Container system

Abstract

A packaging solution can be formed with corrugated cardboard and foldable between flattened and erected positions. In the erected position, packaging solution can be in the form of a container for shipping articles of commerce. The container can include resilient spacers formed of the folded cardboard. The resilient spacers can provide for resilient response and or absorption of impact energy delivered in one or more directions. The container can also include deployable spacers that can be deployed from flattened configurations by a racking movement.

Description

[0001] PAC360-0009-WO PATENT

[0002] CONTAINER SYSTEM

[0003] CROSS-REFERENCE TO APPLICATIONS

[0004]

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 722,021, filed November 18, 2024 and U.S. Provisional Application No. 63 / 906,851, filed October 28, 2025 both of which are incorporated herein by reference in their entirety.

[0005] BACKGROUND OF THE INVENTIONS

[0006] Field of the Inventions

[0007]

[0002] The present inventions relate to container systems, for example, including container systems incorporating a capture feature and a cradle feature that can be formed without the use of plastics or foams.

[0008] Description of the Related Art

[0009]

[0003] Protective container devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact against the inner walls of the box which could be caused by shocks imparted to the box during loading, transit, and unloading.

[0010]

[0004] In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is suspended or retained within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.

[0011]

[0005] U.S. Patent No. 11,124,348 discloses a number of inventions related to retention and suspension structures which incorporate a sheet of resilient material heat sealed to corrugated cardboard. In the designs disclosed in the 11,124,348 patent, the resilient sheet is attached to a piece of foldable cardboard so that the resilient material is tensioned by folding the cardboard, and for example, the resilient sheet material is stretched around the article.

[0012] SUMMARY OF THE INVENTIONS

[0013]

[0006] At least one of the inventions disclosed herein includes the realization that certain additional efficiencies can be obtained in a container process incorporating structures that can support and / or constrict movement of an article within a shipping container, such as a box, without the use of additional foams or plastics, by incorporating structures that can capture a portion of an article in a position spaced away from the internal walls of the external container and / or form a cradle that can support the article in the position spaced away from the internal walls of the outer container.

[0014]

[0007] An aspect of at least one of the inventions disclosed herein includes the realization that including at least one skewed wall in a side of a packaging container can provide additional, optional advantages. For example, by including at least one skewed portion in a resilient spacer of a packaging container, the container can better resiliently deform to absorb impact energy. Optionally, the at least one skewed portion can be configured to absorb impact energy from two directions.

[0015]

[0008] Another aspect of at least one of the inventions disclosed herein includes the realization that including castellations on an inwardly facing edge of a packaging container can provide additional, optional advantages. For example, castellations, which compromise the structural integrity of surrounding material, can more readily buckle and thus more readily absorb imapct energy.

[0016]

[0009] Another aspect of at least one of the inventions disclosed herein includes the realization that including castellations on an inwardly facing edge of a packaging container can provide additional, optional advantages. For example, castellations, which compromise the structural integrity of surrounding material, can more readily buckle and thus more readily absorb imapct energy.

[0017]

[0010] Another aspect of at least one of the inventions disclosed herein includes the realization that including deployable spacers in a packaging container can provide additional optional advantages. For example, including at least one deployable spacer configured to be moved from a flattened position to a deployed position can provide significantly enhanced efficiency in using such packaging solutions.

[0018] [OH] In some aspects, the techniques described herein relate to a container system for shipping an article, the container system including: an article; a monolithic member made of corrugated cardboard and configured to be foldable between flattened and erected positions, wherein in the erected position, the monolithic member fully encloses the article, the monolithic member including: a top wall portion, a first sidewall, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deployable spacers are flexible and configured to be moved between retracted and deployed positions and wherein the top wall portion includes a first, a second, and a third top wall connector portions and wherein the first and second deployable spacers include a first and a second connector portion, respectively, that are configured to engage the first and second top wall connector portions, respectively; wherein in the flattened position, the top wall portion, first sidewall, bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form a substantially flat surface and in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space configured to receive the article such that the article is partially surrounded by the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer; wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer include: a first wall portion connected to the bottom wall along a first fold line so as to be foldable between a retracted position in which the first wall portion is substantially parallel to the bottom wall and a deployed position in which the first wall portion extends generally perpendicular to the bottom wall; a second portion connected to the first wall portion along a second fold line so as to be folded between the retracted position in which the second wall portion is substantially parallel to the bottom wall and the first wall portion and the deployed position in which the second wall portion extends generally perpendicular to the first wall portion and generally parallel to the bottom wall; a third wall portion connected to the second wall portion along a third fold line so as to be folded between the retracted position in which the third wall portion is substantially parallel to the bottom wall, the first wall portion, and the second wall portion, and the deployed position in which the third wall portion extends generally perpendicular to the bottom wall and generally parallel to the first wall portion; and a fourth wall portion connected to the third wall portion along a fourth fold line and fixed to the bottom wall so as to form a closed loop and to allow the first, second and third wall portions to be folded between the retracted position and the deployed position through a racking movement while the fourth wall portion remains in a static position throughout the movement between the retracted and deployed positions; and wherein the second wall portion of the first deployable spacer includes a door that is movable between opened and closed positions, wherein in the opened position, the door allows additional articles to be inserted into and removed from an interior of the first deployable spacer; wherein in the deployed position, each of the first deployable spacer, second deployable spacer, and third deployable spacer forms a dead space serving as an airgap between an outermost surface of the container system and the article when the article is positioned in the open interior space; and a padded paper member fixed to the top wall portion and extending across a portion of the bottom wall such that the padded paper member substantially surrounds the article when the article is positioned in the open interior space and the top wall portion is closed over open interior space with the first, a second, and a third connector portions engaged with the first, second, and third top wall connector portions, respectively; wherein engagement of the first, a second, and a third connector portions with the first, second, and third top wall connector portions, respectively, maintains the first deployable spacer, second deployable spacer, and third deployable spacer in the deployed position.

[0019]

[0012] In some aspects, the techniques described herein relate to a container system, wherein the first, a second, and a third connector portions each include a slot formed proximate to the second fold line and the first, second, and third top wall connector portions each include a tab configured to be inserted into the slot of the first, second, and third connector portions, respectively.

[0013] In some aspects, the techniques described herein relate to a container for shipping an article, the container including: a container member made of foldable material and configured to be foldable between flattened and erected positions, the container member including: a top wall portion, a first sidewall, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deploy able spacers are flexible and configured to be moved between retracted and deployed positions; wherein in the flattened position, the top wall portion, first sidewall, bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form a substantially flat surface and in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space configured to receive an article to be packaged within the container; wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer include: a first wall portion connected to the bottom wall along a first fold line so as to be foldable between the retracted position in which the first wall portion is substantially parallel to the bottom wall and the deployed position in which the first wall portion extends generally perpendicular to the bottom wall; a second wall portion connected to the first wall portion along a second fold line so as to be folded between the retracted position in which the second wall portion is substantially parallel to the bottom wall and the first wall portion and the deployed position in which the second wall portion extends generally perpendicular to the first wall portion and generally parallel to the bottom wall; a third wall portion connected to the second wall portion along a third fold line so as to be folded between the retracted position in which the third wall portion is substantially parallel to the bottom wall, the first wall portion, and the second wall portion, and the deployed position in which the third wall portion extends generally perpendicular to the bottom wall and generally parallel to the first wall portion; and a fourth wall portion connected to the third wall portion along a fourth fold line and fixed to the bottom wall so as to form a closed loop and to allow the first, second and third wall portions to be folded between the retracted position and the deployed position through a racking movement while the fourth wall portion remains in a static position throughout the movement between the retracted and deployed positions.

[0020]

[0014] In some aspects, the techniques described herein relate to a container additionally including an article including a generally rectangular shape with a length, a width, and a thickness that is substantially smaller than the length and width and wherein in the erected position, the container member fully encloses the article.

[0021]

[0015] In some aspects, the techniques described herein relate to a container, wherein the container member is a single, monolithic piece of corrugated cardboard.

[0022]

[0016] In some aspects, the techniques described herein relate to a container, wherein the top wall portion includes a first top wall connector portion and a second top wall connector portion and wherein the first and second deployable spacers include a first and a second connector portion, respectively, that are configured to engage the first and second top wall connector portions, respectively and wherein engagement of the first and second connector portions with the first and second top wall connector portions, respectively, maintains the first deployable spacer and the second deployable spacer in the deployed position.

[0023]

[0017] In some aspects, the techniques described herein relate to a container, wherein in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space partially surrounded by the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer.

[0024]

[0018] In some aspects, the techniques described herein relate to a container, wherein in the deployed position, each of the first deployable spacer, second deployable spacer, and third deployable spacer forms a dead space serving as an airgap between an outermost surface of the container and the article when the article is positioned in the open interior space.

[0025]

[0019] In some aspects, the techniques described herein relate to a container additionally including a padded paper member fixed to the top wall portion and extending across a portion of the bottom wall such that the padded paper member substantially surrounds the article when the article is positioned in the open interior space and the top wall portion is closed over open interior space with the first, a second, and a third connector portions engaged with the first, second, and third top wall connector portions, respectively.

[0026]

[0020] In some aspects, the techniques described herein relate to a container, wherein the second wall portion of the first deployable spacer includes a door that is movable between opened and closed positions, wherein in the opened position, the door allows additional articles to be inserted into and removed from a dead space within the first deployable spacer.

[0027]

[0021] In some aspects, the techniques described herein relate to a container for shipping an article, the container including: a container member made of foldable material and configured to be foldable between flattened and erected positions, the container member including: a top wall portion, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deploy able spacers are flexible and configured to be moved between retracted and deployed positions; wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer include a first wall portion connected to the bottom wall, a second wall portion connected to the first wall portion, and a third wall portion connected to the second wall portion and the bottom wall such that the first, second and third wall portions are foldable between the retracted position and the deployed position.

[0028]

[0022] In some aspects, the techniques described herein relate to a container, wherein the first deployable spacer, the second deployable spacer, and the third deployable spacer are in the deployed position when the container is in the erected position.

[0023] In some aspects, the techniques described herein relate to a container, wherein in the flattened position, the top wall portion, first sidewall, bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form a substantially flat surface and in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space configured to receive an article to be packaged within the container.

[0029]

[0024] In some aspects, the techniques described herein relate to a container, wherein a first wall portion is connected to the bottom wall along a first fold line so as to be foldable between the retracted position in which the first wall portion is substantially parallel to the bottom wall and the deployed position in which the first wall portion extends generally perpendicular to the bottom wall; wherein the second wall portion is connected to the first wall portion along a second fold line so as to be folded between the retracted position in which the second wall portion is substantially parallel to the bottom wall and the first wall portion and the deployed position in which the second wall portion extends generally perpendicular to the first wall portion and generally parallel to the bottom wall; and wherein the third wall portion is connected to the second wall portion along a third fold line and connected to the bottom wall so as to be foldable between the retracted position in which the third wall portion is substantially parallel to the bottom wall, the first wall portion, and the second wall portion, and the deployed position in which the third wall portion extends generally perpendicular to the bottom wall and generally parallel to the first wall portion.

[0030]

[0025] In some aspects, the techniques described herein relate to a container, wherein the first, second, and third wall portions are connected so as to allow the first, second and third wall portions to be folded between the retracted position and the deployed position through a racking movement during the movement between the retracted and deployed positions.

[0031]

[0026] In some aspects, the techniques described herein relate to a container, wherein the third wall portion is connected to the bottom wall with a fourth wall portion that is connected to the third wall portion along a fourth fold line and fixed to the bottom wall so as to form a closed loop.

[0032]

[0027] In some aspects, the techniques described herein relate to a container additionally including an article including a generally rectangular shape with a length, a width, and a thickness that is substantially smaller than the length and width and wherein in the erected position, the container member fully encloses the article.

[0033]

[0028] In some aspects, the techniques described herein relate to a container, wherein the container member is a single, monolithic piece of corrugated cardboard.

[0034]

[0029] In some aspects, the techniques described herein relate to a container, wherein the top wall portion includes a first top wall connector portion and a second top wall connector portion and wherein the first and second deployable spacers include a first and a second connector portion, respectively, that are configured to engage the first and second top wall connector portions, respectively and wherein engagement of the first and second connector portions with the first and second top wall connector portions, respectively, maintains the first deployable spacer and the second deployable spacer in the deployed position.

[0035]

[0030] In some aspects, the techniques described herein relate to a container, wherein in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space partially surrounded by the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer.

[0036]

[0031] In some aspects, the techniques described herein relate to a container, wherein in the deployed position, each of the first deployable spacer, second deployable spacer, and third deployable spacer forms a dead space serving as an airgap between an outermost surface of the container and the article when the article is positioned in an open interior space of the container.

[0037]

[0032] In some aspects, the techniques described herein relate to a container additionally including a padded paper member fixed to the top wall portion and extending across a portion of the bottom wall such that the padded paper member substantially surrounds the article when the article is positioned in an interior space of the container and the top wall portion is closed over the interior space with the first, a second, and a third connector portions engaged with the first, second, and third top wall connector portions, respectively.

[0038]

[0033] In some aspects, the techniques described herein relate to a container, wherein the second wall portion of the first deployable spacer includes a door that is movable between opened and closed positions, wherein in the opened position, the door allows additional articles to be inserted into and removed from a dead space within the first deployable spacer.

[0039]

[0034] In some aspects, the techniques described herein relate to a container for shipping an article, the container including: a container member made of foldable material and configured to be foldable between flattened and erected positions, the container member including: a top wall portion, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deployable spacers are connected to the bottom wall and are configured to be moved between retracted and deployed positions; wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer include a plurality of wall portions that are configured to be foldable between a flattened position and a deployed position through a racking movement.

[0040]

[0035] In some aspects, the techniques described herein relate to a container additionally including a paper-based cushion member attached to the bottom wall.

[0041]

[0036] In some aspects, the techniques described herein relate to a method of forming a container for shipping an article, wherein the container is foldable between a flattened position and an erected position and includes a top wall portion, a bottom wall, a first deployable spacer connected to the bottom wall, a second deployable spacer connected to the bottom wall, and a third deployable spacer connected to the bottom wall, the method including: folding the first deployable spacer from the flattened position to the erected position; folding the second deployable spacer from the flattened position to the erected position; folding the third deployable spacer from the flattened position to the erected position so as to form an interior space between the bottom wall, the first deployable spacer, the second deployable spacer, and the third deployable spacer; inserting an article to be shipped into the interior space; and folding the top wall portion from the flattened position to the erected position in which the top wall portion extends over the first deployable spacer, the second deployable spacer, the third deployable spacer, the interior space, and the article so as to completely enclose the article and the interior space.

[0042]

[0037] In some aspects, the techniques described herein relate to a method, wherein folding the first deployable spacer includes moving the first deployable through a racking movement.

[0043]

[0038] In some aspects, the techniques described herein relate to a method, wherein folding the second deployable spacer includes moving the second deployable through a racking movement, and wherein folding the third deployable spacer includes moving the third deployable through a racking movement

[0039] In some aspects, the techniques described herein relate to a container system for shipping an article , the container system including: an article including a generally rectangular shape in length and width with a generally thin height when compared to the length or width; and a monolithic member configured to be folded into a container, the monolithic member including: a top, a first sidewall, a bottom, a second sidewall, an interior member, a first end member and a second end member, where at least one of the first and second end members is flexible, and configured to form a resilient spacer; wherein the top is foldable between an opened and a closed position; wherein in the closed position, the top, the bottom, the first sidewall, the second sidewall, the interior member, the first resilient spacer and the second resilient spacer form an enclosed interior space and in the opened position form an open interior space; and wherein each of the first and second resilient spacers include: a first angled panel portion connected to the bottom along a first fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the first angled portion extends into the open interior space at an angle relative to the first sidewall, a second angled panel portion connected to the first angled panel portion along a second fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the second angled panel portion extends into the open interior space at an angle parallel to, or greater than parallel, wherein the second angled panel portion is shorter in length to the first angled panel portion, wherein the top panel is folded between an open and closed state, and wherein the top and interior member are parallel and touching when in the closed position.

[0040] In some aspects, the techniques described herein relate to a container system, wherein the resilient spacer has an array of cuts along the fold line between the first and second angled portions.

[0044]

[0041] In some aspects, the techniques described herein relate to a container system, wherein a padded paper member, which is attached to the interior member, is parallel to the top in the open position and surrounds the article when the article is slid into the open interior space.

[0045]

[0042] In some aspects, the techniques described herein relate to a container system, wherein the second angled panel portion of the resilient spacer which is connected to the bottom, is adhered to the second angled panel portion of the resilient spacer connected to the interior member.

[0046]

[0043] In some aspects, the techniques described herein relate to a container system, wherein the second angled panel portion of the resilient spacer is adhered to the first angled panel portion of the resilient spacer.

[0047]

[0044] In some aspects, the techniques described herein relate to a container system, wherein the padded paper member is secured to the container with at least one foldable member extending from the monolithic member.

[0048]

[0045] In some aspects, the techniques described herein relate to a container system, wherein the resilient spacer has a support member folded along at least one edge.

[0049]

[0046] In some aspects, the techniques described herein relate to a container for shipping an article, the container including: a monolithic member including: a top, first sidewall, bottom, second sidewall, interior member, first end member and second end member, where at least one end member is flexible in design, to form an enclosure; wherein the top is configured to be moved between opened and closed positions; wherein in the closed position, the top, bottom, first sidewall, second sidewall, inner member, first resilient spacer and a second resilient spacer form an enclosed interior space and in the opened position form an open interior space; and wherein each of the first and second resilient spacers include: a first angled panel portion connected to the bottom along a first fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the first angled portion extends into the open interior space at an angle relative to the first sidewall, and a second angled panel portion connected to the first angled panel portion along a second fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the second angled panel portion extends into the open interior space at an angle parallel to, or greater than parallel.

[0050]

[0047] In some aspects, the techniques described herein relate to a container, wherein the resilient spacer has an array of cuts perpendicular to the fold line between the first and second angled portions.

[0051]

[0048] In some aspects, the techniques described herein relate to a container additionally including a padded paper member attached to the interior member and is configured to surround the article when the article is slid into the open interior space.

[0049] In some aspects, the techniques described herein relate to a container, wherein the second angled panel portion of the resilient spacer which is connected to the bottom, is adhered to the second angled panel portion of the resilient spacer connected to the interior member.

[0052]

[0050] In some aspects, the techniques described herein relate to a container, wherein the second angled panel portion of the resilient spacer is adhered to the first angled panel portion of the resilient spacer.

[0053]

[0051] In some aspects, the techniques described herein relate to a container, wherein the padded paper member is secured to the container with at least one foldable member extending from the monolithic member.

[0054]

[0052] In some aspects, the techniques described herein relate to a container, wherein the resilient spacer has a support member folded along at least one edge.

[0055]

[0053] In some aspects, the techniques described herein relate to a shipping container made from a monolithic sheet configured to form an enclosure, wherein said enclosure is configured to create a resilient spacer, whereby said resilient spacer is created by adhering at least two edge portions of the monolithic sheet to itself.

[0056]

[0054] In some aspects, the techniques described herein relate to a container, wherein the resilient spacer has an array of cuts along at least one edge.

[0057]

[0055] In some aspects, the techniques described herein relate to a container additionally including a padded member secured to the monolithic sheet.

[0058]

[0056] In some aspects, the techniques described herein relate to a container, wherein the resilient spacer has a support member folded along at least one edge.

[0059]

[0057] In some aspects, the techniques described herein relate to a container, wherein the padded member is secured to the container with at least one foldable member extending from the monolithic member.

[0060]

[0058] In some aspects, the techniques described herein relate to a shipping container configured to enclose an article for shipping, the shipping container including: a monolithic sheet of corrugated cardboard, including: a first wall portion; a first resilient spacer portion extending along a first side of the first wall portion; a second resilient spacer portion extending along a second side of the first wall portion; a second wall portion; wherein the monolithic sheet is configured to be folded with the first and second wall portions being juxtaposed and spaced apart and the first and second resilient spacer portions forming closed sidewalls so as to create an enclosed interior space between the first wall portion, second wall portion, first resilient spacer and the second resilient spacer.

[0061]

[0059] In some aspects, the techniques described herein relate to a shipping container, wherein the first resilient spacer includes a first skewed wall portion.

[0060] In some aspects, the techniques described herein relate to a shipping container, wherein first skewed wall portion extends along an angle that is not parallel or perpendicular to the first wall portion.

[0062]

[0061] In some aspects, the techniques described herein relate to a shipping container, wherein the second resilient spacer includes a second skewed wall portion.

[0063]

[0062] In some aspects, the techniques described herein relate to a shipping container, wherein the first resilient spacer includes a Y-shaped wall configuration.

[0064]

[0063] In some aspects, the techniques described herein relate to a shipping container, wherein the Y-shaped wall configuration includes at least two skewed wall portions.

[0065]

[0064] In some aspects, the techniques described herein relate to a shipping container configured to enclose an article for shipping, the shipping container including: a first wall portion; a first resilient spacer portion having a skewed wall portion connected to a first side of the first wall portion; a second resilient spacer portion extending along a second side of the first wall portion; a second wall portion; wherein the container is configured to be folded with the first and second wall portions being juxtaposed and paced apart and the first and second resilient spacer portions forming closed sidewalls so as to create an enclosed interior space between the first wall portion, second wall portion, first resilient spacer and the second resilient spacer.

[0066]

[0065] In some aspects, the techniques described herein relate to a shipping container additionally including a cushion sheet member fixed to the first wall portion.

[0067]

[0066] In some aspects, the techniques described herein relate to a shipping container, wherein first skewed wall portion extends along an angle that is not parallel or perpendicular to the first wall portion.

[0068]

[0067] In some aspects, the techniques described herein relate to a shipping container, wherein the second resilient spacer includes a second skewed wall portion.

[0069]

[0068] In some aspects, the techniques described herein relate to a shipping container, wherein the first resilient spacer includes a Y-shaped wall configuration.

[0070]

[0069] In some aspects, the techniques described herein relate to a shipping container, wherein the Y-shaped wall configuration includes at least two skewed wall portions.

[0071] BRIEF DESCRIPTION OF THE DRAWINGS

[0072]

[0070] These and other features of the inventions disclosed herein are described below with reference to the drawings of several embodiments of the present container assembly kits which are intended to illustrate, but not to limit, the inventions. The drawings contain the following figures:

[0073]

[0071] FIG. 1 is the schematic layout view of an embodiment of a container system, including a single piece of cardboard shaped to form an outer container and two resilient spacers.

[0074]

[0072] FIG. 2 is a further view of the embodiment of FIG.1 having optional adhesive areas as well as a flexible cushioning member.

[0073] FIG. 3 is a further view of the embodiment of FIG. 2 having been partially folded for assembly to demonstrate the partial construction of the resilient spacers having an optional Y-structure configuration.

[0075]

[0074] FIG. 4 is a further view of the embodiment of FIG. 3 having been partially folded for assembly to demonstrate the location of the adhesive application.

[0076]

[0075] FIG. 5 is a further isometric view of the embodiment of FIG. 4 having been completely folded to create an envelope for the article, with the Y-structures adhered together, creating a resilient spacer, and with the extraction slide partially encapsulating the article.

[0077]

[0076] FIG. 6 is front view of the embodiment in the closed state and ready for shipping.

[0078]

[0077] FIG. 7 is a cross sectional view of the embodiment, taken along line 10.- 10. of FIG. 6 illustrating the resilient spacers and the encapsulation of the article.

[0079]

[0078] FIG. 8 is an isometric view of the container system completely sealed and ready for shipping.

[0080]

[0079] FIG. 9 is a schematic layout view of a modification of the embodiments of Figs 1-8, including a single piece of cardboard shaped to form an outer container, two resilient spacers, a flexible cushioning member, and optional secure tabs.

[0081]

[0080] FIG. 10 is a further view of a modification of the embodiment of FIG. 9 having been partially folded for assembly to demonstrate the construction of the resilient spacers.

[0082]

[0081] FIG. 11 is a further isometric view of the embodiment of FIG. 10 having been completely folded to create an enclosed envelope for the article, with the resilient spacer adhered together and with the flexible cushioning member partially encapsulating the article.

[0083]

[0082] FIG. 12 is front view of the modification of the embodiment in the closed state and ready for shipping.

[0084]

[0083] FIG. 13 is a cross sectional view of the embodiment, taken along line ll.-ll. of FIG. 12 illustrating the resilient spacers and the encapsulation of the article.

[0085]

[0084] FIG. 14 is an isometric view of the container system completely sealed and ready for shipping.

[0086]

[0085] FIG. 15 is a schematic layout view of a modification of the embodiment, including a single piece of cardboard shaped to form an outer container, two resilient spacers, and a flexible cushioning member.

[0087]

[0086] FIG. 16 is a further view of a modification of the embodiment of FIG. 15 having been partially folded for assembly to demonstrate the construction of the resilient spacers.

[0088]

[0087] FIG. 17 is a further isometric view of the embodiment of FIG. 16 having been completely folded to create an envelope for the article, with the resilient spacers adhered together and with the flexible cushioning member partially encapsulating the article.

[0089]

[0088] FIG. 18 is front view of the modification of the embodiment in the closed state and ready for shipping.

[0089] FIG. 19 is a cross sectional view of the embodiment, taken along line 12.-12. of FIG. 18 illustrating the resilient spacers and the encapsulation of the article.

[0090]

[0090] FIG. 20 is an isometric view of the container system completely sealed and ready for shipping.

[0091]

[0091] FIG. 21 is a schematic layout view of another modification of the embodiments of Figures 1-20, including a single piece of cardboard shaped to form an outer container, two resilient spacers, and a flexible cushioning member.

[0092]

[0092] FIG. 22 is a further view of the embodiment of FIG. 21 having partially folded for assembly to demonstrate the construction of the resilient spacers.

[0093]

[0093] FIG. 23 is a further view of the embodiment of FIG. 22 having been further folded for assembly to demonstrate the construction of the resilient spacers.

[0094]

[0094] FIG. 24 is a further view of the embodiment of FIG. 23 having been further folded for assembly to demonstrate the deployed state of the resilient spacers.

[0095]

[0095] FIG. 25 is a further isometric view of the embodiment of FIG. 24 having been nearly completely folded to create an envelope for the article, with the resilient spacers deployed and with the flexible cushioning member partially encapsulating the article.

[0096]

[0096] FIG. 26 is front view of the modification of the embodiment in the closed state and ready for shipping.

[0097]

[0097] FIG. 27 is a cross sectional view of the embodiment, taken along line 13.-13. of FIG. 26 illustrating the resilient spacers and the encapsulation of the article.

[0098]

[0098] FIG. 28 is an isometric view of the container system completely sealed and ready for shipping.

[0099]

[0099] FIG. 29 is a schematic layout view of yet another modification of the embodiments of Figures 1-28, including a single piece of cardboard shaped to form an outer container, two secure tabs and two resilient spacers.

[0100]

[0100] FIG. 30 is a schematic layout view illustrating folding movements for the formation of the resilient spacers.

[0101]

[0101] FIG. 31 is a further view of the embodiment of FIG. 30 having been partially folded for assembly to demonstrate the partial construction of the resilient spacers and demonstrate the location of the adhesive application.

[0102]

[0102] FIG. 32 is a further view of the embodiment of FIG. 31 having been partially folded for assembly to demonstrate the location of the adhesive application.

[0103]

[0103] FIG. 33 is an isometric view of the flexible cushioning member folded around the article.

[0104]

[0104] FIG. 34 is a further isometric view of the embodiment of FIG. 32 having been completely folded to create an envelope for the article, with the resilient spacers adhered together, creating a resilient spacer, and with the flexible cushioning member partially encapsulating the article.

[0105]

[0105] FIG. 35 is front view of the embodiment in the closed state and ready for shipping.

[0106] FIG. 36 is a cross sectional view of the embodiment, taken along line 14.-14. of FIG. 35 illustrating the resilient spacers and the encapsulation of the article.

[0106]

[0107] FIG. 37 is an isometric view of the container system completely sealed and ready for shipping.

[0107]

[0108] FIG. 38 is a schematic layout view of yet another modification of the embodiments of FIGs. 1-38, including a single piece of cardboard shaped to form an outer container, two secure tabs and four resilient spacers.

[0108]

[0109] FIG. 39 is a schematic layout view illustrating folding instructions for the construction of two of the resilient spacers.

[0109] [HO] FIG. 40 is a further isometric view of the embodiment of FIG. 39 having been partially folded for assembly to demonstrate partial formation of the resilient spacers and demonstrate the location of adhesive applications.

[0110] [Hl] FIG. 41 is an angled view of the embodiment of FIG. 40 having been partially folded for assembly to demonstrate the construction of a third resilient spacer.

[0111]

[0112] FIG. 42 is a partial isometric view of the embodiment of FIG. 41 illustrating the construction of a fourth resilient spacer.

[0112]

[0113] FIG. 43 is top view of the embodiment in the closed state.

[0113]

[0114] FIG. 44 is a cross sectional view of the embodiment, taken along line 15.-15. of FIG. 43 illustrating the constructed fourth resilient spacers and the encapsulation of the article.

[0114]

[0115] FIG. 45 is a cross sectional view of the embodiment, taken along line 16.-16. of FIG. 43 illustrating the final deployment of the first and second resilient spacers and the encapsulation of the article.

[0115]

[0116] FIG. 46 is a cross sectional view of the embodiment, taken along line 17.-17. of FIG. 43 illustrating the final deployment of the third and fourth resilient spacers and the encapsulation of the article.

[0116]

[0117] FIG. 47 is an isometric view of the container system completely sealed and ready for shipping.

[0117]

[0118] FIG. 48 is a schematic layout view of yet another modification of the embodiments of FIGs. 1-48, including a single piece of cardboard shaped to form an outer container, two secure tabs, two locking tabs and two resilient spacers.

[0118]

[0119] FIG. 49 is a schematic layout view of an embodiment illustrating folding instructions for the construction of two of the resilient spacers.

[0119]

[0120] FIG. 50 is a further schematic view of the embodiment of FIG. 49 having been partially folded for assembly to demonstrate the partial construction of the resilient spacers.

[0120]

[0121] FIG. 51 is an isometric view of the embodiment of FIG. 50 having been partially folded for assembly to demonstrate the partial construction of the outer container and locking tabs.

[0122] FIG. 52 is an isometric view of the embodiment of FIG. 51 having been completely folded for assembly prior to adhering the secure tabs to the outer container.

[0121]

[0123] FIG. 53 is an isometric view of the embodiment of FIG. 52 demonstrating the location of the pressure sensitive adhesive prior to adhering the secure tabs to the outer container.

[0122]

[0124] FIG. 54 is top view of the embodiment in the closed state.

[0123]

[0125] FIG. 55 is front view of the embodiment in the closed state.

[0124]

[0126] FIG. 56 is a cross sectional view of the embodiment, taken along line 18.-18. of FIG. 54 illustrating the constructed two resilient spacers and the encapsulation of the article.

[0125]

[0127] FIG. 57 is a cross sectional view of the embodiment, taken along line 19.-19. of FIG. 54 illustrating the constructed accessory storage area and the encapsulation of the article.

[0126]

[0128] FIG. 58 is a cross sectional view of the embodiment, taken along line 20.-20. of FIG. 55 illustrating the constructed resilient spacers and further illustrating the constructed accessory storage area and the encapsulation of the article.

[0127]

[0129] FIG. 59 is an isometric view of the container system completely sealed and ready for shipping.

[0128]

[0130] FIG. 60 is a schematic layout view of yet another modification of the embodiments of FIGs. 1-59, including a cardboard component, that can be constructed of one or more pieces of cardboard, shaped to form an outer container, two assembly tabs and three deployable spacers.

[0129]

[0131] FIG. 61 is a schematic layout view of the embodiment of FIG. 60, illustrating the partially folded container with portions of the deployable spacers glued in place.

[0130]

[0132] FIG. 62 is a partial perspective view of the container of FIG. 61 having been partially folded for assembly to demonstrate the partial deployment of the deployable spacers.

[0131]

[0133] FIG. 63 is a perspective view of the embodiment of FIG. 62 having been partially folded for assembly to demonstrate the deployment of the deployable spacers including a cushion member.

[0132]

[0134] FIG. 64 is another perspective view of the embodiment of FIG. 63 having been partially folded for assembly prior to adhering the secure tabs to the outer container.

[0133]

[0135] FIG. 65 is top plan view of the embodiment in the closed state.

[0134]

[0136] FIG. 66 is front elevational view of the embodiment in the closed state.

[0135]

[0137] FIG. 67 is a schematic, cross sectional view of the embodiment, taken along line 21.-21. of FIG. 65 illustrating the two of the constructed resilient spacers, the assembly tabs and the encapsulation of the article.

[0136]

[0138] FIG. 68 is a schematic cross sectional view of the embodiment, taken along line 22.-22. of FIG.

[0137] 66 illustrating the constructed accessory storage area, the deployed resilient spacers and the encapsulation of the article.

[0138]

[0139] FIG. 69 is an isometric view of the container system completely sealed and ready for shipping. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0140] Embodiments of improved container systems are disclosed herein. The container systems include various combinations of one or more improved structures which can provide new alternatives to and advantages over known container systems.

[0139]

[0141] In the following detailed description, terms of orientation such as “top,” “bottom,” “front,” “upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,” “midpoint,” and “end” may be used here to simplify the description in the context of the illustrated embodiments. Because other orientations are possible, however, the present inventions should not be limited to the illustrated orientations. Those skilled in the art will appreciate that other orientations of various components described herein are possible.

[0140]

[0142] FIG. 1 and 2, the container system 100 may include one or more resilient spacers, which optionally can be in the form of Y-structures 106a, 106b, 107a, 107b and flexible cushion member 125. Optionally, the Y-structures 106a, 106b, 107a, 107b can be formed monolithically from a single piece of material. In this case, the single piece of material forming the container system 100 is a corrugated cardboard 101A, although other materials can also be used. Where the container system 100 is made from corrugated cardboard, such corrugated cardboard structure would normally have an inner layer, an outer layer, and an internal, corrugated structure, including, but not limited to, “A-flute,” “B-flute,” “C-flute,” “D-flute,” and “E-flute” cardboard. Other types of corrugated structures using cardboard container similar devices can also be used. The container system 100 can for formed from a flat sheet in the unfolded orientation. The majority of the features begin outwardly facing away from the central members. When formed, the features are created by folding the panels along the score or fold lines inwardly towards the central members, or interior space, where their relative orientation is perpendicular, parallel, or greater than parallel to the central panels. To create an enclosed interior space or enclosure, the panels can be moved into close proximity or be touching in their final orientation in use.

[0141]

[0143] The inventions disclosed herein are described in the context of packaging used for protecting goods (referred to herein as “articles”) during shipping and as such are referred to as containers, shipping containers, packaging, boxes, etc. However, the inventions disclosed here can be used for other applications as well.

[0142]

[0144] With continued reference to FIG. 1, the container system 100 includes top portion 101, side portion 102, back portion 103, Y-offset portion 104, inner panel 105, and Y-structures 106a, 106b, 107a, 107b. The top portion 101, which is foldable between an open and closed position, is connected to the side portion 102 along score line 113. The side portion 102 is connected to the back portion 103 along score line 114. The back portion 103 is connected to the Y-offset portion 104 along score line 115. The Y-offset portion 104 is connected to the inner panel 105 along score line 116. Optionally, the Y-offset portion 104, side portion 102 and Y-structures 106a, 106b, 107a, 107b dimensions can be changed to accommodate different thicknesses of the article as well as to achieve the desired structural properties based on the impact load scenarios of which the container system 100 experiences when mishandled during shipping. As an additional option, the top portion 101, back portion 103 and inner panel 105 dimensions can also be changed to accommodate different lengths and widths of the article as well as to achieve the desired structural properties based on the impact load scenarios of which the container system 100 experiences when mishandled during shipping.

[0143]

[0145] The container system 100 may provide utility for articles that can be packaged for shipping include those with a higher density, flat form factor, such as those with length or width compared to the side height ratio where the length or width is significantly longer than the side. Some potential examples of this rectangular form factor with a thin height are cellular telephones, tablet computers, or e-readers. These devices tend to be comprised of higher density materials and comprise a form factor where the thickness is generally much smaller than the length or width. The higher density of these devices provides a particular challenge when shipping due to the high G forces that can be created when dropped or handled carelessly. Thus, the optional support structures of the embodiments disclosed above can have particular utility in this context.

[0144]

[0146] The score, fold and cut lines that create features and connect the panels together, described herein, can be made through a number of different techniques. One common technique is to crush the material, such as corrugated cardboard, with a standard cardboard processing machine. The crushed portion is a localized area of compromised the rigidity of the material, that provides the end user with preformed fold lines about which the material preferentially bends and folds for assembly. Score lines can also be used, for example, cuts that extend through only one of the outer layers, an outer layer and the corrugated middle layer, and / or completely through the material. Additionally, score lines can be made continuously or broken. The configuration of such fold lines can be chosen to provide the desired amount of remaining bias in the material, for example, bias towards a flat shape thereby providing some spring action, or more relief so that the material is easier to bend. Such different configurations of fold lines can also generate different amounts of shock absorption in the final product. Thus, such configurations of fold lines can also be chosen to provide the desired shock absorption which can be fine-tuned with well-known drop testing techniques which are well known in this art.

[0145]

[0147] With continued reference to FIG. 1, the container system 100 includes at least one resilient spacer. The illustrated embodiment includes first and second resilient spacers 127a, 127b (FIG. 7) formed of Y-structures 106a, 106b, 107a, 107b. The Y-structures 106a, 106b are connected to the back portion 103 along score lines 117a, 117b, respectively. The Y-structures 106a, 106b are composed of flex panels 108a, 108b and the glue panels 109a, 109b, respectively. The flex panels 108a, 108b are connected to the glue panels 109a, 109b along score lines 118a, 118b, respectively. Similarly, the Y-structures 107a, 107b are connected to the inner panel 105 along score lines 119a, 119b, respectively. The Y-structures 107a, 107b are composed of flex panels 110a, 110b and the glue panels Illa, 111b, respectively. The flex panels 110a, 110b, which can be considered as a first angled panel portion and a second angled panel portion, are connected to the glue panels 109a, 109b, along score lines 118a, 118b, respectively. In general, the glue panels 109a, 109b, are shorter in length than the flex panels 110a, 110b. Optionally, the Y-structures can be symmetrical in the container system 100 but are not required to be such for their function. In some embodiments, the flex panels 108a, 108b, 110a, 110b can be considered to be skewed portions of the first and second resilient spacers 127a, 127b. As used herein, “skewed” would mean that the flex panels 108a, 108b, 110a, 110b are oriented at angles that are transverse to the adjacent sidewalls of the container formed by the system 100, in its final configuration, in use. In the illustrated example, the flex panels 108a, 108b, 110a, 110b are oriented at a skewed angle relative to both the inner panel 105 and back portion 103 as well as a plane (not shown) defined by the outermost lateral edges formed along score lines 117a, 117b, 119a, and 119b.

[0146]

[0148] Optionally, at the end of each of the glue panels 109a, 109b, Illa and 11 lb, the panel includes castellations 112a, 112b, 112c and 112d on the respective glue panels. A castellation may be described as an array of cut lines perpendicular to the edge of a panel or a fold line connecting two panels. The castellations 112a, 112b, 112c and 112d are specifically sized cuts in the glue panels 109a, 109b, Illa and 11 lb to achieve the desired structural properties based on the impact load scenarios of which the container system 100 experiences when mishandled during shipping.

[0147]

[0149] With reference to FIG. 2, the container system 100 can include an optional pressure sensitive adhesive 121 adhered to the top portion 101. This is used for closing the container system 100 when it is ready to be shipped. The container system 100 can also optionally include a pressure sensitive adhesive strip 122 adhered to the inner panel 105. The pressure sensitive adhesive strip 122 adheres the flexible cushion member 125 to the inner panel 105.

[0148]

[0150] With continued reference to FIG. 2, the container system 100 possesses a pull tab 126 which allows for opening the container system 100 by pulling on the tab of the pull tab 126. The container system 100 will open without the need for tools or sharp objects.

[0149]

[0151] FIG. 3, the container system 100 has been partially formed by folding Y-structures 106a, 106b, 107a, 107b along score lines 117a, 117b, 119a, 119b, respectively. The glue panels 109a, 109b, Illa, 11 lb have been folded along score lines 118a, 118b, 120a, 120b respectively. This results in the glue panels 109a, 109b, Illa, 111b being parallel to the back portion 103 and the inner panel 105, respectively.

[0150]

[0152] FIG. 4, the container system 100 includes the glue surfaces 123a, 123b, 124a, 124b which may receive an adhesive to adhere the glue surface 123a to glue surface 124a and glue surface 123b to glue surface 124b when the container system 100 is folded along score lines 115 and 116. This results in the back portion 103 being parallel to and facing the inner panel 105. When the Y-structures 106a and 107a are adhered together they create a resilient spacer 127a. When the Y-structures 106b and 107b are adhered together they create a resilient spacer 127b. Thus, the Y-structures 106a, 106b, 107a, 107b can be considered as having a Y-shaped wall configuration.

[0151]

[0153] FIG. 5 illustrates a further view of the embodiment which has the container system 100 folded in a state at which a user may receive it. To achieve this state, the Y-offset portion 104 is folded perpendicular to the back portion 103 along score line 115. The inner panel 105 is folded perpendicular to the Y-offset portion 104 along score line 116. Following that, the glue surfaces 123a, 123b, 124a, 124b may be adhered together to create the resilient spacers 127a, 127b, respectively, as discussed previously.

[0152]

[0154] FIGS. 2-5 illustrate the flexible cushion member 125 which can be flexible and can be made from paper base (e.g., paper-based) so it may be recycled along with the container system 100. The flexible cushion member 125 can optionally be configured to cushion, or provide padding to, the article when completely inserted into the container system 100.

[0153]

[0155] In some configurations, one end of the flexible cushion member 125 can be attached to the corrugated cardboard 101 A so as to configure the flexible cushion member 125 to function as an extraction slide. For example, as shown in FIG. 2, only one end of the flexible cushion member 125 is attached to the inner panel 105, where the rest of the flexible cushion member 125 is not attached. Thus, when the user is ready to insert the article into the container system 100, the flexible cushion member 125 lays on the exterior surface of the top portion 101, side portion 102 and back portion 103. The user slides the article along the back portion 103 while the article is on the flexible cushion member 125. As the article is slid into the container system 100, the article draws the flexible cushion member 125 into an enclosure formed by the system 100. For example, the article may be substantially or completely surrounded by the flexible cushion member 125 when enclosed between the back portion 103, Y-offset portion 104, inner panel 105 and along with the Y-structures 106a, 106b, 107a, 107b. The flexible cushion member 125 creates a cushioned space between the article and the respective corrugated structural member. The flexible cushion member 125 can optionally be formed with a material that is non-abrasive such that it will not scratch or add additional marks to the article during shipping.

[0154]

[0156] When the container system 100 arrives at the final destination, the user may extract the article from the container system 100 by simply pulling on the loose end of the flexible cushion member 125 which slidably lifts the article out of the enclosure formed by the container system 100, easily without further scratching or damaging the article. The illustrated embodiment can be particularly useful for flat, higher density articles such as cell phones, tablets, laptop computers, e-readers, and the like.

[0157] With continued reference the FIG. 5, after the article is inserted into the container system 100, it may be closed for shipping by folding the side portion 102 perpendicular to the back portion 103 along score line 114. The top portion may be folded perpendicular to the side portion 102 along score line 113. Once the pressure sensitive adhesive 121 is exposed, the top portion 101 may be folded along score line 113 and pressed against the inner panel 105 to close the container system 100 completely.

[0155]

[0158] As shown in FIG. 7, each of the resilient spacers 127a, 127b include at least one wall portion that is skewed relative to the adjacent side walls of the closed container formed by the container system 100. This can provide several optional advantages. For example, by including at least one skewed portion in the resilient spacer, the container system can better resiliently deform to absorb impact energy. Optionally, the at least one skewed portion can be configured to absorb impact energy from two directions.

[0156]

[0159] FIGS. 6 and 7 illustrate optional functionality of the resilient spacers 127a, 127b. During shipping, the article may experience forces in the AF1, AF2, CF1 and CF2 directions. If the forces are low enough in amplitude, the flexible cushion member 125 may arrest the movement of the article. In the illustrated configuration, the back portion 103 and the inner panel 105 are juxtaposed and spaced apart from each other so as to form the interior space for receiving the article.

[0157]

[0160] Larger forces can cause deformation of the walls of the container formed by the container system 100. For example, larger forces can cause the article to be pressed against the castellations 112a, 112c (as viewed in FIG. 3) if in the AF1 direction or, conversely, against the castellations 112b, 112d (as viewed in FIG. 3) if in the AF2 direction. The castellations 112a, 112b, 112c and 112d may be designed specifically to buckle to absorb the impact force AF1, AF2 from the article, respectively. In embodiments where the resilient spacers 127a, 127b include at least one skewed wall, the resilient spacers 127a, 127b can also absorb the energy of impact force AF1, AF2 by a resilient deflection. For example, impact force AF1 can cause the article to be pressed against the inner most edge of the resilient spacer 127a, moving the glue panels Illa, 109a outwardly and thereby causing the flex panels 108a, Illa (also referred to as skewed portions) to pivot and resiliently push the inner panel 105 and back portion 103 apart and thereby absorbing some of the impact energy from impact force AF1 which can thereby reduce gross acceleration of the article caused by the impact force AF1.

[0158]

[0161] The resilient spacers 127a, 127b may also absorb compression forces CF1, CF2 experienced while shipping in other optional ways. For example, if the resilient spacers 127a, 127b experience either a force in the CF1 or CF2 direction or both together, the resilient spacers 127a, 127b may translate in a direction towards the article which may result in the resilient spacers 127a, 127b contacting the article and may cause the castellations 112a, 112b, 112c, 112d to buckle to absorb the compression force AF1, AF2 or both, respectively.

[0162] Additionally, the Y-shape of the resilient spacers 127a, 127b also avoid a direct transfer of impact energy to the Article. For example, when the container impacts another object at the outermost edges of the resilient spacer 127a, the flex panels 108a, 110a, and glue panels 109a, Illa are not arranged in a linear configuration (as viewed in FIG.7). This prevents impact energy from being directly transferred to the Article.

[0159]

[0163] FIG. 8 illustrates the container system 100 in the closed state with the article inside and ready to be shipped.

[0160]

[0164] FIG. 9-14 illustrate a modification to the container system 100. The modified container system 200 includes a new numbering sequence beginning with 200 to identify the parts, components, features and advantages of the modification to the initial container system 100 described in FIGS. 1-8.

[0161]

[0165] FIG. 9 illustrates a modified container system 200 which includes resilient spacers 206a, 206b and cushion member 217. The container system 200 includes top portion 201, side portion 202, back portion 203, offset portion 204 and inner panel 205. The side portion 202 is connected to the top portion 201 along score line 209. The back portion 203 is connected to the side portion 202 along score line 210. The offset portion 204 is connected to the back portion 203 along score line 211. The inner panel 205 is connected to the offset portion 204 along score line 212. The top portion 201 includes a pull tab 229 which may be used for opening the container system 200. The pressure sensitive adhesive 216 may also be included on the top portion 201. The inner panel 205 includes a pressure sensitive adhesive strip 218 to adhere the cushion member 217 to the inner panel 205.

[0162]

[0166] Optionally, the addition of secure tabs 224a, 224b extend the top portion 201 on the opposite side of the pull tab 229. The secure tabs 224a, 224b are connected to the top portion 201 along score lines 227a, 227b, respectively. The secure tabs 224a, 224b are created by the extension sides 225a, 225b and extension tabs 226a, 226b which are connected along score lines 228a, 228b, respectively. The addition of the secure tabs 224a, 224b may provide added adhesive surface area and a wrap-around style lock over using only the pressure sensitive adhesive 216.

[0163]

[0167] With continued reference to FIG. 9, the resilient spacer 206a is connected to inner panel 205 along score line 213a. The resilient spacer 206b is connected to the inner panel 205 along score line 213b. The resilient spacers 206a, 206b are created from support portions 207a, 207b and reinforcement portions 208a, 208b. The support portions 207a, 207b are connected to the inner panel 205 along score lines 213a, 213b, respectively. The reinforcement portions 208a, 208b are connected to the support portions 207a, 207b along fold lines 214a, 214b, respectively. Each of the resilient spacers 206a, 206b include castellations 215a, 215b along the fold line 214a, 214b, respectively. Optionally, the container system 200 and the resilient spacers 206a, 206b may be formed monolithically from a single piece of material. In this case, the single piece of material forming the container system 200 is a corrugated cardboard, although other materials can also be used.

[0168] FIG. 10 is a further view of the embodiment of the container system 200 in which the resilient spacers 206a, 206b are folded into a deployed state. This state is achieved by folding reinforcement portions 208a, 208b along fold lines 214a, 214b, respectively, inwardly towards inner panel 205. To complete the formation of the resilient spacers 206a, 206b, the reinforcement portions 208a, 208b are adhered to support portions 207a, 207b, respectively, with glue or other adhesive materials or techniques can also be used. The resilient spacers 206a, 206b are deployed by inwardly folding the resilient spacers 206a, 206b towards the inner panel 205 along score lines 213a, 213b, respectively.

[0164]

[0169] FIG. 11 is a further view of the embodiment of the container system 200 which the article is enveloped by the container system 200 and the cushion member 217. The article may be placed on the cushion member 217 with the long side of the article being parallel to the long side of the inner panel 205. The article, cushion member 217 and inner panel 205, together, are folded along score line 212 to be perpendicular to offset portion 204. The article, cushion member 217, inner panel 205, and offset portion 204 are folded along score line 211 to wrap the article in the cushion member 217. The resilient spacers 206a, 206b are configured to contact with the back portion 203 and biased towards the article. Optionally, the resilient spacers 206a, 206b are not secured to the back portion 203, which can provide optional additional advantages, described in greater detail below.

[0165]

[0170] To complete the assembly of the container system 200, the side portion 202 is folded along score line 210 to be perpendicular to the back portion 203. The top portion 201 is folded along score line 209 to be adhered to the inner panel 205. In this case, the pressure sensitive adhesive 216 is used to adhere the top portion 201 to the inner panel 205 but other adhesive materials can also be used. Optionally, the secure tabs 224a, 224b may be employed to add a further level of security if the user feels it may be needed.

[0166]

[0171] FIGS. 12 and 13, illustrate the function of the resilient spacers 206a, 206b. During shipping, the article may experience forces in the AF1, AF2, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 217 may arrest the movement of the article. If the amplitude of the forces are larger, the article may be forced against the castellation 215a (as viewed in FIG. 9) if in the AF1 direction or, conversely, may be forced against the castellation 215b (as viewed in FIG. 9) if in the AF2 direction. The castellations 215a, 215b may be designed specifically to buckle to absorb the impact force AF1, AF2 from the article, respectively.

[0167]

[0172] The resilient spacers 206a, 206b may also absorb compression forces CF1, CF2 experienced while shipping. If the resilient spacers 206a, 206b experiences either a force in the CF1 or CF2 direction or both together, the resilient spacers 206a, 206b may translate in a direction towards the article which may result in the resilient spacers 206a, 206b contacting the article and may cause the castellations 215a, 215b to buckle to absorb the compression force AF1, AF2 or both, respectively.

[0173] Additionally, in some embodiments where the resilient spacers 206a, 206b are not fixed to the back portion 203. Thus, the portion of the resilient spacers 206a, 206b that contact the inner surface of the back portion 203, can slide relative thereto. Thus, when the container is subjected to compressive forces CF1, CF2, the resilient spacers 206a, 206b can bend further inwardly (as viewed in FIG.13) towards the inner panel 205. As such, the resilient spacers 206a, 206b act as leaf springs, with such resilient deflections being dampened by the resistance provided by the bending of the cardboard that forms the resilient spacers 206a, 206b. In this mode of operation, the portion of the resilient spacers 206a, 206b that contact the back portion 203 slide laterally (as viewed in FIG. 13) along the inwardly facing surface of the back portion 203. In such embodiments, the support portions 207a, 207b and reinforcement portions 208a, 208b can both be considered skewed portions of the resilient spacers 206a, 206b. Thus, such embodiments can also provide the optional additional advantage provided by the inclusion of a skewed portion for avoiding the direct transfer of impact energy to the article.

[0168]

[0174] FIG. 14 illustrates the container system 200 in the closed state with the article inside and ready to be shipped.

[0169]

[0175] FIGS. 15-20 illustrate another modification of the container systems 200 identified generally by the reference numeral 300. Parts, components, features, and advantages are of the container system 300 that are similar or the same as those described above with reference to container systems 200 are identified with the same reference numerals, except that the 100 digit is changed from 2 to a “3.” The similar reference numerals and part names are listed as follows: top portion 301, side portion 302, back portion 303, offset portion 304, inner panel 305, resilient spacers 306a, 306b, support portions 307a, 307b, reinforcement portions 308a, 308b, score lines 309, 310, 311, 312, 313a, 313b, fold lines 314a, 314b, pull tab 315, pressure sensitive adhesive 316 and extraction slide 317.

[0170]

[0176] FIG. 15 illustrates another modification of the container system 300 which adds the addition of a locking fingers 318a, 318b to replace the need for a pressure sensitive adhesive strip. The locking fingers 318a, 318b is created by cut lines 319a, 319b, respectively, in the inner panel 305. Optionally, a pull tab 315 is included in top portion 301.

[0171]

[0177] FIGS. 16 illustrates how the extraction slide 317 may be secured in place by the locking fingers 318a, 318b. To deploy the locking fingers 318a, 318b they are folded along fold lines 320a, 320b, respectively, to any position that is not parallel to the inner panel 305. The long length of the extraction slide 317 is aligned perpendicular to the long length of the inner panel 305 and located between the locking fingers 318a and 318b. The locking fingers 318a, 318b are activated by forcing the extraction slide 317 between the locking fingers 318a, 318b and the inner panel 305. This secures the extraction slide 317 in position for the assembly of the container system 300.

[0178] FIG. 17 is a further view of the embodiment of the container system 300 which the article is enveloped by the container system 300 and the extraction slide 317. The article may be placed on the extraction slide 317 with the long side of the article being parallel to the long side of the inner panel 305. The article, extraction slide 317 and inner panel 305, together, are folded along score line 312 to be perpendicular to offset portion 304. The article, extraction slide 317, inner panel 305, and offset portion 304 are folded along score line 311 to wrap the article in the extraction slide 317. The resilient spacers 306a, 306b are intended to be in contact with the back portion 303 and biased towards the article. To complete the assembly of the container system 300, the side portion 302 is folded along score line 310 to be perpendicular to the back portion 303. The top portion 301 is folded along score line 309 to be adhered to the inner panel 305.

[0172]

[0179] FIGS. 18 and 19, illustrate the function of the resilient spacers 306a, 306b. During mishandling while shipping, the article may experience forces in the AF1, AF2, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 317may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the resilient spacer 306a if in the AF1 direction or, conversely, may be forced against the resilient spacer 306b if in the AF2 direction. The resilient spacers 306a, 306b may move in the direction of the article which will force the resilient spacers 306a, 306b against the inner panel 305. The combination of the top portion 301 being adhered to the inner panel 305 may provide the needed structure in order to absorb the forces experience by the article. The resilient spacers 306a, 306b may also absorb compression forces CF1, CF2 experienced while shipping. If the resilient spacers 306a, 306b experiences either a force in the CF1 or CF2 direction or both together, the resilient spacers 306a, 306b may translate in a direction towards the article which may result in the resilient spacers 306a, 306b contacting the article and may partly deform to absorb the compression force AF1, AF2 or both, respectively. Additionally, the resilient spacers 306a, 306b can be considered as including skewed portions.

[0173]

[0180] FIG. 20 illustrates the container system 300 in the closed state with the article inside and ready to be shipped.

[0174]

[0181] FIGS. 21-26 illustrate another modification of the container systems 200 identified generally by the reference numeral 400. Parts, components, features, and advantages are of the container system 400 that are similar or the same as those described above with reference to container systems 200 are identified with the same reference numerals, except that the 100 digit is changed from 2, 3 to a “4.” The similar reference numerals and part names are listed as follows: top portion 401, side portion 402, back portion 403, offset portion 404, inner panel 405, resilient spacers 406a, 406b, support portion 407a, 407b, reinforcement portions 408a, 408b, score lines 409, 410, 411, 412, 413a, 413b, 414a, 414b, pull tab 415, pressure sensitive adhesive 416 and cushion member 417.

[0182] FIG. 21 illustrates another modification of the container system 400 which is a modified construction of the resilient spacers 406a, 406b. The resilient spacers 406a, 406b are attached to the inner panel 405 along score lines 413a, 413b, respectively. The resilient spacer 406a is created by support portion 407a and reinforcement portions 408a attached along score line 414a. The resilient spacer 406a also has buckling wedges 421a and 421b attached on either end of the support portion 407a by fold lines 422a and 422b, respectively. The resilient spacer 406b is created by support portion 407b and reinforcement portion 408b attached along score line 414b. The resilient spacer 406b also has buckling wedges 421c and 42 Id attached on either end of the support portion 407b by fold line 422c and 422d, respectively.

[0175]

[0183] FIG. 22 is a further view of the container system 400 with the reinforcement portions 408a, 408b folded along score lines 414a, 414b, respectively. An adhesive is applied to support portions 407a, 407b to connect the reinforcement portions 408a, 408b to the support portions 407a, 407b, respectively.

[0176]

[0184] FIG. 23 is a further view of the container system 400 illustrated with the buckling wedges 421a, 421b, 421c and 42 Id being folded into place. The buckling wedges 421a, 421b, 421c and 42 Id are folded perpendicular to the reinforcement portions 408a, 408b along fold lines 422a, 422b, 422c and 422d, respectively.

[0177]

[0185] FIG. 23 is a further view of the container system 400 with the resilient spacers 406a, 406b in the deployed state which is when the buckling wedge edges 423a, 423b, 423c and 423d contact the inner panel 405. The resilient spacers 406a, 406b are folded along score lines 413a, 413b, respectively, until the buckling wedge edges 423a, 423b, 423c and 423d contacts the inner panel 405.

[0178]

[0186] FIG. 25 is a further view of the container system 400 with the article placed on the cushion member 417 for completing the packaging of the article. The resilient spacers 406a, 406b in the deployed state is folded along score line 412 such that the inner panel 405 is perpendicular to the offset portion 404. The offset portion 404 is folded along score line 411 to be perpendicular to the back portion 403. The side portion 402 is folded along score line 410 to be perpendicular to the back portion 403. The top portion 401 is folded along score line 409 to be perpendicular to the side portion 402. To close the container system 400 for shipping, the pressure sensitive adhesive 416 is activated and the top portion 401 is pressed against the inner panel 405.

[0179]

[0187] FIGS. 26 and 27, illustrate the function of the resilient spacers 406a, 406b. During mishandling while shipping, the article may experience forces in the AF1, AF2, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 417 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the resilient spacer 406a if in the AF1 direction or, conversely, may be forced against the resilient spacer 406b if in the AF2 direction. The reinforcement portions 408a, 408b may move in the direction of the article which will force the reinforcement portions 408a, 408b against the inner panel 305. The combination of the top portion 401 being adhered to the inner panel 405 may provide the needed structure in order to absorb the forces experience by the article. The resilient spacers 406a, 406b may also absorb compression forces CF1, CF2 experienced while shipping. If the resilient spacers 406a, 406b experience either a force in the CF1 or CF2 direction or both together, the resilient spacers 406a, 406b may translate in a direction towards the article which may result in the reinforcement portions 408a, 408b bowing to absorb the forces independently or in conjunction with the deformation or buckling of the buckling wedges 421a, 421b, 421c and / or 42 Id depending on the nature of the compression force direction. Thus, the resilient spacers 406a, 406b can also be considered as including skewed portions.

[0180]

[0188] FIG. 28 illustrates the container system 400 in the closed state with the article inside and ready to be shipped.

[0181]

[0189] FIG. 29-37 illustrate a modification of the container systems 100 identified generally by the reference numeral 500. Parts, components, features, and advantages are of the container system 500 that are similar or the same as those described above with reference to container systems 100 are identified with the same reference numerals, except that the 100 digit is changed from a 1 to a “5.” The similar reference numerals and part names are listed as follows: top portion 501, side portion 502, back portion 503, Y-offset portion 504, inner panel 505, Y-structures 506a, 506b, 507a, 507b, flex panels 508a, 508b, glue panels 509a, 509b, flex panels 510a, 510b, glue panels 511a, 511b, castellations 512a, 512b, 512c, 512d, score lines 513, 514, 515, 516, 517a, 517b, 518a, 518b, 519a, 519b, 520a, 520b, pressure sensitive adhesive 521, 522, glue surfaces 523a, 523b, 524a, 524b, flexible cushion member 525 and resilient spacers 527a, 527b.

[0182]

[0190] FIG. 29 illustrates another modification of the container system 100 which adds the addition of an extension panel 528 which extends the size of the top portion 501 on the opposite side of the pull tab 526. Attached to the extension panel 528 are the secure tabs 529a, 529b. The secure tabs 529a, 529b are connected along score lines 532a, 532b, respectively. The secure tabs 529a, 529b are created by the extension sides 530a, 530b and extension tabs 531a, 53 lb which are connected along score lines 533a, 533b, respectively.

[0183]

[0191] FIG. 29 further illustrates the addition of a locking tab 534 and locking slot 537 to the container system 500. The locking tab 534 is created from cut lines 535, 536 in the extension panel 528. The locking slot 537 is created by cut line 538 in the inner panel 505. The locking tab 534 and locking slot 537 may be used together for additional security or may provide the option to remove the pressure sensitive adhesive 521.

[0184]

[0192] FIG. 29 further illustrates the addition of the extraction tab 539 to the container system 500. The extraction tab 539 is created by score line 540 and cut lines 541, 542 in the inner panel 505. The extraction tab 539 may allow the user to more easily insert or extract the article from the container system 500. The extraction tab is able to be easily folded along score line 540 aid in securely inserting the article as well as aiding in safe removal of the article.

[0185]

[0193] FIGS. 30 and 31 illustrate the construction of the Y-structures 506a, 506b, 507a, 507b by folding along score lines 517a, 517b, 519a, 519b. This creates glue surfaces 523a, 523b, 524a, 524b.

[0186]

[0194] FIGS. 31-32 illustrates a further view of the embodiment which has the container system 500 partially folded in a state at which a user may receive it. To achieve this state, the Y-offset portion 504 is folded perpendicular to the back portion 503 (not shown) along score line 515. The inner panel 505 is folded perpendicular to the Y-offset portion 504 along score line 516. Following that, the glue surfaces 523a, 523b, 524a, 524b (only glue surface 523a shown) may be adhered together, respectively, creating the resilient spacers 527a, 527b. The extension sides 530a, 530b are folded perpendicular to the extension panel 528 along score lines 532a, 532b. The extension tabs 531a, 531b are folded perpendicular to the extension sides 530a, 530b along score lines 533a, 533b which create secure tabs 529a, 529b, respectively.

[0187]

[0195] FIG. 33 illustrates how the cushion member 525 may be wrapped around the article prior to the article being inserted into the container system 500. This type of construction may be necessary if the article larger and may present a challenge if the cushion member 525 were already adhered in place.

[0188]

[0196] FIG 34 illustrates the article inserted into the container system 500, it may be closed for shipping by folding the side portion 502 perpendicular to the back portion 503 along score line 514. The top portion may be folded perpendicular to the side portion 502 along score line 513. Once the pressure sensitive adhesive 521 is exposed, the top portion 101 and extension panel 528 may be folded along score line 513 and pressed against the inner panel 505 to close the container system 500. To completely seal the container system 500, the secure tabs 529a, 529b are folded along score lines 532a, 532b, 533a, 533b and the extension tabs 531a, 531b are adhered to the back portion 503, respectively.

[0189]

[0197] FIGS. 35 and 36, illustrate the function of the Y-structures 506a, 506b, 507a, 507b. During mishandling while shipping, the article may experience forces in the AF1, AF2, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 525 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the castellations 512a, 512c (as viewed in FIG. 31) if in the AF1 direction or, conversely, may be forced against the castellations 512b, 512d (as viewed in FIG. 31) if in the AF2 direction. The castellations 512a, 512b, 512c and 512d may be designed specifically to buckle to absorb the impact force AF1, AF2 from the article, respectively. The resilient spacers 527a, 527b may also absorb compression forces CF1, CF2 experienced while shipping. If the resilient spacers 527a, 527b experience either a force in the CF1 or CF2 direction or both together, the resilient spacers 527a, 527b may translate in a direction towards the article which may result in the resilient spacers 527a, 527b contacting the article and may cause the castellations 512a, 512b, 512c, 512d to buckle to absorb the compression force AF1, AF2 or both, respectively. Additionally, the resilient spacers 527a, 527b can be considered as including skewed portions.

[0190]

[0198] FIG. 37 illustrates the container system 500 in the closed state with the article inside and ready to be shipped.

[0191]

[0199] FIG. 38-47 illustrate a modification to the container system 100. The modified container system 600 will utilize a new numbering sequence beginning with 600 to identify the parts, components, features and advantages of the modification to the initial container system 100 described in FIGS. 1-8.

[0192]

[0200] FIG. 38 illustrates a container system 600 which includes resilient spacers 635a, 635b, 636, 637 and cushion member 616. The container system 600 includes top portion 601, side portion 602, back portion 603, offset portion 604 and inner panel 605. The side portion 602 is connected to the top portion 601 along score line 618. The back portion 603 is connected to the side portion 602 along score line 619. The offset portion 604 is connected to the back portion 603 along score line 620. The inner panel 605 is connected to the offset portion 604 along score line 621. Optionally, the addition of secure tabs 612a, 612b extend the top portion 601. The secure tabs 612a, 612b are connected to the top portion 601 along score lines 626a, 626b, respectively. The secure tabs 612a, 612b are created by the extension sides 613a, 613b and extension tabs 614a, 614b which are connected along score lines 627a, 627b, respectively. The pressure sensitive adhesive 615 may also be included on the top portion 601 and may extend across the secure tabs 612a, 612b. The addition of the secure tabs 612a, 612b may provide added adhesive surface area and a wrap-around style lock over using only the pressure sensitive adhesive 615. The inner panel 605 includes an adhesive area 634 to adhere the cushion member 616 to the inner panel 605. The back portion 603 possesses glue areas 617a, 617b for the application of an adhesive to adhere two of the resilient spacers 635a, 635b for assembly, respectively.

[0193]

[0201] FIG. 38 further illustrates an embodiment of the resilient spacers 635a, 635b, 636, 637. The resilient spacer 635a is constructed from vertical support 608a and glue base 609a which are attached along score line 623a. The resilient spacer 635b is constructed from vertical support 608b and glue base 609b which are attached along score line 623b. The resilient spacer 636 is constructed from vertical support 606 and base 607 which are attached along score line 625. The resilient spacer 637 is constructed from vertical support 610 and base 611 which are attached along score line 629. The resilient spacers 635a, 635b, 636, 637 are attached to the inner panel 605 along score lines 622a, 622b, 624, 628, respectively.

[0194]

[0202] FIGS. 39-40 illustrate the construction of the resilient spacers 635a, 635b. The vertical support 608a, 608b are folded perpendicularly to the inner panel 605 along score lines 622a, 622b, respectively. The glue bases 609a, 609b are folded perpendicularly to the vertical supports 608a, 608b and outwardly away from the inner panel 605.

[0203] FIGS. 40 and 41 illustrate the further construction of the container system 600. The resilient spacer 636 is created by folding vertical support 606 perpendicular the inner panel 605 along score line 624. The base 607 is folded perpendicular to the vertical support 606 along score line 625. Following this, the cushion member 616 is adhered in place in the adhesive area 634 on the inner panel 605. The offset portion 604 is folded perpendicular to the back portion 603 along score line 620. The inner panel 605 is folded perpendicular to offset portion 604 along score line 621.

[0195]

[0204] FIG. 41-44 illustrate the construction of the resilient spacer 637 and the final closing of the container system 600. Prior to inserting the article, FIG. 42 illustrates the construction of the resilient spacer 637. The resilient spacer 637 is created from the vertical support 610 and the base 611 which are connected along score line 629. The cut lines 630a, 630b are specifically designed to allow the vertical support 610 to be folded along score line 628 and create a small amount of interference from the thickness of the inner panel 605. This interference is what creates the ability for the vertical support 610 to stay vertical and support the container system 600. The base 611 is created by a series of cut lines 631a, 63 lb, 632 which allow for it to compress the cushion member 616 when the resilient spacer 637 is deployed. The cut line 633 adds to the ease of use of the resilient spacer 637.

[0196]

[0205] FIGS. 45 and 46, illustrate the function of the resilient spacers 635a, 635b, 636, 637. During shipping, the article may experience forces in the AF1, AF2, AF3, AF4, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 616 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the resilient spacer 635a (as viewed in FIG. 45) if in the AF1 direction or, conversely, may be forced against the resilient spacer 635b (as viewed in FIG. 45) if in the AF2 direction. The resilient spacers 635a, 635b may be designed specifically to deform to absorb the impact force AF1, AF2 from the article, respectively. Similarly, The resilient spacers 636, 637 may be specifically designed to deform when experiencing forces in the AF3 and AF4 directions (as viewed in FIG. 46), respectively. The resilient spacers 635a, 635b, 636, 637 may also absorb compression forces CF1, CF2 experienced while shipping. If the resilient spacers 635a, 635b, 636, 637 experiences either a force in the CF1 or CF2 direction or both together, the resilient spacers 635a, 635b, 636, 637 may buckle and leverage the cushion member 616 to help distribute the forces.

[0197]

[0206] FIGS. 48-59 illustrate a modification to the container system 100. The modified container system 700 will utilize a new numbering sequence beginning with 700 to identify the parts, components, features and advantages of the modification to the initial container system 100 described in FIGS. 1-8.

[0198]

[0207] FIG. 48 illustrates a container system 700 which includes resilient spacers 711a and 711b and cushion member 717. The container system 700 includes top portion 701, side portion 702, back portion 703, offset portion 704, inner portion 705, accessory wall 706 and accessory panel 707. The side portion 702 is connected to the top portion 701 along fold line 721. The back portion 703 is connected to the side portion 702 along fold line 722. The offset portion 704 is connected to the back portion 703 along fold line 723. The inner portion 705 is connected to the offset portion 704 along fold line 724. The accessory wall 706 is connected to the inner portion 705 along score line 725. The accessory panel 707 is connected to the accessory wall 706 along score line 726. The accessory wall 706 and accessory panel 707, together make the accessory support 708.

[0199]

[0208] Optionally, the addition of secure tabs 714a, 714b extend the top portion 701. The secure tabs 714a, 714b are connected to the top portion 701 along score lines 729a, 729b, respectively. The secure tabs 714a, 714b are created by the extension sides 712a, 712b and the extension tabs 713a, 713b which are connected along score lines 730a 730b, respectively. The pressure sensitive adhesives 721a, 721b may also be included on the extension tabs 713a, 713b, respectively. The addition of the secure tabs 714a, 714b may provide a wrap-around style lock. The inner portion 705 includes an adhesive area to adhere the cushion member 717 to the inner portion 705. The adhesive area may extend across the offset portion 704 and the back portion 703 if additional adhesion of the cushion member 717 is necessary based on the size and weight of the article. Additionally, the top portion 701 includes a pull tab 720 which may be used for opening the container system 700.

[0200]

[0209] FIG. 48 further illustrates an embodiment of the resilient spacers 711a, 711b including accessory slots 718a, 718b. Also illustrated are the locking tabs 716a, 716b along with the respective tab cutouts 719a, 719b. The resilient spacer 711a is constructed from vertical support 709a and horizontal support 710a which are attached along score line 728a. The resilient spacer 711b is constructed from vertical support 709b and horizontal support 710b which are attached along score line 728b. The resilient spacers 711a, 711b are attached to the inner portion 705 along score lines 727a, 727b, respectively. The resilient spacers 711a, 711b additionally possess accessory slots 718a, 718b, respectively. The accessory slots 718a, 718b are cutouts that are located on vertical supports 709a, 709b and horizontal support 710a, 710b and cross score lines 728a, 728b, respectively. Optionally, the addition of locking tabs 716a, 716b extend the back portion 703. The locking tabs 716a, 716b are connected to the locking sides 715a, 715b along score line 732a, 732b, respectively. The locking sides 715a, 715b are connected to the back portion 703 along fold lines 731a, 731b, respectively. The addition of locking tabs 716a, 716b may utilize tab cutouts 719a, 719b which may be located on the inner portion 705 and partially located on the vertical support 709a, 709b and cross score lines 727a, 727b, respectively.

[0201]

[0210] FIGS. 49-50 illustrate the construction of the resilient spacers 711a, 711b. The vertical support 709a, 709b are folded parallel to the inner portion 705 along score lines 727a, 727b, respectively inward towards the centerline of the inner portion 705. The horizontal supports 710a, 710b are folded parallel to the vertical supports 709a, 709b along score lines 728a, 728b, respectively and outwardly away from the center line of the inner portion 705.

[0202]

[0211] FIGS. 51-53, 57, 58 illustrate the partial construction of the container system 700 into the closed state as well as the construction and use of the locking tabs 716a, 716b. The article is placed on the cushion member 717. The article, inner portion 705 and resilient spacers 71 la, 71 lb are folded vertically along fold line 724. The offset portion 704 is folded vertically along fold line 723. Optionally, the locking sides 715a, 715b are folded vertically along fold lines 731a, 731b (not shown) and the locking tabs 716a, 716b are folded along score lines 732a, 732b which may engage the tab cutouts 719a, 719b, respectively. The locking tabs 716a, 716b may provide a means for securing the article while creating the area for storing additional accessories to be shipped with the article. Following the securing of the article, the accessory wall 706 is folded vertically inward towards the back portion 703 along score line 725. When the accessory wall 706 is folded inward, it engages the accessory slots 718a, 718b to create a barrier in the event of mishandling during shipping. The accessory panel 707 is folded parallel to the back portion 703 and directed towards the side portion 702 along score line 726. The combination of the top portion 701, side portion 702, back portion 703, accessory panel 707, held in place by the accessory slots 718a, 718b and the resilient spacers 711a, 711b create an area to store accessories that is independent of the area for the article which preserves the ability for the container to support the article in the event of mishandling during shipping.

[0203]

[0212] FIGS. 52 and 53 illustrate the construction of the container system 700 in the closed state. The top portion 701 is folded perpendicularly along fold line 721. The side portion 702 is folded perpendicularly along fold line 722 which results in the top portion 701 being parallel to the back portion 703. Prior to engaging the secure tabs 714a, 714b, the pressure sensitive adhesives 721a, 721b located on extension tabs 713a, 713b, respectively are activated by removing their protective strips. The secure tabs 714a, 714b are engaged by folding extension sides 712a, 712b perpendicularly along score line 729a, 729b and folding extension tabs 713a, 713b parallel to back portion 703 and adhering the extension tabs 713a, 713b by pressing them against the back portion 703.

[0204]

[0213] FIGS. 56-58, illustrate the function of the resilient spacers 711a, 711b, offset portion 704, accessory support 708, in conjunction with the accessory slots 718a, 718b, along with the cushion member 717. During mishandling while shipping, the article may experience forces in the AF1, AF2, AF3, AF4, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 717 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the resilient spacer 711a (as viewed in FIG. 56 and 58) if in the AF1 direction or, conversely, may be forced against the resilient spacer 711b (as viewed in FIG. 56 and 58) if in the AF2 direction. The resilient spacers 71 la, 71 lb may be designed specifically to deform to absorb the impact force AF1, AF2 from the article, respectively. Additionally, the accessory support 708 is designed to work with the cushion member 717 when experiencing forces in the AF3 direction (as viewed in FIGS.

[0205] 57 and 58). The accessory wall 706 is constrained by the accessory slots 718a, 718b located in the resilient spacers 711a, 711b, respectively. If the forces is low enough in amplitude, the cushion member 717 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the accessory wall 706 which may deform sliding the accessory panel 707 along the back portion 703 and into the side portion 702 causing the accessory panel 707 to buckle. Also, the offset portion 704 and the cushion member 717 may be specifically designed to deform when experiencing forces in the AF4 direction (as viewed in FIG. 57 and 58), respectively. If the forces is low enough in amplitude, the cushion member 717 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the towards the offset portion 704 which provides a barrier for the cushion member 717 to deform against. The article is surrounded on three sides by the cushion member 717 which may receive support from the offset portion 704. The resilient spacers 71 la, 71 lb along with the cushion member 717 may also absorb compression forces CF1, CF2 experienced while shipping. If the container system 700 experiences either a force in the CF1 or CF2 direction or both together, the resilient spacers 71 la, 71 lb may compress and leverage the cushion member 717 to help distribute the forces.

[0206]

[0214] FIG. 59 illustrates the container system 700 in the closed state with the article and any needed accessories inside and ready to be shipped.

[0207]

[0215] FIGS. 60-69 illustrate a modification to the container system 100. The modified container system 800 will utilize a new numbering sequence beginning with 800 to identify the parts, components, features and advantages of the modification to the container system 100 described in FIGS. 1-8.

[0208]

[0216] FIG. 60 illustrates a container system 800 which includes deployable spacers 805, 812a, 812b, assembly tabs 817a, 817b and cushion member 840.

[0209]

[0217] As shown in Figure 60, the container system 800 can optionally be formed from a single piece of cardboard. Thus, in some embodiments, the container system 800 includes adhesive panel 801, top portion 802, side portion 803, back portion 804 and deployable spacers 805, 812a, 812b.

[0210]

[0218] The top portion 802 is connected to the adhesive panel 801 along score line 822. The side portion 803 is connected to the top portion 802 along score line 823. The back portion 804 is connected to the side portion 803 along score line 824. The deployable spacer 805 is connected to the back portion 804 along score line 825. The deployable spacers 812a, 812b are connected to the back portion 804 along fold lines 830a, 830b, respectively. Optionally, the assembly tabs 817a, 817b are connected to the top portion 802 along fold lines 834a, 834b, respectively. The adhesive panel 801 includes pressure sensitive adhesive strips 818a, 818b as well as tear string 819. The back portion 804 includes glue areas 820a, 820b, 821.

[0219] FIG. 60 further illustrates an embodiment of the deployable spacers 805, 812a, 812b. The deployable spacer 805 includes accessory door 810 and construction tabs 811a, 811b. The deployable spacer 805 is constructed from accessory back 806, accessory top 807, accessory support 808 and accessory base 809. The accessory back 806 is connected to the back portion 804 along score line 825. The accessory top 807 is connected to the accessory back 806 along score line 826. The accessory support 808 is connected to the accessory top 807 along score line 827. The accessory base 809 is connected to the accessory support 808 along score line 828. The accessory door 810 is connected to the accessory top 807 along score line 827. The construction tabs 811a, 811b are created by cut lines 836a, 836b and are connected to the accessory top 807 along fold lines 829a, 829b, respectively. The accessory door 810 is created by cutting the accessory top 807 along the cut lines 837a, 837b, 838 along with cut line 839 which is located on the accessory back 806. As such, the accessory door 810 is movable between opened and closed positions. In the opened position, the accessory door 810 allows a user to insert and / or remove additional articles from the dead pace withing the deployable spacer 805.

[0211]

[0220] FIG. 60 further illustrates an embodiment of the deployable spacers 812a, 812b, the assembly slots 831a, 831b and construction cutouts 835a, 835b. The deployable spacers 812a, 812b are constructed from spacer backs 813a, 813b, spacer tops 814a, 814b, spacer supports 815a, 815b and spacer bases 816a, 816b. The deployable spacer 812a is constructed from spacer back 813a which is connected to spacer top 814a along fold line 831c. The spacer support 815a is connected to spacer top 814a along fold line 832a. The spacer base 816a is connected to the spacer support 815a along score 833a. The deployable spacer 812b is constructed from spacer back 813b which is connected to spacer top 814b along fold line 83 Id. The spacer support 815b is connected to spacer top 814b along fold line 832b. The spacer base 816b is connected to the spacer support 815b along score 833b. The spacer backs 813a, 813b include assembly slots 831a, 831b located along fold line 831c, 83 Id, respectively. The spacertops 814a, 814b include the construction cutouts 835a, 835b.

[0212]

[0221] FIG. 61 illustrates the initial construction of the deployable spacers 805, 812a, 812b and the assembly of the cushion member 840. Optionally, the embodiment of the container system 800 may be shipped in the state illustrated in FIG. 61, to simply future assembly and loading operations. The position or configuration illustrated in FIG. 61 can be referred to as a “flattened” or “retracted” position. In this position, the container system 800 is in a substantially flattened state, even though parts of the deployable spacers 805, 812a, 812b are folded over and thus double layered while other parts of the container system 800 are only single layer. Additionally, in the position illustrated in FIG.

[0213] 61, all four walls of the deployable spacers 805, 812a, 812b are parallel with the back portion 804 and thus parallel or substantially parallel with each other. Further, in this configuration, with the spacer backs 813a, 813b connected to the spacer tops 814a, 814b which are connected to spacer supports 815a, 815b which are connected to the back portion 804 by way of the spacer bases 816a, 816b, the deployable spacers 812a, 812b form closed loops. Thus, they are moved to the deployed or erected position by way of a racking motion. In some embodiments, the spacer bases 816a, 816b remain in a static position during such a racking movement.

[0214]

[0222] The deployable spacer 805 is folded parallel to the back portion 804 along score line 826 and pointing inward towards the back portion 804. The accessory base 809 is adhered to the glue area 821 located on the back portion 804. The deployable spacers 812a, 812b are folded parallel to the back portion 804 along fold lines 831c, 83 Id and pointing inward toward the back portion 804. The spacer bases 816a, 816b are adhered to the back portion 804 at glue areas 820a, 820b, respectively. The cushion member 840 is adhered to the accessory support 808 in the designated glue area 841. Optionally, the cushion member 840 may be adhered to the container in additional locations if needed to contain the article. FIG. 61 further illustrates the layout of the container system 800 as a customer may receive it prior to adding an article for shipping to an end user.

[0215]

[0223] FIG. 62 illustrates the partial construction of the deployable spacers 805, 812a, 812b. The forming of the deployable spacer 805 is achieved by pressing down on the back portion 804 while pressing the score line 826 inwardly. The forming of the deployable spacers 812a, 812b is achieved by pressing along fold lines 831c, 83 Id, simultaneously. This movement can be referred to as a “racking” movement. Thus, the deployable spacers 805, 812a, 812b can be considered as being configured to be moved through a racking movement between retracted and deployed positions.

[0216]

[0224] This process moves the deployable spacers 805, 812a, 812b from a state in which they are folded flat against themselves (a retracted position), to a state in which the opposing walls move apart and encircle an empty or dead space (a deployed position). The dead space can serve as an airgap between the outermost surfaces of the container and the article that is packaged therein. As such, the deployable spacers 805, 812a, 812b become walls around a space used for receiving an article to be packaged and shipped.

[0217]

[0225] FIG. 63 illustrates the fully deployed state of the deployable spacers 805, 812a, 812b along with the addition of the cushion member 840. To completely deploy the deployable spacers 805, 812a, 812b, the deployable spacer 805 may be connected to the deployable spacers 812a, 812b using the construction tabs 811a, 811b. To activate the constructions tabs 811a, 811b, the construction tabs 811a, 811b are folded perpendicularly to accessory top 807 along fold lines 829a, 829b, respectively. The construction tabs 811a, 811b are folded into the construction cutouts 835a, 835b located in the spacer tops 814a, 814b of the respective deployable spacers 812a, 812b. The orientation or position illustrated in FIG. 63 can be referred to as the “deployed” or “erected” position. In the illustrated orientation, some of the walls of the deployable spacers 805, 812a, 812b are parallel to each other and perpendicular to the back portion 804 and at least one wall is parallel to the bottom wall. As used herein, the term “perpendicular”, “substantially perpendicular” or “generally perpendicular” does not require a 90.00 degree angle. Rather, these terms are intended to convey the typical precision associated with structures commonly formed in typical corrugated cardboard structures. Substantially perpendicular, as used herein, is intended to include 90 degrees, plus or minus about 5 degrees.

[0218]

[0226] As such, in the orientation or position illustrated in FIG. 63, the spacer back 813a can be parallel or generally parallel to the spacer support 815a and thus both are perpendicular or generally perpendicular to the back portion 804. Additionally, the spacer top 14a is parallel or generally parallel to the back portion 804. The same description also applies to the corresponding portions of the deployable spacer 812b.

[0219]

[0227] In the fully deployed state illustrated in FIG. 63, the deployable spacers 805, 812a, 812b together form three walls around an empty space. Additionally, because each of the deployable spacers 805, 812a, 812b encircle an inner dead space, they can provide an air gap between an article placed in the empty space and the exterior of the container system, in use. Additionally, the illustrated configuration of the deployable spacers 805, 812a, 812b can provide some resilient response to loading caused during use. For example, the walls of the accessory support 808 and spacer supports 815a, 815b can distort into the dead spaces defined by the deployable spacers 805, 812a, 812b during an impact, thereby absorbing impact energy caused by collision of the outer walls against other bodies while preventing direct contact of the packaged article with the other body with which the container system 800 may have collided. Thus, the deployable spacers 805, 812a, 812b can also be considered to be deployable spacers 805, 812a, 812b, in some embodiments.

[0220]

[0228] FIG. 64 illustrates the partial construction of the container system 800 into the closed state. An article is placed on the cushion member 840. Any needed accessories that may accompany the article may be included in the container system 800 by utilizing the accessory door 810 which is located on the accessory top 807 of the deployable spacer 805. After the addition of the article and accessories, the side portion 803 is folded perpendicularly to the back portion 804 along score line 824. The top portion 802 is folded perpendicularly to the side portion 803 along score line 823. The assembly tabs 817a, 817b are folded perpendicularly to the top portion 802 along fold lines 834a, 834b. The adhesive panel 801 is folded perpendicularly to the top portion 802 along score line 822. The assembly tabs 817a, 817b are inserted into the assembly slots 831a, 83 lb located in the spacertops, respectively. The pressure sensitive adhesive strips 818a, 818b are pressed against the accessory back 806 to complete the assembly of the container system 800. As such, the assembly tabs 817a, 817b can be considered as serving as top wall connector portions and the assembly slots 831a, 831b can be considered as serving as connector portions of the deployable spacers 812a, 812b. When engaged, the assembly tabs 817a, 817b maintain the deployable spacers 812a, 812b in the erect position.

[0229] FIGS. 65-68 illustrate the function of the deployable spacers 805, 812a, 812b, side portion 803, accessory support 808, along with the cushion member 840. During mishandling while shipping, the article may experience forces in the AF1, AF2, AF3, AF4, CF1 and CF2 directions. If the forces are low enough in amplitude, the cushion member 840 may arrest the movement of the article. If the amplitude of the forces are too great, the article may be forced against the deployable spacer 812a (as viewed in FIG. 67 and 68) if in the AF1 direction or, conversely, may be forced against the deployable spacer 812b (as viewed in FIG. 67 and 68) if in the AF2 direction. The deployable spacers 812a, 812b may be designed specifically to deform to absorb the impact force AF1, AF2 from the article, respectively. Additionally, the deployable spacer 805 is designed to work with the cushion member 840 when experiencing forces in the AF3 direction (as viewed in FIGS. 68). If the forces are low enough in amplitude, the cushion member 840 may arrest the movement of the article. If the amplitude of the forces is too great, the article may be forced against the deployable spacer 805 which may be designed specifically to deform to absorb the impact force AF3 from the article. Also, the side portion 803 and the cushion member 840 may be specifically designed to deform when experiencing forces in the AF4 direction (as viewed in FIG. 68). If the forces are low enough in amplitude, the cushion member 840 may arrest the movement of the article. If the amplitude of the forces is too great, the article may be forced against the towards the side portion 803 which provides a barrier for the cushion member 840 to deform against. The article is surrounded on three sides by the cushion member 840 which may receive support from the side portion 803. The deployable spacers 805, 812a, 812b along with the cushion member 840 may also absorb compression forces CF1, CF2 experienced while shipping. If the container system 800 experiences either a force in the CF1 or CF2 direction or both together, the deployable spacers 805, 812a, 812b may compress and leverage the cushion member 840 to help distribute the forces.

[0221]

[0230] FIG. 69 illustrates the container system 800 in the closed state with the article and any needed accessories inside and ready to be shipped.

[0222]

[0231] It has been discovered that the embodiments of FIGs. 60-69 can provide significant additional optional advantages such as labor cost reductions for large packaging operations. For example, as background, in some end-use scenarios, large numbers of container systems 800 are sent to a customer in the configuration of FIG. 61. A user, such as a human packaging worker, would manipulate the system 800 to reconfigure it from the configuration illustrated in FIG. 61 to the configuration illustrated in FIG. 63 - a configuration in which the system 800 is ready to be loaded with articles to be packaged / shipped. It has been discovered through experimental testing that with training, a human packaging worker can manipulate the system 800 from the configuration in FIGS. 61 to the configuration illustrated in FIGS. 63 in about 2 seconds. This can provide a substantial labor cost reduction for a high volume user, for example, where a prior packaging system can require about one minute to assemble into a state in which it is ready to be loaded with articles to be packaged.

[0223]

[0232] Methods for assembling or readying the container system for use are described above with reference to the above structures of the various embodiments, their functions and use.

[0224]

[0233] While several embodiments are presented in the foregoing detailed description, a vast number of variations exist. The embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description provides those skilled in the art with a convenient road map for implementing the described embodiments. Various changes can be made in the function and arrangement of elements without departing from the scope defined by any claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.

Claims

WHAT IS CLAIMED IS:

1. A container system for shipping an article, the container system comprising:an article;a monolithic member made of corrugated cardboard and configured to be foldable between flattened and erected positions, wherein in the erected position, the monolithic member fully encloses the article, the monolithic member comprising:a top wall portion, a first sidewall, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deployable spacers are flexible and configured to be moved between retracted and deployed positions and wherein the top wall portion comprises a first, a second, and a third top wall connector portions and wherein the first and second deployable spacers comprise a first and a second connector portion, respectively, that are configured to engage the first and second top wall connector portions, respectively;wherein in the flattened position, the top wall portion, first sidewall, bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form a substantially flat surface and in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space configured to receive the article such that the article is partially surrounded by the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer;wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer comprise:a first wall portion connected to the bottom wall along a first fold line so as to be foldable between a retracted position in which the first wall portion is substantially parallel to the bottom wall and a deployed position in which the first wall portion extends generally perpendicular to the bottom wall;a second portion connected to the first wall portion along a second fold line so as to be folded between the retracted position in which the second wall portion is substantially parallel to the bottom wall and the first wall portion and the deployed position in which the second wall portion extends generally perpendicular to the first wall portion and generally parallel to the bottom wall;a third wall portion connected to the second wall portion along a third fold line so as to be folded between the retracted position in which the third wall portion is substantially parallel to the bottom wall, the first wall portion, and the second wall portion, and the deployed position in which the third wall portion extendsgenerally perpendicular to the bottom wall and generally parallel to the first wall portion; anda fourth wall portion connected to the third wall portion along a fourth fold line and fixed to the bottom wall so as to form a closed loop and to allow the first, second and third wall portions to be folded between the retracted position and the deployed position through a racking movement while the fourth wall portion remains in a static position throughout the movement between the retracted and deployed positions; andwherein the second wall portion of the first deployable spacer includes a door that is movable between opened and closed positions, wherein in the opened position, the door allows additional articles to be inserted into and removed from an interior of the first deployable spacer;wherein in the deployed position, each of the first deployable spacer, second deployable spacer, and third deployable spacer forms a dead space serving as an airgap between an outermost surface of the container system and the article when the article is positioned in the open interior space; anda padded paper member fixed to the top wall portion and extending across a portion of the bottom wall such that the padded paper member substantially surrounds the article when the article is positioned in the open interior space and the top wall portion is closed over open interior space with the first, a second, and a third connector portions engaged with the first, second, and third top wall connector portions, respectively;wherein engagement of the first, a second, and a third connector portions with the first, second, and third top wall connector portions, respectively, maintains the first deployable spacer, second deployable spacer, and third deployable spacer in the deployed position.

2. The container system of Claim 1, wherein the first, a second, and a third connector portions each comprise a slot formed proximate to the second fold line and the first, second, and third top wall connector portions each comprise a tab configured to be inserted into the slot of the first, second, and third connector portions, respectively.

3. A container for shipping an article, the container comprising:a container member made of foldable material and configured to be foldable between flattened and erected positions, the container member comprising:a top wall portion, a first sidewall, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deployable spacers are flexible and configured to be moved between retracted and deployed positions;wherein in the flattened position, the top wall portion, first sidewall, bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form a substantially flat surface and in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space configured to receive an article to be packaged within the container; wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer comprise:a first wall portion connected to the bottom wall along a first fold line so as to be foldable between the retracted position in which the first wall portion is substantially parallel to the bottom wall and the deployed position in which the first wall portion extends generally perpendicular to the bottom wall;a second wall portion connected to the first wall portion along a second fold line so as to be folded between the retracted position in which the second wall portion is substantially parallel to the bottom wall and the first wall portion and the deployed position in which the second wall portion extends generally perpendicular to the first wall portion and generally parallel to the bottom wall;a third wall portion connected to the second wall portion along a third fold line so as to be folded between the retracted position in which the third wall portion is substantially parallel to the bottom wall, the first wall portion, and the second wall portion, and the deployed position in which the third wall portion extends generally perpendicular to the bottom wall and generally parallel to the first wall portion; anda fourth wall portion connected to the third wall portion along a fourth fold line and fixed to the bottom wall so as to form a closed loop and to allow the first, second and third wall portions to be folded between the retracted position and the deployed position through a racking movement while the fourth wall portion remains in a static position throughout the movement between the retracted and deployed positions.

4. The container of Claim 3 additionally comprising an article comprising a generally rectangular shape with a length, a width, and a thickness that is substantially smaller than the length and width and wherein in the erected position, the container member fully encloses the article.

5. The container of Claim 3, wherein the container member is a single, monolithic piece of corrugated cardboard.

6. The container of Claim 3, wherein the top wall portion comprises a first top wall connector portion and a second top wall connector portion and wherein the first and second deployable spacerscomprise a first and a second connector portion, respectively, that are configured to engage the first and second top wall connector portions, respectively and wherein engagement of the first and second connector portions with the first and second top wall connector portions, respectively, maintains the first deployable spacer and the second deployable spacer in the deployed position.

7. The container of Claim 3, wherein in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space partially surrounded by the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer.

8. The container of Claim 3, wherein in the deployed position, each of the first deployable spacer, second deployable spacer, and third deployable spacer forms a dead space serving as an airgap between an outermost surface of the container and the article when the article is positioned in the open interior space.

9. The container of Claim 3 additionally comprising a padded paper member fixed to the top wall portion and extending across a portion of the bottom wall such that the padded paper member substantially surrounds the article when the article is positioned in the open interior space and the top wall portion is closed over open interior space with the first, a second, and a third connector portions engaged with the first, second, and third top wall connector portions, respectively.

10. The container of Claim 3, wherein the second wall portion of the first deployable spacer includes a door that is movable between opened and closed positions, wherein in the opened position, the door allows additional articles to be inserted into and removed from a dead space within the first deployable spacer.

11. A container for shipping an article, the container comprising:a container member made of foldable material and configured to be foldable between flattened and erected positions, the container member comprising:a top wall portion, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deployable spacers are flexible and configured to be moved between retracted and deployed positions; wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer comprise a first wall portion connected to the bottom wall, a second wall portion connected to the first wall portion, and a third wall portion connected to the second wall portion and the bottom wall such that the first, second and third wall portions are foldable between the retracted position and the deployed position.

12. The container of Claim 11, wherein the first deployable spacer, the second deployable spacer, and the third deployable spacer are in the deployed position when the container is in the erected position.

13. The container of Claim 11, wherein in the flattened position, the top wall portion, first sidewall, bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form a substantially flat surface and in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space configured to receive an article to be packaged within the container.

14. The container of Claim 11, wherein a first wall portion is connected to the bottom wall along a first fold line so as to be foldable between the retracted position in which the first wall portion is substantially parallel to the bottom wall and the deployed position in which the first wall portion extends generally perpendicular to the bottom wall;wherein the second wall portion is connected to the first wall portion along a second fold line so as to be folded between the retracted position in which the second wall portion is substantially parallel to the bottom wall and the first wall portion and the deployed position in which the second wall portion extends generally perpendicular to the first wall portion and generally parallel to the bottom wall; andwherein the third wall portion is connected to the second wall portion along a third fold line and connected to the bottom wall so as to be foldable between the retracted position in which the third wall portion is substantially parallel to the bottom wall, the first wall portion, and the second wall portion, and the deployed position in which the third wall portion extends generally perpendicular to the bottom wall and generally parallel to the first wall portion.

15. The container of Claim 11, wherein the first, second, and third wall portions are connected so as to allow the first, second and third wall portions to be folded between the retracted position and the deployed position through a racking movement during the movement between the retracted and deployed positions.

16. The container of Claim 11, wherein the third wall portion is connected to the bottom wall with a fourth wall portion that is connected to the third wall portion along a fourth fold line and fixed to the bottom wall so as to form a closed loop.

17. The container of Claim 11 additionally comprising an article comprising a generally rectangular shape with a length, a width, and a thickness that is substantially smaller than the length and width and wherein in the erected position, the container member fully encloses the article.

18. The container of Claim 11, wherein the container member is a single, monolithic piece of corrugated cardboard.

19. The container of Claim 11, wherein the top wall portion comprises a first top wall connector portion and a second top wall connector portion and wherein the first and second deployable spacers comprise a first and a second connector portion, respectively, that are configured to engage the first and second top wall connector portions, respectively and wherein engagement of the first and secondconnector portions with the first and second top wall connector portions, respectively, maintains the first deployable spacer and the second deployable spacer in the deployed position.

20. The container of Claim 11, wherein in the erected position, the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer form an open interior space partially surrounded by the bottom wall, first deployable spacer, second deployable spacer, and third deployable spacer.

21. The container of Claim 11, wherein in the deployed position, each of the first deployable spacer, second deployable spacer, and third deployable spacer forms a dead space serving as an airgap between an outermost surface of the container and the article when the article is positioned in an open interior space of the container.

22. The container of Claim 11 additionally comprising a padded paper member fixed to the top wall portion and extending across a portion of the bottom wall such that the padded paper member substantially surrounds the article when the article is positioned in an interior space of the container and the top wall portion is closed over the interior space with the first, a second, and a third connector portions engaged with the first, second, and third top wall connector portions, respectively.

23. The container of Claim 14, wherein the second wall portion of the first deployable spacer includes a door that is movable between opened and closed positions, wherein in the opened position, the door allows additional articles to be inserted into and removed from a dead space within the first deployable spacer.

24. A container for shipping an article, the container comprising:a container member made of foldable material and configured to be foldable between flattened and erected positions, the container member comprising:a top wall portion, a bottom wall, a first deployable spacer, a second deployable spacer, and a third deployable spacer, wherein each of the first, second and third deployable spacers are connected to the bottom wall and are configured to be moved between retracted and deployed positions;wherein each of the first deployable spacer, second deployable spacer, and third deployable spacer comprise a plurality of wall portions that are configured to be foldable between a flattened position and a deployed position through a racking movement.

25. The container of Claim 24 additionally comprising a paper-based cushion member attached to the bottom wall.

26. A method of forming a container for shipping an article, wherein the container is foldable between a flattened position and an erected position and includes a top wall portion, a bottom wall, a first deployable spacer connected to the bottom wall, a second deployable spacerconnected to the bottom wall, and a third deployable spacer connected to the bottom wall, the method comprising:folding the first deployable spacer from the flattened position to the erected position; folding the second deployable spacer from the flattened position to the erected position;folding the third deployable spacer from the flattened position to the erected position so as to form an interior space between the bottom wall, the first deployable spacer, the second deployable spacer, and the third deployable spacer;inserting an article to be shipped into the interior space; andfolding the top wall portion from the flattened position to the erected position in which the top wall portion extends over the first deployable spacer, the second deployable spacer, the third deployable spacer, the interior space, and the article so as to completely enclose the article and the interior space.

27. The method of Claim 26, wherein folding the first deployable spacer comprises moving the first deployable through a racking movement.

28. The method of Claim 26, wherein folding the second deployable spacer comprises moving the second deployable through a racking movement, and wherein folding the third deployable spacer comprises moving the third deployable through a racking movement29. A container system for shipping an article , the container system comprising:an article comprising a generally rectangular shape in length and width with a generally thin height when compared to the length or width; anda monolithic member configured to be folded into a container, the monolithic member comprising:a top, a first sidewall, a bottom, a second sidewall, an interior member, a first end member and a second end member, where at least one of the first and second end members is flexible, and configured to form a resilient spacer;wherein the top is foldable between an opened and a closed position;wherein in the closed position, the top, the bottom, the first sidewall, the second sidewall, the interior member, the first resilient spacer and the second resilient spacer form an enclosed interior space and in the opened position form an open interior space; and wherein each of the first and second resilient spacers comprise:a first angled panel portion connected to the bottom along a first fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the first angled portion extends into the open interior space at an angle relative to the first sidewall,a second angled panel portion connected to the first angled panel portion along a second fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the second angled panel portion extends into the open interior space at an angle parallel to, or greater than parallel,wherein the second angled panel portion is shorter in length to the first angled panel portion,wherein the top panel is folded between an open and closed state, andwherein the top and interior member are parallel and touching when in the closed position.

30. The container system of Claim 29, wherein the resilient spacer has an array of cuts along the fold line between the first and second angled portions.

31. The container system of Claim 29, wherein a padded paper member, which is attached to the interior member, is parallel to the top in the open position and surrounds the article when the article is slid into the open interior space.

32. The container system of Claim 29, wherein the second angled panel portion of the resilient spacer which is connected to the bottom, is adhered to the second angled panel portion of the resilient spacer connected to the interior member.

33. The container system of Claim 29, wherein the second angled panel portion of the resilient spacer is adhered to the first angled panel portion of the resilient spacer.

34. The container system of Claim 31, wherein the padded paper member is secured to the container with at least one foldable member extending from the monolithic member.

35. The container system of Claim 34, wherein the resilient spacer has a support member folded along at least one edge.

36. A container for shipping an article, the container comprising:a monolithic member comprising:a top, first sidewall, bottom, second sidewall, interior member, first end member and second end member, where at least one end member is flexible in design, to form an enclosure; wherein the top is configured to be moved between opened and closed positions; wherein in the closed position, the top, bottom, first sidewall, second sidewall, inner member, first resilient spacer and a second resilient spacer form an enclosed interior space and in the opened position form an open interior space; andwherein each of the first and second resilient spacers comprise:a first angled panel portion connected to the bottom along a first fold line so as to be folded between a first unfolded orientation which is outwardly facing from thearticle and a second folded position in which the first angled portion extends into the open interior space at an angle relative to the first sidewall, anda second angled panel portion connected to the first angled panel portion along a second fold line so as to be folded between a first unfolded orientation which is outwardly facing from the article and a second folded position in which the second angled panel portion extends into the open interior space at an angle parallel to, or greater than parallel.

37. The container of Claim 36, wherein the resilient spacer has an array of cuts perpendicular to the fold line between the first and second angled portions.

38. The container of Claim 36 additionally comprising a padded paper member attached to the interior member and is configured to surround the article when the article is slid into the open interior space.

39. The container of Claim 36, wherein the second angled panel portion of the resilient spacer which is connected to the bottom, is adhered to the second angled panel portion of the resilient spacer connected to the interior member.

40. The container of Claim 36, wherein the second angled panel portion of the resilient spacer is adhered to the first angled panel portion of the resilient spacer.

41. The container of Claim 38, wherein the padded paper member is secured to the container with at least one foldable member extending from the monolithic member.

42. The container of Claim 41, wherein the resilient spacer has a support member folded along at least one edge.

43. A shipping container made from a monolithic sheet configured to form an enclosure, wherein said enclosure is configured to create a resilient spacer, whereby said resilient spacer is created by adhering at least two edge portions of the monolithic sheet to itself.

44. The container of Claim 43, wherein the resilient spacer has an array of cuts along at least one edge.

45. The container of Claim 43 additionally comprising a padded member secured to the monolithic sheet.

46. The container of Claim 43, wherein the resilient spacer has a support member folded along at least one edge.

47. The container of Claim 45, wherein the padded member is secured to the container with at least one foldable member extending from the monolithic member.

48. A shipping container configured to enclose an article for shipping, the shipping container comprising:a monolithic sheet of corrugated cardboard, comprising:a first wall portion;a first resilient spacer portion extending along a first side of the first wall portion;a second resilient spacer portion extending along a second side of the first wall portion; a second wall portion;wherein the monolithic sheet is configured to be folded with the first and second wall portions being juxtaposed and spaced apart and the first and second resilient spacer portions forming closed sidewalls so as to create an enclosed interior space between the first wall portion, second wall portion, first resilient spacer and the second resilient spacer.

49. The shipping container of Claim 48, wherein the first resilient spacer comprises a first skewed wall portion.

50. The shipping container of Claim 49, wherein first skewed wall portion extends along an angle that is not parallel or perpendicular to the first wall portion.

51. The shipping container of Claim 49, wherein the second resilient spacer comprises a second skewed wall portion.

52. The shipping container of Claim 48, wherein the first resilient spacer comprises a Y-shaped wall configuration.

53. The shipping container of Claim 52, wherein the Y-shaped wall configuration comprises at least two skewed wall portions.

54. A shipping container configured to enclose an article for shipping, the shipping container comprising:a first wall portion;a first resilient spacer portion having a skewed wall portion connected to a first side of the first wall portion;a second resilient spacer portion extending along a second side of the first wall portion; a second wall portion;wherein the container is configured to be folded with the first and second wall portions being juxtaposed and paced apart and the first and second resilient spacer portions forming closed sidewalls so as to create an enclosed interior space between the first wall portion, second wall portion, first resilient spacer and the second resilient spacer.

55. The shipping container of Claim 54 additionally comprising a cushion sheet member fixed to the first wall portion.

56. The shipping container of Claim 55, wherein first skewed wall portion extends along an angle that is not parallel or perpendicular to the first wall portion.

57. The shipping container of Claim 54, wherein the second resilient spacer comprises a second skewed wall portion.

58. The shipping container of Claim 54, wherein the first resilient spacer comprises a Y-shaped wall configuration.

59. The shipping container of Claim 58, wherein the Y-shaped wall configuration comprises at least two skewed wall portions.

Images