Full Suspension E-Commerce Shipping Box

This application claims the benefit of priority to U.S. provisional application No. 63/574,981 filed Apr. 5, 2024, which is incorporated herein by reference in its entirety.

The present invention relates to a shipping package assembly, for example, a suspension shipping package that includes a box and a platform within the box, which permits displacement of an article support surface relative to an interior of the box. Protective packaging 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 with the inner walls of the box that might be caused by shocks imparted to the box during loading, transit, and/or unloading. Typically, some additional structure is used to keep the article from moving uncontrollably within the box, such as paper or plastic packing material. The contents to be packaged are suspended within the box so as to be spaced from at least some of the walls of the box, thus protecting the contents from other foreign objects which may impact or compromise the outer walls of the box.

Thus, there is a need for a suspension package assembly that does not utilize separate suspension or retention devices like air pillows, crumped paper, and plastic retention devices like Korrvu or foam peanuts that is a sustainable solution that can be placed in curbside recycling.

The present invention is directed to a full suspension shipping box used in eCommerce to deliver goods to a consumer. In an embodiment, the box is configured to suspend contents on a platform to prevent damage to the contents during shipping. The contents could be any item suitable for shipping. An embodiment of the invention is specifically created as a solution for the transport of items such as cosmetics or beauty products which vary in size and shape. The items are suspended by corrugated features incorporated into the shipping box, eliminating the need for separate suspension or retention devices like air pillows, crumped paper, and plastic retention devices like Korrvu or foam peanuts. The full suspension eCommerce shipping box of the present invention is a sustainable solution as the entire package is made of corrugated cardboard which can be placed in curbside recycling.

Also of importance is the desired appearance of the box. The desire is to present the package so that when opened the contents appear like a hand-wrapped gift to elevate the prestige of the packaging. The configuration of the box of the present invention puts the contents wrapped in tissue paper onto a pedestal suspension platform. The upper tensioners appear to be dust flaps (which are common features in boxes) however they are deployed in a different orientation by being folded inward so that they can act as two separate upper tensioners.

In an embodiment, a suspension shipping package for preventing damage to contents held therein comprises a box having a top, a right side flap, a left side flap, a front flap, a bottom, a right side wall, a left side wall, a rear side wall, and a reduced front wall; and a suspension platform with a top surface for supporting contents placed thereon, a bottom surface, a folded right arm, a folded left arm, and a rear flap, the folded right arm and the folded left arm extending from the bottom surface of the suspension platform acting as springs to provide upward tension to the suspension platform, wherein the right side flap and the left side flap are folded inward and are deployed as upper spring-loaded tensioners to support the suspension platform.

In an embodiment, the suspension shipping package further comprises two wings configured to suspend different height items placed on the suspension platform.

In an embodiment, the folded right arm is folded in a z-shaped configuration and the folded left arm is folded in a z-shaped configuration.

In an embodiment, the suspension platform has one end connect to the box to create a lever to facilitate suspension of the contents placed thereon.

In an embodiment, the suspension platform is separate from the box.

In an embodiment, the box has a roll end lock front (RELF).

In an embodiment, the suspension shipping package is formed from a single piece of material.

In an embodiment, the material is stamp-cut and includes fold-lines for assembly of the shipping package by folding along the fold-lines.

In an embodiment, the material of the suspension shipping package is a corrugated fiber.

In an embodiment, the material of the suspension shipping package is compostable.

In an embodiment, the material of the suspension shipping package is curbside recyclable.

In an embodiment, the material of the suspension shipping package is repulpable.

In an embodiment, the material of the suspension shipping package includes at least one of cardboard, corrugated cardboard, cellulose, and postconsumer paper.

In an embodiment, the suspension configuration of the box provides at least the following key features:

1. The box has a bottom suspension platform that acts as a spring; there are folded arms beneath the platform that provide upward tension or a springiness to the platform. These arms maybe z-folded or folded in other orientations that provide springiness to the platform.

2. Items placed on top of the suspension platform are suspended between the platform top and two wing tensioners at the top. The wings at the top look like dust flaps but they instead are folded inward and are deployed as upper spring-loaded tensioners. There are two wings that act to suspend different height items on the platform.

3. The seams on the box are covered when closed by moving the box folds outward.

These as well as still further features, objects and benefits of the invention will now become clear upon a review of the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings.

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components, concentrations, applications and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the attachment of a first feature and a second feature in the description that follows may include embodiments in which the first feature and the second feature are attached in direct contact and may also include embodiments in which additional features may be positioned between the first feature and the second feature, such that the first feature and the second feature may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

The detailed description set forth below is intended as a description of various configurations of the present invention and is not intended to represent the only configurations in which the present invention may be practiced. It will be apparent, however, to those of ordinary skill in the art that the present invention is not limited to the specific details set forth herein and may be practiced without these specific details.

Referring to, an embodiment of a boxin accordance with the present invention is shown having a top, a right side flap, a left side flap, a front flap, a bottom, a right side wall, a left side wall, a rear side wall, and a reduced front wall. Boxhas a suspension platformwith a top surface, a bottom surface, a z-folded right arm, a z-folded left arm, and a rear flap. Suspension platformacts as a spring in that z-folded arms,provide upward tension or a springiness to platform. Arms,maybe z-folded or folded in other orientations that provide springiness to suspension platform.

Right side flapand left side flaplook like dust flaps but they instead are folded inward and are deployed as upper spring-loaded tensioners. Preferably, there are two wings that act to suspend different height items placed on suspension platform. Suspension platformhaving one end connect to boxcreates a lever configuration to facilitate suspension on contents placed thereon.

As shown in, boxcan be formed from a single-piece blank of a suitable material such a corrugated fiber. The blank is stamp-cut and remains as a single piece and fold lines are formed such that the blank can be folded into the configuration of the boxin accordance with the present invention. In this configuration, suspension platformremains attached to the remainder of box. Alternatively, as shown in, suspension platformcan be separate from the remainder of box.

Referring to, contentsare placed on suspension platformand can be wrapped in tissueand secured with tapeif desired. Contentsfit within boxand are held within the interior of boxspaced apart from bottomof boxand spaced apart from topof box. In this manner, the contents are protected from any direct impact to boxthat may be incurred during shipping and handling of box.

Referring to, the results are shown of a drop sequence of boxfilled with contentswrapped in tissuesecured with tape. The contents were not damaged by the drops of boxwith only minimal tearing occurred to the tissue paper wrapping the contents.

Referring to, boxhas seamsat the juncture of topand side walls,forming a gap. In another embodiment, overlapping seamis created by adding overlap creases to cover the gap between topand side walls,.

Referring to, another embodiment of boxis shown. Boxhas a top, a right side flap, a left side flap, a front flap, a bottom, a right side wall, a left side wall, a rear side wall, a reduced front wall, a wing tensioner, and a wing tensioner. Boxincludes a suspension platformhaving a top surface, a bottom surface, a z-folded arm, and a z-folded arm. Z-folded arms,provide upward tension or a springiness to platform. Arms,maybe z-folded or folded in other orientations that provide springiness to suspension platform.

Wing tensionerand wing tensionerare deployed as upper spring-loaded tensioners. Preferably, there are two wing tensioners that act to suspend different height items placed on suspension platform. In this embodiment, wing tensioners,are wider, providing pressure across the entire top of boxand creates two doors that can include print with branding and other graphics behind and on the doors. Boxin one embodiment is a roll end lock front (RELF) having a type of closure that does not require using an adhesive as different customers may prefer different versions of box closures.

Referring to, another embodiment of a suspension platformis shown. Suspension platformhas a top surface, a bottom surface, a z-folded arm, and a z-folded arm. Arms,maybe z-folded or folded in other orientations that provide springiness to suspension platform. Suspension platformis a separate component that may be used to suspend contents within a conventional box such as a mailer box having a corresponding size and shape. Suspension platformprovides desired protections to contents supported on the platformwithin a box.

The materials of the containers of the present invention are not required to be separated from one another to be recycled in the mainstream. Materials used include, for example cardboard, corrugated cardboard, and cellulose with at least a portion of the materials preferably being made from postconsumer paper. The container in accordance with the present invention was specifically designed to ensure the repulpability of the packaging.

The foregoing outlines features of several examples or embodiments so that those of ordinary skill in the art may better understand various aspects of the present disclosure. Those of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of various examples or embodiments introduced herein. Those of ordinary skill in the art should also realise that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Although the subject matter has been described in language specific to structural features or methodological acts, it is to be understood that the subject matter of the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing at least some of the claims.

Various operations of examples or embodiments are provided herein. The order in which some or all the operations are described should not be construed to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated having the benefit of this description. Further, it will be understood that not all operations are necessarily present in each embodiment provided herein. Also, it will be understood that not all operations are necessary in some examples or embodiments.

Moreover, “exemplary” is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous. As used in this application, “or” is intended to mean an inclusive “or” rather than an exclusive “or”. In addition, “a” and “an” as used in this application and the appended claims are generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and/or the like generally means A or B or both A and B. Furthermore, to the extent that “includes”, “having”, “has”, “with”, or variants thereof are used, such terms are intended to be inclusive in a manner similar to the term “comprising”. Also, unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first element and a second element generally correspond to element A and element B or two different or two identical elements or the same element.

Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others of ordinary skill in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure comprises all such modifications and alterations and is limited only by the scope of the following claims. In particular regard to the various functions performed by the above-described features (e.g., elements, resources, etc.), the terms used to describe such features are intended to correspond, unless otherwise indicated, to any features which performs the specified function of the described features (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure. In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the broad scope of the disclosure.

Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.