Shipping Container Systems

Shipping products to consumers has become a vital part of our everyday lives. Shipping containers are typically designed to maximize efficiency in packing shipping vehicles. Frequently, a shipping container contains items that fill only a small portion of the volume of the container, requiring the space to be filled with other material, such as air-filled plastic pouches or shredded paper. Alternative solutions include affixing products to a piece of cardboard using plastic film of sorts and adding some pieces to cause the plastic wrapped board and product to remain positioned in the cavity of the box. Existing solutions are expensive and use excess materials, including excessive waste materials. More economical and ecologically friendly systems are needed.

The present disclosure is directed to shipping container systems, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.

In some embodiments of the present disclosure, a shipping container is described. In some embodiments, the container system comprises an outer container comprising a base and a plurality of upstanding walls defining a cavity, a first closure flap extending from a top end of one of the plurality of upstanding walls opposite the base wherein the first closure flap overlays the base and substantially covers an opening formed by the top ends of the upstanding walls when the outer container is in a closed configuration, and wherein the first closure flap includes a retention element that extends from the closure flap downward into the cavity of the outer container when the outer container is in a closed configuration, and a suspension insert including a product retention compartment comprising a top section connected to a bottom section, and a suspension element extending outwardly from a first end of the product retention compartment, wherein the suspension element abuts against a first upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein a cushion gap is on all sides of the product retention compartment when the suspension insert is installed in the outer container, wherein the bottom section of the product retention compartment comprises a first bottom panel connected to a first side of the top section and folds to connect to a second side of the product retention compartment opposite the first side of the top section.

In some embodiments, the bottom section of the product retention compartment further comprises a second bottom panel connected to the second side of the top section opposite the first side of the top section, and the first bottom panel and the second bottom panel fold to connect on the bottom section of the product retention compartment.

In some embodiments, the product retention compartment has a volume when a product is inserted into the product retention compartment and the top section and the bottom section of the product retention compartment physically contact the product contained therein.

In some embodiments, the suspension insert further comprises a second suspension element extending outwardly from a second end of the product retention compartment, wherein the suspension element abuts against a second upstanding wall of the outer container when the suspension insert is installed in the outer container, wherein the first upstanding wall and the second upstanding wall are opposite each other.

In some embodiments, the second suspension element extends from a second end of the top section of the product retention compartment, wherein the second end is opposite the first end of the top section of the product retention compartment.

In some embodiments, the first suspension element and the second suspension element exert a retention force while abutting against the first upstanding wall and the second upstanding wall of the outer container.

In some embodiments, the retention force holds the suspension insert secure in a height of the outer container and along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.

In some embodiments, the suspension element folds in at least one of an upwards direction and a downwards direction maintaining the cushion gap between the product retention compartment and the outer container.

In some embodiments, a maximum height of the suspension element when installed in the outer container is less than an interior height of the outer container.

In some embodiments, at least one of the first bottom panel and the second bottom panel further comprises a bottom suspension element abutting against at least one of the first upstanding wall and a second upstanding wall of the outer container.

In some embodiments, the suspension insert further comprises an aperture in the top section of the product retention compartment allowing visibility into the product retention compartment.

In some embodiments, the product retention compartment is substantially flat when the product retention compartment is empty.

In some embodiments, the seam on the bottom section of the product retention compartment is held together by at least one of an interlocking closure, a locking closure, a glue, a tape, a semi-permanent adhesive, a permanent adhesive, a radio-frequency (RF) welding, a heat bond, and a stitching.

The container system of claim, wherein the suspension element secures the suspension insert along a length of the outer container while maintaining the cushion gap between the product retention compartment and the outer container.

In some embodiments, the outer container and the suspension insert are formed from a single blank, wherein the suspension insert folds over a second upstanding wall of the outer container and down towards the base of the outer container maintaining the cushion gap between the suspension insert and the second upstanding wall, wherein the second upstanding wall is opposite the first upstanding wall of the outer container.

In some embodiments, the outer container is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics.

In some embodiments, the suspension insert is formed from one of corrugated board, paper board, flexible plastics, foamed plastics, rigid plastics, and corrugated plastics.

In some embodiments, the product retention compartment includes a selectively closeable opening.

In some embodiments, the outer container further comprises a plurality of support elements maintaining the cushion gap between the product retention compartment and the outer container.

In some embodiments, the plurality of upstanding walls comprises a third upstanding wall and a fourth upstanding wall opposite each other, wherein the third upstanding wall further comprises a first sidewall flap extending along the base of the outer container, and the fourth upstanding wall further comprises a second sidewall flap extending along the base of the outer container.

The following description contains specific information pertaining to implementations in the present disclosure. The drawings in the present application and their accompanying detailed description are directed to merely exemplary implementations. Unless noted otherwise, like or corresponding elements among the figures may be indicated by like or corresponding reference numerals. Moreover, the drawings and illustrations in the present application are generally not to scale, and are not intended to correspond to actual relative dimensions.

shows a perspective view of a shipping container system, according to one embodiment of the present disclosure. As shown in, the shipping container system includes outer containerand suspension insert. In a preferred embodiment, the shipping container system includes a base, a plurality of upstanding walls, and a lid. Outer containermay include a base, a plurality of upstanding walls, and a lid that, when in a closed configuration, define a volume. In the depicted embodiment, outer containercomprises a base (not visible), four upstanding walls,,,, and lid. As depicted, upstanding walls,,,extend upwards from the sides of base (not visible) substantially perpendicular to base (not visible). In the depicted embodiment, upstanding walls,,,include side walland side wallon opposing sides, and front end walland back end wallare on opposing ends. As depicted, base (not visible) and upstanding walls,,,define cavity. In some embodiments, outer containermay have less than four upstanding walls. In some embodiments, outer containermay have more than four upstanding walls.

Outer containermay be arranged in an open configuration as shown in. Outer containermay also be arranged in a closed configuration. In the depicted embodiment, a lid extends from a top end of back end wall. In some embodiments, the lid comprises first closure flapand second closure flap. In a closed configuration, first closure flapmay be rotated about its hinged attachment to the top end of back end wallso that closure flapfolds over towards front end walland substantially covers cavityor opening defined by the top ends of upstanding walls,,,such that outer containeris in a closed configuration. When in a closed configuration, outer container, upstanding walls,,,, and a first closure flapdefine a volume.

In the depicted embodiment, first closure flapincludes retention element,that extend from the terminal ends of a first side and a second side of first closure flap, wherein the first side and the second side of first closure flapare opposite each other. In the depicted embodiment, when the outer container is in a closed configuration, retention elements,may rotate about its hinged attachment to ends of the first side and the second side of first closure flapso that retention elements,fold extending downward into cavitywhen outer containeris in a closed configuration. Retention elements,may have a length less than a length of outer containeror substantially the same as the length of outer container. Retention elements,may have a height less than a height of outer containeror substantially the same as the height of outer container.

In the depicted embodiment, the lid includes second closure flapextending from a side of first closure flapthat is opposite the side of first closure flapthat is coupled to the top end of back end wall. In a closed configuration, second closure flapsubstantially covers the front end walland closure tabs,tuck into the slots formed in side walls,. Closure tabs,may have a width less than a height of upstanding walls,,,, substantially the same as the height of upstanding walls,,,, less than a height of outer container, or substantially the same as the height of outer container.

As shown in, the shipping container system further includes suspension insert. Suspension insertmay be disposed within cavityof outer container. Suspension insertincludes product retention compartment. In some embodiments, product retention compartmentmay include a top section connected to a bottom section. In some embodiments, product retention compartmentmay include a top, a plurality of sidewalls, and a bottom configured to contain a product for shipping. In some embodiments, product retention compartmentmay include sidewalls between the top section and the bottom section, forming a rectangular cavity for containing a product. In some embodiments, product retention compartmentmay include a top and a bottom connected at the sides forming a marquise shape when a product is placed into the product retention compartment. Product retention compartmentmay encapsulate a product for shipping, such as a mobile phone, a tablet computer device, and the like. In the depicted embodiment, suspension insertincludes portal. In some embodiments, portalmay be an opening cut in the top section of product retention compartment. In other embodiments, portalmay include a translucent or transparent covering to allow visibility into product retention compartmentwithout leaving a large opening in product retention compartment.

In the depicted embodiment, product retention compartmentis empty. When product retention compartmentis empty, the bottom section of product retention compartmentmay be visible through portal. In some embodiments, the bottom section of product retention compartmentmay include bottom panels,, wherein a first bottom panelconnected to a first side of the top section, and a second bottom panelconnected to a second side of the top section opposite the first side of the top section, and the first bottom panel and the second bottom panel fold to connect on the bottom section of product retention compartment.

In the depicted embodiment, bottom panels,connecting at seamon the bottom section of product retention compartmentare visible through portal. In some embodiments, seamextends along a length of the product retention compartment. In some embodiments, seamon the bottom section of the product retention compartmentis held together by at least one of an interlocking closure, a locking closure, a glue, a tape, a semi-permanent adhesive, a permanent adhesive, a radio-frequency (RF) welding, a heat bond, a stitching, or any other ways to attach or lock seam. In some embodiments, seamis an overlapping section of material from bottom panels,. In some embodiments, seamis formed from bottom panels,folding and the free edge of each of bottom panels,joining together at seam.

In some embodiments, product retention compartmentincludes a selectively closeable opening. In some embodiments, the bottom panels,include a selectively closeable mechanism such that bottom panels,may selectively close and open at seam. In some embodiments, the selectively closeable mechanism may include various types of slit closures. For example, wherein each of bottom panels,have at least one slit perpendicular to the free edge of bottom panels,such that bottom panels,may interlock with each other at the corresponding slit. In another example, a first bottom panel may have a slit substantially parallel to the free edge, and a second bottom panel may have a cutout tab to insert into the slit when bottom panels,fold to connect on the bottom section of product retention compartment. The selectively closeable opening allows for a product to be easily placed into and removed from product retention compartment with little to no damage to suspension insert.

shows another perspective view of the shipping container system of, according to one embodiment of the present disclosure. As shown in, suspension insertis installed in outer container. As depicted, suspension insertincludes product retention compartmentand suspension elementextending outwardly from an end of protect retention compartment. In the depicted embodiment, suspension elementextends from an end of the top section of product retention compartment. In some embodiments, suspension element may extend from an end of the bottom section of product retention compartment. In some embodiments, a plurality of suspension elements may extend from product retention compartment. In the depicted embodiment, when suspension insertis installed in outer container, suspension elementabuts against back end wallcreating a cushion gap on all sides of product retention compartmentfor maintaining the security of the product contained therein. In some embodiments, one or more suspension elements extending from one or more ends of product retention compartmentmay abut against one or more of upstanding walls,,,of outer container.

In the depicted embodiment, suspension elementfolds in an upwards direction maintain the cushion gap between product retention compartmentand outer container. In some embodiments, suspension elementfolds in at least one of an upwards direction and a downwards direction maintaining the cushion gap between production retention compartmentand outer container. A maximum height of suspension elementwhen installed in outer containeris less than a maximum interior height of outer container.

shows a cross-section of the shipping container system of, according to one embodiment of the present disclosure. As shown in, the shipping container system may be formed from a single blank of material. In the depicted embodiment, outer containerand suspension insertare formed from a single blank of material. As depicted, suspension insertis connected to front end wallby joint elementand connector element. In the depicted embodiment, a first side of joint elementis connected to a top end of front end wall. As depicted, joint elementextends from a top end of front end wallfolding at a substantially 90-degree angle forming a flat surface at the top of front end wall. In the depicted embodiment, connector elementextends from joint elementfolding at a substantially 90-degree angle in relation to joint element. In the depicted embodiment, connector elementextends from a second side of joint elementthat is opposite the first side of joint element that is connected to the top end of front end wall. In the depicted embodiment, connector elementis substantially parallel to front end wallwhen suspension insertis installed in outer containersuch that there is a cushion gap between front end walland product retention compartment.

In the depicted embodiment, suspension insertextends along a length of an interior length of outer containerfrom front end walltowards back end wall. A maximum length of product retention compartmentis less than the maximum length of the interior length of outer container. As depicted, product retention compartmentis shown in its substantially flat, unoccupied configuration. In some embodiments, a first end of product retention compartmentis connected to connector elementat a front end of outer container, and a second end of product retention compartmentis connected to suspension elementthat abuts against back end wall. As depicted, connector elementis connected to one end of top section of product retention compartment, and suspension elementis connected to an opposite end of top section of product retention compartment.

Additionally,shows support elements,formed by diagonal support sections extending from the side walltowards the front end walland back end wall, respectively. Support elements,maintain the cushion gap between product retention compartmentand outer container. In some embodiments support elements,may represent internal sidewall tabs. Product retention compartmentis shown in its flat, unoccupied configuration. When a product is installed in product retention compartment, the space between the top section and the bottom section of product retention compartment expands to accommodate the product.

shows another cross-section of the shipping container system of, according to one embodiment of the present disclosure.depicts cushion gapbetween front end walland connector elementthat is connected to the first end of product retention compartment. In the depicted embodiment, the suspension elementextends from the second end of product retention compartment. As depicted, suspension elementabuts against back end wallcreating a cushion gap on all sides of product retention compartment. As depicted a maximum length of product retention compartmentis less than the maximum interior length of outer containerfurther ensuring a cushion gap on all sides (front, back, left, right, above, and below) of product retention compartment. In the depicted embodiment, at least a portion the side walls,are double layered providing reinforcement to outer containerand protection of a product when suspension insertis installed in outer container. In some embodiments, one or more of the plurality of upstanding walls,,,may be one or more layers.

In the depicted embodiment, the juncture at which suspension elementmeets the end of top section of product retention compartmentshows inward notches such that suspension elementis a trapezoid shape and the width of top section of product retention compartmentat the juncture is less than the width of the remainder of top section of product retention compartment. In some embodiments, the entire top section product retention compartmentis substantially the same width from the first end to the second end of product retention compartment. In some embodiments, suspension elementis a rectangular shape. In some embodiments, suspension elementhas a maximum width that is less than or substantially equal to a maximum interior width of outer container.

shows another cross-section of the shipping container system of, according to one embodiment of the present disclosure.shows the structure of the outer containerunderneath suspension insert (not pictured), including the support and cushion system of shipping container system. The depicted embodiment shows base, side walls,, front end wall, and back end wallof outer container. Additionally,shows support elements,,,formed by diagonal support sections extending from side walls,towards the front end walland back end wall. In some embodiments support elements,,,may represent internal sidewall tabs. As depicted, support elementextends from an inner layer of side wallin a diagonal direction to abut against front end wall, and support elementextends from an inner layer of side wallin a diagonal direction to abut against front end wall. Similarly, support elementextends from an inner layer of side wallin a diagonal direction to abut against back end wall, and support elementextends from an inner layer of side wallin a diagonal direction to abut against back end wall. Support elements,,,maintain the cushion gap between product retention compartment (not pictured) and outer container, particularly beneath product retention compartment (not pictured) as well as in front, back, and to the sides of product retention compartment (not pictured).

In the depicted embodiment, side wallfurther includes sidewall flapextending from an end of an inner layer of side wall. Similarly, side wallfurther includes sidewall flapextending from an end of an inner layer of side wall. Sidewall flaps,extending along baseof outer containerare visible in this view. Sidewall flaps,are properly depicted inside cavityof outer container. In some embodiments, sidewall flaps,provide structural reinforcement to outer container. Sidewall flaps,have a maximum length less than the maximum interior length of outer container. The depicted embodiment shows an interior edge of sidewall flaps,each have a semi-circle cutout. In some embodiments, the interior edge of sidewall flaps,have a substantially flat edge.

In the depicted embodiment, sidewall flaps,each have a width that is less than half the width of outer container, such that the portion of basethat a full interior length of baseis visible between sidewall flaps,as it is not covered by sidewall flaps,. In some embodiments, sidewall flaps,may each have a width that is substantially equal to half the width of interior width of outer containersuch that the full interior length of baseis not visible between sidewall flaps,. In some embodiments, sidewall flaps,may each have a width that is greater than half the width of interior width of outer containersuch that sidewall flapsoverlap over base. In the depicted embodiment, there are two sidewall flaps,. In some embodiments, there are less than two sidewall flaps. In some embodiments, there are more than two sidewall flaps. In some embodiments, there are no sidewall flaps.

shows another cross-section of the shipping container system of, according to one embodiment of the present disclosure. As shown in, bottom sectionof outer containerof product retention compartmentis separately visible through portalin top sectionof product retention compartment. At a first end of product retention compartment, cushion gapbetween front end walland product retention compartmentis visible. Cushion gapis formed by connector elementextending from the end of product retention compartmentfolding upwards to joint elementthat folds and connects with front end wall. In some embodiments, product retention compartment connector elementend flap extends past an end of bottom sectionof product retention compartmentand top sectionof product retention compartmentand folds upwards or downwards to create cushion gapIn some embodiments, at least one of a first end and a second end of product retention compartmentincludes an aperture through which a product may be inserted into or removed from product retention compartment.

At a second end of product retention compartment, cushion gapis formed between a second end of product retention compartmentand back end wall. In the depicted embodiment, a first end of suspension elementis connected to an end of top sectionof product retention compartment, and a second end of suspension elementopposite the first end of suspension elementabuts against back end wall. A maximum length of product retention compartmentis less than the maximum interior length of outer container, such that cushion gaps are maintained between all sides of product retention compartmentand outer container. In the depicted embodiment, suspension elementsecures suspension insertalong a length of outer containerwhile maintaining cushion gaps between product retention compartmentand outer container.

shows another cross-section of the shipping container system of, according to one embodiment of the present disclosure.shows product retention compartmentmaintains a floating configuration with an air gap between the edges of product retention compartmentand sidewalls,of outer container. In the depicted embodiment, top sectionof product retention compartmentand bottom sectionof product retention compartmentdo not contact outer container. In some embodiments, the sides of the product retention compartmentdo not contact sidewalls,of outer container. The contact between suspension elementand back end wallof outer container, and the contact between connector element with joint element and front end wall of outer containermaintain air gaps or cushion gaps around product retention compartment, thereby maintaining the security of a product in product retention compartment.

In the depicted embodiment, product retention compartmentis substantially flat as it is empty without any product inside. In some embodiments, product retention compartmenthas a volume when a product is inserted in between top sectionand bottom sectionof product retention compartment, and top sectionand bottom sectionof product retention compartmentphysically contact the product contained therein. In some embodiments, product retention compartment further includes sidewalls connecting top sectionwith bottom section, such that product retention compartmentis a rectangular shape with a volume even empty. In some embodiments, product retention compartmentmay be a marquise shape formed by tension resulting from a seam that overlaps on the bottom section of the product retention compartment pulling tension across the top section of the product retention compartment causing the top section to bow upwards and the bottom section to bow downwards.

shows a bottom view of the shipping container system of, according to one embodiment of the present disclosure.shows a bottom view of baseof outer containerin an open configuration as first closure flap, closure tabs,, and second closure flapare visible.

shows a front view of the shipping container system of, according to one embodiment of the present disclosure.shows the front view of front end wallof outer containerin an open configuration as first closure flap, closure tabs,, and second closure flapare visible.

shows a rear view of the shipping container system of, according to one embodiment of the present disclosure.shows the rear view of back end wallof outer containerin an open configuration as first closure flap, closure tabs,, and second closure flapare visible.

shows a top view of the shipping container system of, according to one embodiment of the present disclosure. The cushion gapsbetween product retention compartmentand outer containerare visible from this vantage point.

shows a left-side view of the shipping container system of, according to one embodiment of the present disclosure.shows outer containerin an open configuration with side wall, retention element, and closure tab.