Packaging System

Abstract

A packaging system including a corrugated cardboard box having a vertical compartmented insert nested within the box, wherein the first vertical compartmented insert comprises a rectangular vertical array of interior dividing walls to form rectangular compartments. The insert comprises a back-to-back long support insert extending along a length of the corrugated cardboard box to form a longitudinal vertical wall, the long support insert having interlocking cutouts. A plurality of pairs of short support inserts, assembled back-to-back and each having interlocking cutouts that register with the cutouts of the long support insert are arrayed perpendicularly to the pair of long support inserts to form a plurality of lateral walls. The long support inserts and the short support inserts create vertical walls with compartments there between.

Claims

1. A corrugated cardboard box comprising: a first vertical compartmented insert nested within the corrugated cardboard box, wherein the first vertical compartmented insert comprises a rectangular vertical array of interior dividing walls forming there between a plurality of rectangular compartments, each having a storage volume, the compartmented insert comprising: a pair of back-to-back long support inserts extending along a length of the corrugated cardboard box to form a longitudinal vertical wall, each one of the pair of long support inserts having a plurality of interlocking cutouts that registers with a respective interlocking cutout of another of the pair of long support inserts; a plurality of pairs of short support inserts, the pairs of short support inserts assembled back-to-back and arrayed perpendicularly to the pair of long support inserts to form a plurality of lateral walls, each of the plurality of pairs of back-to-back short support insert assemblies having registration of interlocking cutouts to form a common cutout in the back-to-back assembly, the interlocking cutouts of the pairs of back-to-back short support inserts registering with and mechanically locking with the interlocking cutout of the pair of long support inserts such that the pair of long support inserts and the plurality of back-to-back short support inserts create the plurality of rectangular compartments there between; wherein each of the pair of long support inserts has a middle panel flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a first interior wall surface of the corrugated box, and the second side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a second interior wall surface, opposite to the first interior wall surface, of the corrugated box; wherein each of the plurality of back-to-back assemblies of short support inserts includes a middle panel, flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a third interior wall surface of the corrugated box, and the second side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a fourth wall surface, opposite to the third interior wall surface of the corrugated box.

2. The corrugated cardboard box of claim 1, wherein the long support insert and the plurality of pairs of short support inserts are each comprised of corrugated cardboard box.

3. The corrugated cardboard box of claim 2, wherein corrugations of the corrugated cardboard material are arrayed vertically in the rectangular vertical array of interior dividing walls.

4. The corrugated cardboard box of claim 1, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back long support inserts is equal to a width of a respective interior wall against which the side panels abut.

5. The corrugated cardboard box of claim 1, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back long support inserts is equal to a width of a respective interior wall against which the side panels abut and wherein configuration of the side panels is such as to direct externally applied force to the first and second walls to the back-to-back middle panels of the long support inserts thereby increasing structural rigidity of the corrugated cardboard box.

6. The corrugated cardboard box of claim 1, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back short support inserts is less than a width of a respective interior walls against which the side panels abut.

7. The corrugated cardboard box of claim 1, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back short support inserts is less than a width of a respective interior wall against which the side panels abut, and wherein configuration of the side panels is such as to direct externally applied force to the third and fourth walls to the back-to-back middle panels of the short support inserts thereby increasing structural rigidity of the corrugated cardboard box.

8. The corrugated cardboard box of claim 1, wherein the long support insert includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, that extend outward in the same direction at right angles to the middle panel.

9. The corrugated cardboard box of claim 1, wherein each of the pair of back-to-back long support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that the back-to-back pair of long support inserts has at each end two side panels extending outward in opposite directions.

10. The corrugated cardboard box of claim 1, wherein each of the plurality of short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the short support insert into a middle panel flanked by a first and a second side panel, that each extend outward in the same direction at right angles to the middle panel.

11. The corrugated cardboard box of claim 1, wherein each of the plurality of pairs of back-to-back assembled short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that each of the plurality of back-to-back assembled pairs of long support inserts has at each end two side panels extending outward in opposite directions.

12. A corrugated cardboard box comprising: a first vertical compartmented insert nested within the corrugated cardboard box, wherein the first vertical compartmented insert comprises a rectangular vertical array of interior dividing walls forming there between a plurality of rectangular compartments, each having a storage volume, the compartmented insert comprising: a pair of back-to-back long support inserts extending along a length of the corrugated cardboard box to form a longitudinal vertical wall, each one of the pair of long support inserts having a plurality of interlocking cutouts that registers with a respective interlocking cutout of another of the pair of long support inserts; a plurality of pairs of short support inserts, the pairs of short support inserts assembled back-to-back and arrayed perpendicularly to the pair of long support inserts to form a plurality of lateral walls, each of the plurality of pairs of back-to-back short support insert assemblies having registration of interlocking cutouts to form a common cutout in the back-to-back assembly, the interlocking cutouts of the pairs of back-to-back short support inserts registering with and mechanically locking with the interlocking cutout of the pair of long support inserts such that the pair of long support inserts and the plurality of back-to-back short support inserts create the plurality of rectangular compartments there between; wherein each of the pair of long support inserts has a middle panel flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a first interior wall surface of the corrugated box, and the second side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a second interior wall surface, opposite to the first interior wall surface, of the corrugated box; wherein each of the plurality of back-to-back assemblies of short support inserts includes a middle panel, flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a third interior wall surface of the corrugated box, and the second side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a fourth wall surface, opposite to the third interior wall surface of the corrugated box; wherein a sum of horizontal lengths of opposed side panels at an end of each of the pair of back-to-back long support inserts is equal to a width of a respective interior wall against which the side panels abut; and wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back short support inserts is less than a width of a respective interior walls against which the side panels abut.

13. The corrugated cardboard box of claim 12, wherein the long support insert and the plurality of short support inserts are each comprised of corrugated cardboard material.

14. The corrugated cardboard box of claim 13, wherein corrugations of the corrugated cardboard material are arrayed vertically in the rectangular vertical array of interior dividing walls.

15. The corrugated cardboard box of claim 12, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back long support inserts is equal to a width of a respective interior wall against which the side panels abut and wherein configuration of the side panels is such as to direct externally applied force to the first and second walls to the back-to-back middle panels of the long support inserts thereby increasing structural rigidity of the corrugated cardboard box.

16. The corrugated cardboard box of claim 12, wherein configuration of the side panels is such as to direct externally applied force to the third and fourth walls to the back-to-back middle panels of the short support inserts thereby increasing structural rigidity of the corrugated cardboard box.

17. The corrugated cardboard box of claim 12, wherein the long support insert includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, that extend outward in the same direction at right angles to the middle panel.

18. The corrugated cardboard box of claim 12, wherein each of the pair of back-to-back long support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that the back-to-back pair of long support inserts has at each end two side panels extending outward in opposite directions.

19. The corrugated cardboard box of claim 12, wherein each of the plurality of short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the short support insert into a middle panel flanked by a first and a second side panel, that each extend outward in the same direction at right angles to the middle panel.

20. The corrugated cardboard box of claim 12, wherein each of the plurality of pairs of back-to-back assembled short support insert includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that each of the plurality of back-to-back assembled pairs of long support inserts has at each end two side panels extending outward in opposite directions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood from the Detailed Description, here below, with reference to the following illustrations of exemplary non-limiting embodiments, wherein:

[0025] FIGS. 1A, 1B, 1C, 1D, 1E, and 1F illustrate prior art corrugated cardboard boxes with inserts that vertically compartmentalize the corrugated cardboard boxes.

[0026] FIG. 2A is an illustration of exemplary embodiment of a long support insert of the present invention.

[0027] FIG. 2B illustrates a pair of exemplary embodiments of long support inserts, arrayed back-to-back, of the present invention;

[0028] FIG. 2C illustrates the exemplary pair of long supports FIG. 2 B as positioned inside an exemplary box.

[0029] FIG. 3A illustrates an exemplary embodiment of a long support insert and an exemplary embodiment of a short support insert of the present invention.

[0030] FIG. 3B illustrates an exemplary long support insert within an exemplary box, and an exemplary short support insert with indicia showing (by dashed lines) how the long support inserts and the short support inserts interlock.

[0031] FIG. 3C illustrates the embodiments of FIG. 3B, wherein both the long support inserts and the short support inserts are in the box.

[0032] FIG. 3D illustrates an exemplary embodiment of a short support insert in an exemplary box to create two compartments, and wherein the insert slides freely within the box to vary the relative sizes of the compartments.

[0033] FIG. 4A illustrates a back-to-back arranged pair of exemplary long support inserts, each having three interlocking cutouts, in this example.

[0034] FIG. 4B illustrates the pair of back-to-back arranged pair of exemplary long support inserts of FIG. 4A, as inserted within a box, with two interlocked exemplary short support inserts in position, and a third exemplary short support insert being put into position, as shown by the dashed lines.

[0035] FIG. 4C illustrates the compartmentalized box of FIG. 4B after the third short support insert has been put into position.

DETAILED DESCRIPTION

[0036] The following non-limiting detailed descriptions of examples of embodiments of the invention may refer to appended Figure drawings and are not limited to the drawings, which are merely presented for enhancing explanations of features of the technology. In addition, the detailed descriptions may refer to particular terms of art, some of which are defined herein, as appropriate and necessary for clarity. It will be understood by those skilled in the art that various changes, in form and detail may be made therein without departing from the spirit and scope of the invention, as disclosed and claimed herein.

[0037] The container-compartmentalization embodiments and methods described herein provide many advantages over the prior art. As will become clear, the embodiments utilize less materials for a compartmentalized container of comparable size and number of compartments in the prior art. This results in a lighter, stronger compartmentalized box, while reducing costs of manufacture, and reducing weight to be transported resulting in fuel savings. Moreover, with less material being used, there is less material to recycle, so that environmental benefits may be expected. Further, on account of the double-layered support inserts used in accordance with exemplary embodiments, and the side panels of the support inserts that extend across an entire width of the interior of the box, the compartmentalized containers have greater resistance to externally-applied crush forces on the container, from the sides, or from above and below. The double layered short support inserts are also effective in improving both strength and rigidity of the compartmentalized box.

[0038] The system of double-layered support inserts (both the long as well as the short inserts are double-layered, as explained in more detail here below) presented herein provide improved strength in resistance to applied forces, and allow the packer with a great deal of flexibility. For example, the side panels of the long support inserts extend across the entire lateral width of the container and urge against the wall against which it abuts to provide structural strength. Thus, these divide the box into two sections, one on either side of the long support insert. Conventionally, herein, the long support insert extends along the length of the box, and is said to extend longitudinally, even when the box is square.)

[0039] In addition, it can be readily seen that since the side panels of the short support inserts do not extend across an entire length of the container, once installed, the short support insert can slide internally along the length of the container to thereby divide the container volume into two volumes (compartments) of varying relative size. Conventionally, herein, the short support insert extends along the width of the box, and is said to extend laterally.)

[0040] Further, the number of compartments per container can be varied by judicious selection of the number of interlocking cutouts per long support insert. And, the sizes of the compartments can be varied, based on the spacing between interlocking cutouts. Thus, the system provides for wide variation in sizes of items to be packaged in a compartmented fashion.

[0041] The system can be configured for use in virtually any size of box. The system can be configured as a retrofit to boxes used in a variety of functions, including e-commerce order fulfillment.

[0042] In addition, while the illustrations indicate, for simplicity, compartments of equal size, of course, changing the spacing between interlocking cutouts will allow the possibility to package items of different sizes effectively and snugly, and thereby permit protection of these items.

[0043] FIGS. 2A, 2B, 2C illustrate the deployment of long support inserts of an exemplary embodiment of the present invention. FIG. 2A illustrates an exemplary long support insert 210 in an expanded configuration, as laid down flat (unfolded) on a surface, for example. Thus, these can be stacked easily for storage. The sections of an exemplary long support insert 210 include a middle panel 212, a first side panel 211, a second side panel 213, and an interlocking cutout 214, which will be discussed in further detail below. Of course, while the long support panel shown has one interlocking cutout 214, the panel may have as many such as required to create the number of compartments per box as desired. The first side panel 211 and the second side panel 213 are each separated from the middle panel 212 by score lines 215, 216 respectively that are transverse to the length of the long support insert 210; i.e. they extend laterally across the long support insert 210. The long support insert 210 may be a single sheet of corrugated cardboard, and the panels 212, 211, 213 are formed in the single corrugated cardboard sheet by the score lines 215, 216.

[0044] It should be understood that the dimensions of the sections of the long support insert described herein can vary depending on the size of the corrugated cardboard box in which the components are to be used. By way of example only, in one embodiment the height of the long support insert 210 is about 6 inches; the length of the middle panel 212 is about 9.875 inches, and the length of the first side and second side panels 211, 213 is about 3.5 inches. FIG. 2A defines the length of the long support insert 210 as L, and the width of the long support insert 210 as W. The long support insert described herein can be designed for square compartments or rectangular compartments of different dimensions, as necessary to fit the box in which the long support insert 210 will nest.

[0045] Other embodiments of the long support insert 210 and their approximate measurements are listed below with reference to corresponding corrugated cardboard box:

TABLE-US-00001 Dimensions of Length of Length of Corrugated Length of Middle Panel Side Panels Width of Cardboard Box Long of Long of Long Long (in. in. in.) Support Support Support Support (length width Insert Insert Insert Insert height) (inches) (inches) (inches) (inches) 10 7 6 16.875 9.875 3.5 6 13 9 6 21.875 12.875 4.5 6 13 9 12 21.875 12.875 4.5 12 16 11 6 26.875 15.875 5.5 6 16 11 12 26.875 15.875 5.5 12 22 15 12 36.875 21.875 7.5 12 14 10 9 23.875 13.875 5 9 16 14 12 29.875 15.875 7 12 20 18 10.5 37.875 19.875 9 10.5 32 16 9 47.875 31.875 8 9 26 14 12 39.875 25.875 7 12 28 16 12 43.875 27.875 8 12

[0046] FIG. 2B illustrates two exemplary long support inserts 210, 220 of the present invention, arrayed back-to-back and registering the interlocking cutouts with each other, in a partially deployed condition for nesting in a corrugated cardboard box. As illustrated, the first side panel 211 and the second side panel 213 are partially folded along the score lines 215, 216. When the first side panel 211 and second side panel 213 are fully folded along the score lines 215, 216, the first side panel 211 and the second side panel 213 extend outward perpendicular to the middle panel 212. Similarly, the first side panel 221 and the second side panel 223 are partially folded along a set of score lines (not shown) for the other of the two long support inserts 220. Likewise, when fully folded along the score lines, the first side panel 221 and the second side panel 223 extend outboard perpendicular to the middle panel 220. As shown, the two long support inserts 210, 220 are oriented so the back sides of the middle panels 212, 222 of the long support inserts 210, 220 contact each other. When the side panels are perpendicular to the middle panels of each of the two long support inserts 210, 220, these can be deployed to nest snugly in the corrugated cardboard box. The flat outward surfaces of the side panels 210, 211, 220, 221 urge up against the inboard surface of the box, and as shown in FIG. 2C extend across the internal width of the box. This deployment provides stability and support to the middle panels 212, 220. Of course, from FIG. 2C, the deployment is symmetrical, and so there is stabilization and support from both ends from the side panels.

[0047] The exemplary embodiment shown in FIG. 2B provides a configuration with two individual longitudinally separated compartments or cells. As will be shown below, however, an advantage of the present invention over the prior art is the ease of using short support inserts in conjunction with long support inserts to form a compartmentalized box having any desired number of compartments or cells. Thus, the inventive system provides flexibility in the size and variety of the products that can be loaded within the compartmentalized box, which is discussed in further detail below.

[0048] FIG. 2C shows the two exemplary long support inserts 210, 220 of the present invention deployed, and nested with a corrugated box 290. The corrugated box 290 illustrated in FIG. 2C is shown in an open configuration with the (closure) flaps 292, 294 in relatively horizontal positions. The length, width, and height of the corrugated box 290 are noted as L, W, and H respectively. For ease of nomenclature, a box wall extending along L is a longitudinally extending wall, while a wall extending along the width W is a laterally extending wall.

[0049] It can be seen from FIG. 2C that, in this embodiment, the total outward extension of length of the two second side panels 213, 223 added together is about equal to the distance from one interior wall (which is parallel to the long support insert) to the opposite interior wall of the container 290. The long support inserts are sized such that when deployed, each side panel 213, 223 is urged up against one lateral end wall of the box, and the opposite side panels 211, 221 are urged against the opposite lateral end wall of the box. Further, the long support inserts are held immovably in position because each second side panel 213, 223 has outermost vertical edges that are in contact with or fit up against an interior longitudinal wall of the container 290. Similarly, the lengths of the first side panels 211, 221 added together is also about equal to the distance from one interior longitudinal wall to an opposite interior longitudinal wall of the container 290. Because the side panels 211, 213, 221, 223 add a layer of corrugated cardboard to their corresponding container walls against which they are abutted, the contents of the container 290 have an additional layer of structural protection and stability.

[0050] In the exemplary embodiment, the height of the long support insert is the same height as the interior side walls of the container 290, but of course they can also be shorter. The insert height should be such that, when the container is sealed, the inserts do not protrude out of the container and do not obstruct the sealing of the container.

[0051] Put another way, the two long support inserts 210, 220 as illustrated in FIG. 2C are sized and configured to stably compartmentalize the corrugated box 290 into at least two compartments. The first side panels (not shown) together span one interior side of the corrugated box 290 and the second side panels 213, 223 together span another interior side of the corrugated box 290. While the first side panels (not shown) and the second side panels 213, 223 are adjacent to the interior sides of the corrugated box 290, the middle panels 212, 222 are positioned at or near the center of the corrugated box 290, and thereby compartmentalize the corrugated box 290 into two compartments that are approximately equal in size. Further, the interlocking cutouts 214, 224 register with each other so that cross-wise short support inserts can pass through both to interlock, as discussed in further detail below.

[0052] Depending upon the box, the desired number and size of the compartments to be created with inserts, several variables can be manipulated. For example, in the illustrated examples, the side panels are of equal length. However, this need not necessarily be the case. Side panels on one side of the long support insert may be longer than those on the other side, when deployed, but the added lengths would still approximate the length of the interior lateral wall of the box so that the insert is snugly held in position. In this instance, when the long support insert is deployed, the middle panels 212, 222 are no longer centered in the corrugated box 290 but are positioned according to the relative lengths of the first side panels (not shown) and the second side panels 213, 223. Accordingly, the compartments are offset from center and have different sizes.

[0053] The functionality described above regarding changing the configuration of a two-cell load plan to a four- or six-cell load plan (or more, as required) using short support inserts, in conjunction with long support inserts, is illustrated in FIGS. 3A-3C and 4A-4C, which are discussed in further detail below.

[0054] Another component of the inventive packaging system is the short support insert, exemplified in FIG. 3A by short support insert 330. Depending on the desired insert configuration, the short support insert 330 can be placed so as to interlock with the long support insert 310, as shown in FIG. 3B or 3C. The use of the short support inserts 330 reduces the size of the compartments (and increases the number of compartments) created by the deployment of the long support inserts 310, 320, by means that will be explained shortly.

[0055] Referring to FIG. 3A, the short support insert 330 of the present invention can lie flat as shown in FIG. 2A in order to accommodate storage in a flat configuration. It can be seen that the sections of a short support insert 330 include the middle panel 332, the first side panel 331, the second side panel 333, and an interlocking cutout 334. The first side panel 331 and the second side panel 333 are separated from the middle panel 332 by means of score lines 335, 336 respectively, which are perpendicular to the length of the short support insert 330. The short support insert 330 may be a single sheet of corrugated cardboard, and the panels 331, 332, 333 are formed from the single corrugated cardboard sheet by the score lines 335, 336.

[0056] By way of example, in one embodiment the height of a panel 332 is about 6 inches, the length of the middle panel 332 is about 6.875 inches, and the length of the first side and second side panels 331, 333 is about 2.5 inches. FIG. 3A defines the length of the short support insert 210 as L, and the width of the short support insert 210 as W. The short support insert described herein can be designed for square compartments or rectangular compartments of different dimensions, again designed as necessary to fit the box in which the short support insert will nest. The dimensions for the long support insert 310 in this embodiment are similar to the dimensions of the long support insert shown and first described in relation to FIGS. 2A-2C.

[0057] Other embodiments of the short support insert 330 and their approximate measurements are listed below with reference to corresponding corrugated cardboard box:

TABLE-US-00002 Dimensions of Length of Length of Corrugated Length of Middle Panel Side Panels Width of Cardboard Box Short of Short of Short Short (in in. in.) Support Support Support Support (length width Insert Insert Insert Insert height) (inches) (inches) (inches) (inches) 10 7 6 11.875 6.875 2.5 6 13 9 6 14.875 8.875 3 6 13 9 12 14.875 8.875 3 12 16 11 6 18.875 10.875 4 6 16 11 12 18.875 10.875 4 12 22 15 12 22.875 14.875 4 12 14 10 9 15.875 9.875 3 9 16 14 12 21.875 13.875 4 12 20 18 10.5 25.875 17.875 4 10.5 32 16 9 29.875 15.875 7 9 26 14 12 25.875 13.875 6 12 28 16 12 29.875 15.875 7 12

[0058] The interlocking cutout 314 of the long support insert 310 is designed to accommodate the thickness of two short support inserts, and similarly, the interlocking cutout 334 of the short support insert 330 is also designed to accommodate the thickness of two long support inserts. The length of the interlocking cutouts 314, 334 measures to be half of the width of the long support insert 310 and the short support insert 330, and in the present exemplary embodiment, the length of the interlocking cutouts 314, 334 is approximately 3 inches.

[0059] FIG. 3B shows an expanded view of two (back-to-back) short support inserts 330, 340 ready to intersect two (back-to-back) long support inserts 310, 320, that are fully deployed in a four-cell configuration. FIG. 3C shows the two short support inserts 330, 340 and the two long support inserts 310, 320 fully deployed in a four-cell configuration, nested in a corrugated cardboard box 390. The present exemplary embodiment is designed for a corrugated cardboard box 390 that measures 10 inches by 7 inches by 6 inches. Other embodiments can vary in size and dimensions to accommodate different types and sizes of corrugated cardboard boxes, and the corresponding components of the long support inserts and the short support inserts vary correspondingly to accommodate the differing types and sizes of corrugated cardboard boxes.

[0060] As shown in FIG. 3B, the long support inserts 310, 320 are deployed and configured in a manner somewhat similar to the long support inserts of FIGS. 2B and 2C. Accordingly, the middle panels 312, 322 run parallel to the length of the corrugated cardboard box 290, and abut each other to create the partition for the two-cell configuration.

[0061] The short support inserts 330, 340 are deployed and configured in a similar manner to the configuration of the long support inserts 310, 320 of the present exemplary embodiment but in a 90 degree off set orientation. FIG. 3B is an exploded view of the present exemplary embodiment intended to show how the two inserts interlock utilizing their respective interlocking cutouts.

[0062] The first side panels 331, 341 of the short support inserts 330, 340 are folded perpendicular to the middle panels 332, 342 but in opposing directions, and the second side panels (not shown) of the short support inserts 330, 340 are likewise folded perpendicular to the middle panels 332, 342 but in opposing directions. The short support inserts 330, 340 are oriented so that the registering pair of interlocking cutouts 334 (other not visible) of the short support inserts 330, 340 are located on the bottom half of the short support inserts 330, 340 and open downward. The interlocking cutouts of the short support inserts 330, 340 line up with the interlocking cutouts 314, 324 of the long support inserts 310, 320. The short support inserts 330, 340 are pushed downward into interconnection relationship so that the long support and short support inserts are locked at 90 degrees to each other. In this embodiment, the interlocking cutouts of both the long support inserts 310, 320 and the short support inserts 330, 340 are designed to accommodate half the height of the inserts such that when interlocked in vertical deployed position in the box, the inserts each span the entire width of the other insert. Of course, that may not be necessary in all cases, and it may be desirable to have a gap at the top or bottom when the inserts are interlocked and deployed in the box.

[0063] FIG. 3C illustrates a four-cell box. Of course, by judicious and appropriate selection of the number of interlocking cutouts in the long support insert, and the corresponding number of short support inserts, any number of cells can be had.

[0064] FIG. 3D illustrates another embodiment and configuration of the short support inserts 330, 340, without any long support inserts. Short support inserts 330, 340 can be used without long support inserts, just as long support inserts can be used without short support inserts as shown in FIG. 2A-2C. In this manner one can create partitions for any number, variety and combination of compartments. In the present exemplary embodiment, two short support inserts 330, 340 are deployed and configured in accordance with the disclosed principles, and can be positioned in the corrugated cardboard box 390 so that the first side panels 331, 341 abut the distal interior back side of the corrugated cardboard box 390 and that the second side panels (not shown) abut the proximal interior front side of the corrugated cardboard box 290. Accordingly, the short support inserts can slide freely to be placed at any position along the length of the corrugated cardboard box 290. In this way, the compartments of the total volume of the box can vary in size to accommodate any load plan.

[0065] As illustrated in FIG. 3D, the side panels of the short support inserts together do not span the entire interior wall with which they are in contact; instead the side panels of the short support inserts are designed to allow for maximum flexibility in configuration. Because the side panels do not together span the contacting interior wall, the resulting two compartments can be altered to different dimensions by adjusting the position of the short support inserts 330, 340 anywhere along the length of the container 290. Also, the amount of corrugated cardboard is reduced by not having side panels that span the entire interior wall of the container 290. In other embodiments, as will be illustrated with FIGS. 4A-4C, there are multiple short support inserts, and in these embodiments, the side panels together do span the entire contacting interior wall.

[0066] The functionality of another exemplary embodiment of the invention can accommodate a variety of load configurations, one of which is illustrated by FIGS. 4A, 4B, and 4C. Referring to FIG. 4A, the present exemplary embodiment illustrates a long support insert, similar to the expanded configuration shown in FIGS. 2A and 3A. However, the long support insert shown in FIGS. 4A-4C differs from the long support inserts of FIGS. 2A-2C and 3A-3C in that the long support inserts of FIGS. 4A-4C comprise more than one interlocking cutout. The long support insert can comprise any number of interlocking cutouts, as needed, and the present exemplary embodiment illustrates the long support insert with three interlocking cutouts: first interlocking cutouts 414; second interlocking cutouts 415; and third interlocking cutouts 416.

[0067] Referring to FIGS. 4B and 4C, a corrugated box 490 is shown with the flaps 492, 494 in a horizontal position, thus providing an opening in the box 490. Also shown is a long support insert 410, with a middle panel 412, a first side panel (not shown), a second side panel 413, a first interlocking cutout engaged with a first set of short support inserts 430, 440; a second interlocking cutout (not shown) engaged with a second set of short support inserts 450, 460; and a third interlocking cutouts 416, 426. Another long support insert 420 is positioned so that the back side of the middle panel 412 of the first long support insert 410 abuts the back side of the middle panel 422 of the second long support insert 420. The two long support inserts 410, 420 line up so that the each set of interlocking cutouts align with each other (first interlocking cutouts (not shown); second interlocking cutouts (not shown); third interlocking cutouts 416, 426).

[0068] In the embodiment shown in FIG. 4B, two sets of short support inserts 430, 440, 450, 460 are deployed and engaged with the long support inserts 410, 420 in accordance with the above disclosed principles. Each set of short support inserts engages with a set of interlocking cutouts, e.g., the engaged set of short support inserts 430, 440 engages with the first interlocking cutouts, and the engaged set of short support inserts 450, 460 engages with the second interlocking cutouts.

[0069] Also shown in the embodiment of FIG. 4B is a set of short support inserts 470, 480 deployed and ready to engage the long support inserts 410, 420 at the third interlocking cutouts 416, 426. This set of short support inserts 470, 480 illustrates how the short support inserts 430, 440, 450, 460, 470, 480 engage with the long support inserts 410, 420. The short support inserts of the present exemplary embodiment can be the short support inserts of the exemplary embodiment of FIGS. 3A-3D. The short support inserts of the present exemplary embodiment are oriented so that the interlocking cutouts of the short support inserts are open downwards, as illustrated with the interlocking cutouts 474 of short support insert 470. The short support inserts 470, 480, with first side panels 471, 481 and second side panels 473, 483 deployed, are lined up so that the interlocking cutouts of the short support inserts 470, 480 line up with the interlocking cutouts 416, 426 of the long support inserts 410, 420. The short support inserts 470, 480 are then engaged with the long support inserts 410, 420, with the middle panels 412, 422 of the long support inserts 410, 420 sliding into the interlocking cutouts 474 (one not shown) of the short support inserts 470, 480, and the middle panels 472, 482 of the short support inserts 470, 480 sliding into the interlocking cutouts 416, 426 of the long support inserts 410, 420. FIG. 4C illustrates all sets of short support inserts 430, 440, 450, 460, 470, 480 fully engaged with the long support inserts 410, 420, and thereby creating an eight-cell load pattern.

[0070] It can be understood that the flexibility of the instant packaging system and its components provides for a larger variety of configurations that can accommodate a number of different load plans or load patterns. The examples provided by the drawings are only a few of the potential configurations. In particular, the long support inserts that are of a double-layered construction, along with the end panels that in deployed position extend completely across the width of the box interior, and abuts and urges against the adjacent box wall, provides added strength and resistance to applied outside forces to the box. The number of interlocking cutouts in the long support insert and the spacing between these allow flexibility in number and size of short support inserts, and thus number of compartments.

[0071] While examples of embodiments of the technology have been presented and described in text and also by way of illustration, it will be appreciated that various changes and modifications may be made in the described technology without departing from the scope of the inventions, which are set forth in, and only limited by, the scope of the appended patent claims, as properly interpreted and construed.

Additional Description

[0072] The following clauses are offered as further description of the disclosed invention:

[0073] 1. A corrugated cardboard box comprising:

[0074] a vertical compartmented insert nested within the corrugated cardboard box, wherein the vertical compartmented insert comprises a rectangular vertical array of interior dividing walls forming there between a plurality of rectangular compartments, each having a storage volume, the compartmented insert comprising:

[0075] a pair of back-to-back long support inserts extending along a length of the corrugated cardboard box to form a longitudinal vertical wall, each one of the pair of long support inserts having a plurality of interlocking cutouts that registers with a respective interlocking cutout of another of the pair of long support inserts;

[0076] a plurality of pairs of short support inserts, the pairs of short support inserts assembled back-to-back and arrayed perpendicularly to the pair of long support inserts to form a plurality of lateral walls, each of the plurality of pairs of back-to-back short support insert assemblies having registration of interlocking cutouts to form a common cutout in the back-to-back assembly, the interlocking cutouts of the pairs of back-to-back short support inserts registering with and mechanically locking with the interlocking cutout of the pair of long support inserts such that the pair of long support inserts and the plurality of back-to-back short support inserts create the plurality of rectangular compartments there between;

[0077] wherein each of the pair of long support inserts has a middle panel flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a first interior wall surface of the corrugated box, and the second side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a second interior wall surface, opposite to the first interior wall surface, of the corrugated box;

[0078] wherein each of the plurality of back-to-back assemblies of short support inserts includes a middle panel, flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a third interior wall surface of the corrugated box, and the second side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a fourth wall surface, opposite to the third interior wall surface of the corrugated box.

[0079] 2. The corrugated cardboard box of any preceding clause, wherein the long support insert and the plurality short support inserts are each comprised of corrugated cardboard box.

[0080] 3. The corrugated cardboard box of any preceding clause, wherein corrugations of the corrugated cardboard material are arrayed vertically in the rectangular vertical array of interior dividing walls.

[0081] 4 The corrugated cardboard box of any preceding clause, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back long support inserts is equal to a width of respective interior wall against which the side panels abut.

[0082] 5. The corrugated cardboard box of any preceding clause, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back long support inserts is equal to a width of respective interior wall against which the side panels abut and wherein configuration of the side panels is such as to direct externally applied force to the first and second walls to the back-to-back middle panels of the long support inserts thereby increasing structural rigidity of the corrugated cardboard box.

[0083] 6. The corrugated cardboard box of any preceding clause, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back short support inserts is less than a width of respective interior walls against which the side panels abut.

[0084] 7. The corrugated cardboard box of any preceding clause, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back short support inserts is less than a width of respective interior wall against which the side panels abut, and wherein configuration of the side panels is such as to direct externally applied force to the third and fourth walls to the back-to-back middle panels of the short support inserts thereby increasing structural rigidity of the corrugated cardboard box.

[0085] 8. The corrugated cardboard box of any preceding clause, wherein the long support insert includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, that extend outward in the same direction at right angles to the middle panel.

[0086] 9. The corrugated cardboard box of any preceding clause, wherein each of the pair of back-to-back long support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that the back-to-back pair of long support inserts has at each end two side panels extending outward in opposite directions.

[0087] 10. The corrugated cardboard box of any preceding clause, wherein each of the plurality of short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the short support insert into a middle panel flanked by a first and a second side panel, that each extend outward in the same direction at right angles to the middle panel.

[0088] 11. The corrugated cardboard box of any preceding clause, wherein each of the plurality of pairs of back-to-back assembled short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that each of the plurality of back-to-back assembled pairs of long support inserts has at each end two side panels extending outward in opposite directions.

[0089] 12. A corrugated cardboard box comprising:

[0090] a first vertical compartmented insert nested within the corrugated cardboard box, wherein the first vertical compartmented insert comprises a rectangular vertical array of interior dividing walls forming there between a plurality of rectangular compartments, each having a storage volume, the compartmented insert comprising:

[0091] a pair of back-to-back long support inserts extending along a length of the corrugated cardboard box to form a longitudinal vertical wall, each one of the pair of long support inserts having a plurality of interlocking cutouts that registers with a respective interlocking cutout of another of the pair of long support inserts;

[0092] a plurality of pairs of short support inserts, the pairs of short support inserts assembled back-to-back and arrayed perpendicularly to the pair of long support inserts to form a plurality of lateral walls, each of the plurality of pairs of back-to-back short support insert assemblies having registration of interlocking cutouts to form a common cutout in the back-to-back assembly, the interlocking cutouts of the pairs of back-to-back short support inserts registering with and mechanically locking with the interlocking cutout of the pair of long support inserts such that the pair of long support inserts and the plurality of back-to-back short support inserts create the plurality of rectangular compartments there between;

[0093] wherein each of the pair of long support inserts has a middle panel flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a first interior wall surface of the corrugated box, and the second side panels of each of the back-to-back long support inserts extend outboard in opposite directions at right angles to the middle panel, abut flush against, and urge against a second interior wall surface, opposite to the first interior wall surface, of the corrugated box;

[0094] wherein each of the plurality of back-to-back assemblies of short support inserts includes a middle panel, flanked by a first side panel and a second side panel, such that in deployed position in the corrugated box, the first side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a third interior wall surface of the corrugated box, and the second side panels of each of the back-to-back short support inserts extend outward in opposite directions at right angles to said middle panel, abut flush against, and urge against a fourth wall surface, opposite to the third interior wall surface of the corrugated box;

[0095] wherein a sum of horizontal lengths of opposed side panels at an end of each of the pair of back-to-back long support inserts is equal to a width of respective interior wall against which the side panels abut; and

[0096] wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back short support inserts is less than a width of respective interior walls against which the side panels abut.

[0097] 13. The corrugated cardboard box of clause 12, wherein the long support insert and the plurality of short support inserts are each comprised of corrugated cardboard material.

[0098] 14. The corrugated cardboard box of clause 13, wherein corrugations of the corrugated cardboard material are arrayed vertically in the rectangular vertical array of interior dividing walls.

[0099] 15. The corrugated cardboard box of any one of clauses 12-14, wherein a sum of horizontal lengths of opposed side panels at an end of each of the back-to-back long support inserts is equal to a width of respective interior wall against which the side panels abut and wherein configuration of the side panels is such as to direct externally applied force to the first and second walls to the back-to-back middle panels of the long support inserts thereby increasing structural rigidity of the corrugated cardboard box.

[0100] 16. The corrugated cardboard box of any one of clauses 12-15, wherein configuration of the side panels is such as to direct externally applied force to the third and fourth walls to the back-to-back middle panels of the short support inserts thereby increasing structural rigidity of the corrugated cardboard box.

[0101] 17. The corrugated cardboard box of any one of clauses 12-16, wherein the long support insert includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, that extend outward in the same direction at right angles to the middle panel.

[0102] 18. The corrugated cardboard box of any one of clauses 12-17, wherein each of the pair of back-to-back long support insert includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that the back-to-back pair of long support insert has at each end two side panels extending outward in opposite directions.

[0103] 19. The corrugated cardboard box of any one of clauses 12-18, wherein each of the plurality of short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the short support insert into a middle panel flanked by a first and a second side panel, that each extend outward in the same direction at right angles to the middle panel.

[0104] 20. The corrugated cardboard box of any one of clauses 12-19, wherein each of the plurality of pairs of back-to-back assembled short support inserts includes a pair of spaced apart score lines extending across a width thereof, the score lines providing ease of folding of the long support insert into a middle panel flanked by a first and a second side panel, such that each of the plurality of back-to-back assembled pairs of long support inserts has at each end two side panels extending outward in opposite directions.