allowing the user to quickly reconfigure the interior of the protective system 100 to accommodate different items.

[0066] In the foregoing disclosure, the cushioning elements 204 are illustrated as having a particular length and width, thereby possessing a specific aspect ratio. It is to be understood, however, that in various implementations, the cushioning elements 204 may have a different aspect ratio. For example, the width of the cushioning elements 204 may be increased relative to their height, resulting in cushioning elements 204 that are comparatively shorter and / or wider.

[0067] Such variations in aspect ratio may be implemented to suit specific applications or requirements of the protective system 100. For instance, a shorter and wider cushioning element 204 may provide enhanced stability or may be better suited for supporting larger or heavier items. Conversely, a taller and narrower cushioning element 204 may allow for greater flexibility in configuring the voids 202 or may be ideal for protecting smaller or more delicate items. These variations in aspect ratio may enhance the adaptability and versatility of the cushioning elements 204, enabling the protective system 100 to accommodate a broad range of use cases.

[0068] Referring to FIGS. 14A, 14B, and 15, in certain implementations, the protective system 100 may include an intermediate panel 1400 positioned within the interior of the housing 102 (e.g., between the bottom panel 300 and the top panel 206 or, if the top panel 206 is omitted, simply on top of the bottom panel 300). The intermediate panel 1400 may be a planar or substantially planar piece of cushioning material 200 that has a length in the longitudinal direction 101a, a width in the lateral direction 101b, and a thickness in the transverse direction 101c. The intermediate panel 1400 may be configured for selective customization.

[0069] For example, the cushioning material 200 forming the intermediate panel 1400 may have a plurality of cushioning elements 204 formed therein (e.g., at least partially cut therein). Such cushioning elements 204 may initially (e.g., at manufacture, sale, or shipment to an end user) be connected to one another by connecting regions 1402 (e.g., tear-away regions, weakened portions, perforations, or reduced-thickness connections). Thus, prior to customization, the cushioning elements 204 may be part of an intermediate panel 1400 that is unitary or semi-unitary and has a shape (e.g., a length in the longitudinal direction 101a and a width in the lateral direction 101b) that matches that of the bottom panel 300. Accordingly, apertures 1404 for receiving dowels 1202 in the respective bodies 1204 of the respective cushioning elements 204 may align (e.g., be a continuation thereof in the transverse direction 101c) with the corresponding apertures 1200 in the base panel 300.

[0070] In these implementations, selected cushioning elements 204 may be separated from the rest of the cushioning elements 204 in the intermediate panel 1400 by cutting, tearing, or otherwise severing one or more connection regions 1402. This may be accomplished while leaving adjacent cushioning elements 204 connected to one another via one or more other connection regions 1402. Accordingly, this configuration may allow a user to rapidly customize the arrangement of cushioning elements 204 without requiring precise placement of entirely separate components. The remaining connected cushioning elements 204 may continue to provide structural stability and positional alignment within the protective system 100.

[0071] In selected implementations, not every cushioning element 204 within the intermediate panel 1400 (e.g., not every cushioning element 204 remaining in the intermediate panel 1400 after it is customized) need include a dowel 1202. Instead, a dowel 1202 associated with one cushioning element 204 may stabilize adjacent cushioning elements 204 that remain connected thereto, thereby reducing the total number of dowels 1202 required while maintaining positional stability of the cushioning material 200. Accordingly, dowels 1202 may be placed as needed to support a desired layout or arrangement of voids 202.

[0072] In certain implementations, the dowel 1202 need not be permanently secured within the body 1204 of the corresponding cushioning element 204. For example, the dowel 1202 may be removably inserted into the aperture 1404 formed in the cushioning element 204. The dowel 1202 may be retained within that aperture 1404 by a frictional or interference fit similar to the engagement between the dowel 1202 and the aperture 1200 in the bottom panel 300. This removable configuration may allow the dowel 1202 to be repositioned, replaced, or omitted as desired during customization.

[0073] A user may customize the protective system 100 by selectively removing one or more cushioning elements 204 from the intermediate panel 1400. One or more dowels 1202 may then be positioned to engage selected apertures 1200 formed in the bottom panel 300. Each dowel 1202 may further extend through the corresponding aligned aperture 1404 formed in the body 1204 of a cushioning element 204 that remains connected to the intermediate panel 1400, thereby securing the intermediate panel 1400 relative to the bottom panel 300. By removing or repositioning dowels 1202, and by selectively separating cushioning elements 204 from the intermediate panel 1400, the user may define one or more voids 202 having sizes, shapes, and locations corresponding to a particular item to be protected. This approach may enable rapid, user-defined customization without requiring permanent modification of the bottom panel 300 or individual placement of every cushioning element 204 applied thereto.

[0074] In selected implementations, the connection regions 1402 may be formed as relatively small portions of the cushioning material 200 that join adjacent cushioning elements 204 prior to customization. The connection regions 1402 may be located along one or more sides, the top, or the bottom of the cushioning elements 204 and may be defined by partial cuts (e.g., cuts that do not fully separate one cushioning element 204 from another) formed during manufacture.

[0075] In the longitudinal direction 101a, each connection region 1402 may extend a first distance 1406a along the length of the corresponding cushioning element 204, such as less than about 50 percent, less than about 30 percent, less than about 20 percent, less than about 10 percent, or less than about 5 percent of the length of the cushioning element 204. In the lateral direction 101b, each connection region 1402 may extend a second distance 1406b along the width of the corresponding cushioning element 204, such as less than about 50 percent, less than about 30 percent, less than about 20 percent, less than about 10 percent, or less than about 5 percent of the width of the cushioning element 204. In the transverse direction 101c, each connection region 1402 may extend a third distance 1406c along the height of the corresponding cushioning element 204, such as less than about 50 percent, less than about 30 percent, less than about 20 percent, less than about 10 percent, or less than about 5 percent of the height of the cushioning element 204. Accordingly, the connection regions 1402 may allow the cushioning elements 204 to be separated by tearing or cutting while maintaining sufficient strength to hold the cushioning elements 204 together prior to customization. This configuration may allow the intermediate panel 1400 to be handled as a single piece while enabling controlled separation of selected cushioning elements 204 by an end user.

[0076] In certain implementations, the connection regions 1402 may extend in different directions to interconnect cushioning elements 204 in multiple orientations within the intermediate panel 1400. For example, first connection regions 1402a may extend between adjacent cushioning elements 204 in the longitudinal direction 101a, thereby connecting cushioning elements 204 that are aligned side-to-side along the length of the intermediate panel 1400. Additionally, second connection regions 1402b may extend between adjacent cushioning elements 204 in the lateral direction 101b, thereby connecting cushioning elements 204 that are positioned side-by-side across the width of the intermediate panel 1400. In some implementations, both the first connection regions 1402a and the second connection regions 1402b may be provided, such that each cushioning element 204 is initially connected to multiple adjacent cushioning elements 204 in both the longitudinal direction 101a and the lateral direction 101b. This multidirectional connectivity may enhance the structural integrity of the intermediate panel 1400 prior to customization (as well as after customization) while still allowing selected cushioning elements 204 to be separated by severing one or more of the connection regions 1402a, 1402b as desired.

[0077] In certain implementations, a protective system 100 may include a housing 102 that defines an interior region. A bottom panel 300 may be positioned within the interior of the housing 102. The bottom panel 300 may be formed of a first material and may define a plurality of apertures 1200. A plurality of cushioning elements 204 may be supported on the bottom panel 300. Each cushioning element 204 may include a body 1204 formed of a second material and a dowel 1202 extending from the body 1204 in an axial direction. The dowel 1202 of each cushioning element 204 may be receivable within a respective aperture 1200 of the plurality of apertures 1200 to releasably secure the cushioning element 204 to the bottom panel 300.

[0078] In some implementations, the dowel 1202 and the respective aperture 1200 may be dimensioned to provide a frictional engagement. This frictional engagement may maintain the cushioning element 204 in an upright orientation relative to the bottom panel 300 while allowing the cushioning element 204 to be selectively removed and repositioned by a user.

[0079] The bottom panel 300 may have a length extending in a longitudinal direction 101a, a width extending in a lateral direction 101b, and a height extending in a transverse direction 101c. The longitudinal direction 101a, lateral direction 101b, and transverse direction 101c may extend substantially orthogonal to one another. Each aperture 1200 of the plurality of apertures 1200 may extend in the transverse direction 101c at least partially through the bottom panel 300. In such implementations, the axial direction of each cushioning element 204 may be parallel to the transverse direction 101c.

[0080] In certain implementations, the protective system 100 may further include a top panel 206 positioned within the interior of the housing 102. The top panel 206 may be formed of a third material and may be arranged to overlie the cushioning elements 204 when the protective system 100 is assembled and the housing 102 is in a closed position or configuration.

[0081] In some implementations, the first material forming the bottom panel 300, the second material forming the bodies 1204 of the cushioning elements 204, and the third material forming the top panel 206 may each comprise a resiliently compressible foam of a common type. That is, the first material, the second material, and the third material may be the same material. In other implementations, the first material, the second material, and the third material may each independently comprise a resiliently compressible foam that may have different properties (e.g., density, resistance to compression, color, or the like). In certain implementations, the resiliently compressible foam forming the first material may have a greater resistance to compression than the resiliently compressible foam forming the second material. This may provide a more secure foundation to support the cushioning elements 204 extending therefrom in an upright configuration.

[0082] The top panel 206, the bottom panel 300, and selected cushioning elements 204 of the plurality of cushioning elements 204 may cooperate to define boundaries of a void 202 shaped to receive an item therewithin. In such configurations, the bottom panel 300 may be configured to support the item from below, the bodies 1204 of the selected cushioning elements 204 may extend upwardly relative to the bottom panel 300 to provide lateral support along at least one side, opposing sides, or all sides of the item, and the top panel 206 may overlie the cushioning elements 204 to define a top boundary of the void 202.

[0083] In certain implementations, the dowel 1202 of each cushioning element 204 may be formed from a fourth material having a greater rigidity than the second material forming the body 1204 of the cushioning element. In some implementations, the dowel 1202 may extend into the body 1204 of the cushioning element 204 and may reinforce the second material against lateral deflection (e.g., deflection of a distal end of the body 1204 in the longitudinal direction 101a, the lateral direction 101b, or some combination thereof). In further implementations, the dowel 1202 may be formed from a fourth material having a greater rigidity than the first material forming the bottom panel 300.

[0084] The plurality of apertures 1200 defined by the bottom panel 300 may be arranged in a rectangular grid pattern across the bottom panel 300, thereby facilitating systematic placement and repositioning of the cushioning elements 204.

[0085] In some implementations, the bottom panel 300 may be formed of a resiliently compressible foam and may have a length extending in the longitudinal direction 101a, a width extending in the lateral direction 101b, and a height extending in the transverse direction 101c. The plurality of first apertures 1200 may extend at least partially through the bottom panel 300 in the transverse direction 101c. The intermediate panel 1400 may comprise a first plurality of cushioning elements 204 that each may include a body 1204 formed of a resiliently compressible foam and a dowel 1202 extending from the body in an axial direction parallel to the transverse direction 101c. Each dowel 1202 may be inserted within a respective aperture 1200.

[0086] In selected implementations, a top panel 206 formed of a resiliently compressible foam may be positioned within the interior of the housing 102 such that the top panel 206, selected cushioning elements 204, and the bottom panel 300 respectively define a top, at least one side, and a bottom of a void 202 within the housing 102.

[0087] In certain implementations, the intermediate panel 1400 may further comprise a second plurality of cushioning elements 204 supported on the bottom panel 300. Each cushioning element 204 of the second plurality of cushioning elements 204 may comprise a body 1204 formed of a resiliently compressible foam and a second aperture 1404 extending through the body 1204 in an axial direction parallel to the transverse direction 101c. The second aperture 1404 may be empty and may be aligned with a corresponding first aperture 1200 of the plurality of first apertures 1200. Thus, the second aperture 1404 may be positioned to receive a dowel 1202, but may not receive one if the support provided thereby is not needed.

[0088] In some implementations, the first plurality of cushioning elements 204 and the second plurality of cushioning elements 204 may be mutually connected to one another by connection regions 1402 formed of the resiliently compressible foam that forms the intermediate panel 1400. These connection regions 1402 may initially couple or tether cushioning elements 204 of the first plurality and cushioning elements 204 of the second plurality into a unitary or semi-unitary structure.

[0089] In certain implementations, a method of configuring a protective system 100 to accommodate a particular item may include obtaining (e.g., manufacturing, assembling, purchasing, selecting) a housing 102 defining an interior and having a bottom panel 300 positioned within the interior, the bottom panel 300 may define a plurality of apertures 1200. The method may further include selecting a plurality of cushioning elements 204, each cushioning element 204 may comprise a resiliently compressible body 1204 and a dowel 1202 extending from the body 1204. The dowel 1202 of each cushioning element 204 may be inserted into a respective aperture 1200 to releasably secure the cushioning elements 204 to the bottom panel 300 in an upright orientation. The plurality of cushioning elements 204 may cooperate with the bottom panel 300 to define a void 202 having a size and shape corresponding to the particular item. The particular item may be positioned within the void 202 such that the bottom panel 300 supports the item from below and at least a subset of the cushioning elements 204 provide lateral cushioning support to the item.

[0090] In some implementations of the method, at least one cushioning element 204 may be repositioned by removing the dowel 1202 of the at least one cushioning element 204 from a first aperture 1200 and inserting the dowel 1202 into a second aperture 1200 to modify the size or shape of the void 202. In further implementations, after positioning the particular item within the void 202, the housing 102 may be closed such that a top panel 206 overlies the cushioning elements 204 and defines a top boundary of the void 202.

[0091] In certain implementations, the protective system 100 may be provided to an end user as a kit configured to enable user assembly and customization of the protective system 100 in accordance with the methods described herein. The kit may include a housing 102 defining an interior, a bottom panel 300 configured to be positioned within the interior of the housing 102 and defining a plurality of apertures 1200, and a plurality of cushioning elements 204 (or an intermediate panel 1400 comprising a plurality of cushioning elements 204). Each of the cushioning elements 204 may comprise a resiliently compressible body 1204. The kit may include a plurality of dowels 1202. The cushioning elements 204 may be provided in different sizes, heights, or shapes to allow the user to selectively arrange the cushioning elements 204 on the bottom panel 300 by inserting the dowels 1202 into selected apertures 1200. The kit may further include a top panel 206 configured to be positioned within the housing 102 such that, when assembled, the top panel 206, bottom panel 300, and selected cushioning elements 204 cooperate to define one or more voids 202 shaped to receive a particular item. In this manner, the kit enables the end user to repeatedly configure and reconfigure the interior of the housing 102 to accommodate different items without permanent modification of the components.

[0092] While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

Claims

1. A protective system comprising:a housing defining an interior;a bottom panel formed of a first material and positioned within the interior of the housing, the bottom panel defining a plurality of apertures; anda plurality of cushioning elements supported on the bottom panel, each cushioning element comprising a body formed of a second material and a dowel extending in an axial direction from the body,wherein the dowel of each cushioning element of the plurality of cushioning elements is receivable within a respective aperture of the plurality of apertures to releasably secure the cushioning element to the bottom panel.

2. The protective system of claim 1, wherein the dowel and the respective aperture are dimensioned to provide a frictional engagement that maintains the cushioning element in an upright orientation relative to the bottom panel.

3. The protective system of claim 1, wherein:the bottom panel has a length extending in a longitudinal direction, a width extending in a lateral direction, and a height extending in a transverse direction;the longitudinal direction, lateral direction, and transverse direction extend substantially orthogonal to one another; andeach aperture of the plurality of apertures extends in the transverse direction at least partially through the bottom panel.

4. The protective system of claim 3, wherein the axial direction of each cushioning element of the plurality of cushioning elements is parallel to the transverse direction.

5. The protective system of claim 1, further comprising a top panel formed of a third material and positioned within the interior of the housing.

6. The protective system of claim 5, wherein the first material, the second material, and the third material each comprise a resiliently compressible foam of a common type.

7. The protective system of claim 5, wherein:the first material is a resiliently compressible foam;the second material is a resiliently compressible foam; andthe third material is a resiliently compressible foam.

8. The protective system of claim 7, wherein the resiliently compressible foam forming the first material has a greater resistance to compression than the resiliently compressible foam forming the second material.

9. The protective system of claim 5, wherein the top panel, bottom panel, and selected cushioning elements of the plurality of cushioning elements define boundaries of a void shaped to receive an item therewithin.

10. The protective system of claim 9, wherein:the bottom panel is configured to support the item from below;the body of each cushioning element of the selected cushioning elements extends upwardly relative to the bottom panel to provide lateral support along at least one side of the item; andthe top panel overlies the plurality of cushioning elements to define a top boundary of the void.

11. The protective system of claim 1, wherein the dowel is formed from a fourth material having a greater rigidity than the second material.

12. The protective system of claim 11, wherein the dowel extends into the body and reinforces the second material against lateral deflection.

13. The protective system of claim 1, wherein the dowel is formed from a fourth material having a greater rigidity than the first material.

14. The protective system of claim 1, wherein the plurality of apertures is arranged in a rectangular grid pattern across the bottom panel.

15. A protective system defining a longitudinal direction, a lateral direction, and a transverse direction that extend substantially orthogonal to one another, the protective system comprising:a housing defining an interior;a bottom panel formed of a resiliently compressible foam and positioned within the interior of the housing, the bottom panel having a length extending in the longitudinal direction, a width extending in the lateral direction, and a height extending in the transverse direction, the bottom panel defining a plurality of first apertures extending at least partially through the bottom panel in the transverse direction; andan intermediate panel comprising a first plurality of cushioning elements supported on the bottom panel, each cushioning element of the first plurality of cushioning elements comprising a body formed of a resiliently compressible foam and a dowel extending from the body in an axial direction parallel to the transverse direction, the dowel being inserted within a respective first aperture of the plurality of first apertures.

16. The protective system of claim 15, further comprising a top panel formed of a resiliently compressible foam and positioned within the interior of the housing, wherein the top panel, selected cushioning elements of the plurality of cushioning elements, and the bottom panel respectively define a top, at least one side, and a bottom of a void within the housing.

17. The protective system of claim 15, wherein the intermediate panel further comprises a second plurality of cushioning elements supported on the bottom panel, each cushioning element of the second plurality of cushioning elements comprising a body formed of a resiliently compressible foam and a second aperture extending into the body in an axial direction parallel to the transverse direction, the second aperture being empty and aligned with a corresponding first aperture of the plurality of first apertures.

18. The protective system of claim 17, wherein the first plurality of cushioning elements and the second plurality of cushioning elements are mutually connected to one another via connection regions of the resiliently compressible foam forming the intermediate panel.

19. A method of configuring a protective system to accommodate an item, the method comprising:obtaining a housing defining an interior and having a bottom panel positioned within the interior, the bottom panel defining a plurality of apertures;selecting a plurality of cushioning elements, each cushioning element comprising a resiliently compressible body and a dowel extending from the resiliently compressible body;inserting the dowel of each cushioning element of the plurality of cushioning elements into a respective aperture of the plurality of apertures to releasably secure the plurality of cushioning elements to the bottom panel in an upright orientation;cooperating, by the plurality of cushioning elements, with the bottom panel to define a void having a size and shape corresponding to the item; andpositioning the item within the void such that the bottom panel supports the item from below and at least a subset of the plurality of cushioning elements provide lateral cushioning support to the item.

20. The method of claim 19, further comprising removing at least one cushioning element of the plurality of cushioning elements by:severing at least one connection region tethering the at least one cushioning element to one or more adjacent cushioning elements of the plurality of cushioning elements; andremoving the dowel of the at least one cushioning element from a first aperture of the plurality of apertures.

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