PACKAGING FOR BREAKABLE PRINT PRODUCTS

Abstract

Packaging for a breakable print product having a top side, a bottom side, a left side and a right side is provided. The packaging is formed from a single sheet of a corrugated, recyclable and bio-degradable material. The bottom side is formed from four flaps, each flap having a top horizontal inward fold and a bottom horizontal inward fold, the top horizontal inward fold of each of the four flaps forming the bottom side and the bottom horizontal inward fold of the four flaps forming an integrated cross cut section. Notches in each bottom horizontal inward fold hold a type and at least one size of a breakable print product.

Claims

1. Packaging for a breakable print product, the packaging comprising: a top side, a bottom side, a left side and a right side, wherein the packaging is formed from a single sheet of a corrugated, recyclable and bio-degradable material; wherein the bottom side is formed from four bottom flaps, each bottom flap having a top horizontal inward fold and a bottom horizontal inward fold, the top horizontal inward fold of each of the four bottom flaps forming the bottom side and the bottom horizontal inward fold of the four bottom flaps forming an integrated cut cross section, and wherein notches in each bottom horizontal inward fold hold a type and at least one size of a breakable print product.

2. The packaging of claim 1, the packaging further comprising: a front side and a back side, wherein the four bottom flaps corresponds to the front side, the back side, the left side and the right side of the packaging, respectively.

3. The packaging of claim 2, wherein the bottom flap corresponding to the front side comprises a vertical notch extending downwardly from a top edge of the top horizontal section into the bottom horizontal section, and wherein the bottom flap corresponding to the back side comprises a vertical notch extending downwardly from a top edge of the top horizontal section into the bottom horizontal section.

4. The packaging of claim 3, wherein the bottom horizontal inward fold of the bottom flap corresponding to the left side and the bottom horizontal inward fold of the bottom flap corresponding to the right side are inserted into the vertical notch of the bottom flap corresponding to the front side and the vertical notch of the bottom flap corresponding to the back side.

5. The packaging of claim 1, further comprising a securing tab positioned at an outer edge of the single sheet of a corrugated, recyclable and bio-degradable material and configured to join together two outermost sides of the packaging.

6. The packaging of claim 2, wherein the four top flaps correspond to the front side, the back side, the left side and the right side of the packaging, respectively, wherein the top flap corresponding to the left side and the top flap corresponding to the right side have a top horizontal inward fold and a bottom horizontal inward fold, and wherein the top flap corresponding to the front side and the top flap corresponding to the back side have a top horizontal inward fold, a middle horizontal inward fold and a bottom horizontal inward fold, and wherein the bottom horizontal inward fold of each of the four top flaps forming the top side.

7. The packaging of claim 6, wherein the top flap corresponding to the front side comprises a vertical notch extending upwardly from a bottom edge of the bottom horizontal section into the middle horizontal section, and wherein the top flap corresponding to the back side comprises a vertical notch extending upwardly from a bottom edge of the bottom horizontal section into the middle horizontal section.

8. The packaging of claim 7, wherein notches in the top horizontal inward fold of the top flaps corresponding to the left side and the right side divide an upper edge of the top horizontal inward fold into tabs, and wherein the tabs of the top horizontal inward fold of the top flaps corresponding to the left side and the right side are inserted into the vertical notch of the top flap corresponding to the front side and the vertical notch of the top flap corresponding to the back side.

9. Packaging for a breakable print product, the packaging comprising: a single sheet of a corrugated, recyclable and bio-degradable material with a generally rectangular outline, the sheet in landscape orientation comprising four columns, three rows and a securing tab extending beyond an outer most edge of a middle row of the sheet; wherein a top row of the of the three rows comprises, from left to right, a first top flap, a second top flap, a third top flap and a fourth top flap, each top flap being separated from a neighboring top flap by a vertical notch extending down from a top of the sheet to the middle row of the sheet, wherein the first top flap has a top horizontal section and a bottom horizontal section, the bottom horizontal section having a larger area compared to the top horizontal section, the top horizontal section having two notches extending down from a top of the sheet, the two notches creating three tabs, wherein the second top flap has a top horizontal section, a middle horizontal section and a bottom horizontal section, the bottom horizontal section having a center notch through the bottom horizontal section and into the middle horizontal section, wherein the bottom horizontal section has a largest area of the three horizontal sections, the center horizontal section having a smallest area of the three horizontal section and the top horizontal section having an area between that of the bottom horizontal section and the middle horizontal section, wherein the third top flap has a shape, notches, tabs and horizontal sections that mirror the first top flap; wherein the fourth top flap has a bottom horizontal section, a middle horizontal section, a top horizontal section, and a vertical notch extending from a bottom of the fourth top flap upward into the middle horizontal section; wherein a bottom row of the three rows comprises, from left to right, a first bottom flap, a second bottom flap, a third bottom flap and a fourth bottom flap, each bottom flap separated from a neighboring bottom flap by a notch extending up from a bottom of the sheet to the middle row of the sheet; wherein the first bottom flap has a top horizontal section and a bottom horizontal section, the bottom horizontal section having three notches, the three notches creating four tabs; wherein the second bottom flap has a top horizontal section and a bottom horizontal section, a notch extending downwardly from a top of the second bottom flap into the bottom horizontal section, and the bottom horizontal section having two notches extending up from a bottom of the sheet, the two notches creating three tabs; wherein the third bottom flap has a shape, notches, tabs and horizontal sections that mirror the first bottom flap; wherein the fourth bottom flap has a shape, notches, tabs and horizontal sections that mirror the second bottom flap; wherein boundaries between horizontal sections in each flap and boundaries between each flap and the middle row of the sheet are bendable for assembling the packaging from the sheet; and wherein no fillers internal to the packaging are needed to protect the breakable printed product.

10. The packaging of claim 9, wherein the bottom horizontal inward fold of the first bottom flap and the bottom horizontal inward fold of the third bottom flap are inserted into the notch extending downwardly of the second bottom flap and the notch extending downwardly of the fourth bottom flap.

11. The packaging of claim 9, wherein the securing tab is configured to join together two outermost sides of the packaging.

12. The packaging of claim 9, wherein the three tabs of the first upper flap and the three tabs of the third upper flap are inserted into the center notch of the second top flap and the center notch of the fourth top flap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become apparent and be better understood by reference to the following description of the invention in conjunction with the accompanying drawing, wherein:

[0009] FIG. 1 depicts packaging prior to assembly for a breakable print product;

[0010] FIGS. 2 and 3 are photographs showing a sheet being weighed (in this case, 0.11 lbs);

[0011] FIG. 4 is a photograph of the sheet folded vertically in half with the bottom flaps on top with two columns visible;

[0012] FIG. 5 is a photograph of the sheet in FIG. 4 with two other columns visible;

[0013] FIG. 6 is a photograph showing the packaging in the process of being assembled from the sheet;

[0014] FIG. 7A is a photograph showing two bottom flaps of the fours bottom flaps inserted, forming half of the integrated cut cross section;

[0015] FIG. 7B is a photograph showing the bottom of the packaging after inserting the two uninserted bottom flaps of FIG. 7A, forming the second half of the integrated cut cross section (not shown);

[0016] FIG. 8 is a photograph depicting the packaging after being flipped from FIG. 7 such that the top flaps are pointed upward;

[0017] FIG. 9 is a photograph showing a standard 11 oz mug to the scene of FIG. 8;

[0018] FIG. 10 is a photograph of a top down view of the packaging from FIGS. 8 and 9 showing an example of the integrated cut cross section;

[0019] FIG. 11 is a photograph showing the packaging from FIG. 10 after top-down placement of the mug of FIG. 9;

[0020] FIG. 12 is a photograph showing the packaging of FIG. 11 with the mug therein after assembling two of the top flaps; and

[0021] FIG. 13 is a photograph showing the packaging of FIG. 12 after placement of the other two top flaps.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] The present invention seeks to address packaging concerns with a one-piece design for a breakable print product that uses a corrugated, bio-degradable and recyclable packaging material, for example, corrugated card board, to make the packaging lighter and dispensing with the need for filler material or a separate insert. In an embodiment, the packaging can be used for different sizes of a type of breakable print product, such that the packaging can accommodate, for example, 11 oz mugs and 15 oz mugs. Also, multiples of the packaging can be shipped using a same shipping service or courier. In another embodiment, the packaging can be designed solely for one size and type of breakable print product.

[0023] Breakable print products are products on which an image can be printed and which are breakable, e.g., ceramic or glass, for example, mugs, bowls, cups, jars, etc.

[0024] As used herein, the term notch, when used to describe the inventive packaging, refers to an area of a sheet of a corrugated, recyclable and bio-degradable material, such as, for example, corrugated card board, where there is an absence of the material, the notches are present either to secure other flaps in closing the packaging or to hold a breakable print product. Such notches can be made using a rotary blade, for example.

[0025] Vertical notches along top and bottom edges, ending at the middle row, of the sheet create top flaps and bottom flaps. Tabs along the bottom edge of the sheet, created by the vertical notches, are brought together in making the packaging from the sheet to create an integrated cut cross section, which is essentially a raised plus sign (+) with notches at a top thereof that accept a top-down breakable print product.

[0026] The overall concept for the customized packaging is to size it to accommodate at least a type of particular breakable print product, locating the notches of the bottom row flaps to accommodate insertion of the top of the breakable print product. This can be achieved by, for example, placing the breakable print product on a cut cross section without notches, noting where the top of the breakable print product touches the cut cross section. Where the product has an extremity off the main body (e.g., a handle of a mug), the orientation of the extremity is preferably across from the securing tab for extra protection. Using notches and placement/size of the flap sections, the top flaps are designed to secure the bottom of the breakable print product.

[0027] FIG. 1 depicts packaging prior to assembly for a breakable print product made from, for example, a sheet 100 of corrugated, recyclable and bio-degradable material in a roughly rectangular shape, the sheet in landscape orientation having four columns (columns 102, 104, 106 and 108), three rows (rows 110, 112 and 114) and a securing tab 116 extending beyond an edge of an outermost column of a middle row of the sheet (e.g., middle row 112). FIG. 1 also includes various measurements of elements of the sheet in inches, for example, securing tab 116 having a width of 1.5 inches.

[0028] In certain embodiments the columns 102, 104, 106 and 108 may have different widths. Additionally, alternating columns, which are used to form opposite sides of packaging, according to embodiments of the disclosure, may have different, non-identical widths. For example, when sheet 100 is to be used as packaging for an 11 ounce ceramic mug, column 102 may have a width of 5 and 5/16 inches, column 104 may have a width of 6 and ? inches, column 106 may have a width of 5 and ? inches, and column 108 may have a width of 6 and 1/16 inches.

[0029] Row 110, which will serve as the top of the packaging when assembled, includes, from left to right, a first top flap 118, a second top flap 120, a third top flap 122 and a fourth top flap 124, each top flap being separated from a neighboring top flap (e.g., first top flap 118 and second top flap 120) by a vertical notch (vertical notches 126, 128 and 130) extending down from a top 132 of the sheet to the middle row 112 of the sheet. Vertical notches 126, 128 and 130 may have any suitable width. For example, vertical notches 126, 128 and 130 may have a width of ? inches.

[0030] First top flap 118 has a top horizontal section 134 and a bottom horizontal section 136, wherein the bottom horizontal section 136 may have a larger area compared to the top horizontal section 134. The top horizontal section 134 has two notches 138 and 140 extending down from the top 132 of the sheet, the two notches creating three tabs 142, 144 and 146 of varying height and shape. The height of tab 146 may be achieved by, for example, cutting off a top section.

[0031] The second top flap 120 has a top horizontal section 148, a middle horizontal section 150 and a bottom horizontal section 152, the bottom horizontal section having a center vertical notch 154 through the bottom horizontal section 152 and into the middle horizontal section 150. The bottom horizontal section 152 has a largest area of the three horizontal sections 148, 150 and 152, the center horizontal section 150 has a smallest area of the three horizontal sections 148, 150 and 152 and the top horizontal section 148 has an area between that of the bottom horizontal section 152 and the middle horizontal section 150. Vertical notch 154 may have any suitable width. For example, vertical notch 154 may have a width of ? inches.

[0032] The third top flap 122 has an overall shape, including notches (156 and 158), tabs (160, 162 and 164) and horizontal sections 270 and 272 that mirror the first top flap 118.

[0033] The fourth top flap 124 has a bottom horizontal section 166, a middle horizontal section 168, a top horizontal section 170, and a vertical notch 172 extending from a bottom 174 of the fourth top flap 124 upward into the middle horizontal section 168. Vertical notch 172 may have any suitable width. For example, vertical notch 172 may have a width of ? inches.

[0034] Middle row 112 will serve as the sides of the packaging when assembled and includes sides 280, 282, 284 and 286 and the securing tab 116. The securing tab 116 extends beyond an edge of an outermost side of the middle row 112 (e.g., side 280 or side 286) of the sheet and is configured to secure side 280 to side 286 when an appropriate adhesive is applied to an outer surface of securing tab 116. When an appropriate adhesive is applied, securing tab 116 may be secured to the side 280 or 286 from which it is not extending.

[0035] Bottom row 114 of the three rows 110, 112 and 114 includes, from left to right, a first bottom flap 176, a second bottom flap 178, a third bottom flap 180 and a fourth bottom flap 182. Each bottom flap is separated from a neighboring bottom flap (e.g., bottom flaps 176 and 178) by a vertical notch 184, 186 and 188 extending up from a bottom 190 of the sheet to the middle row 112 of the sheet 100. As with previously described vertical notches, vertical notches 184, 186 and 188 may have any suitable width. For example, vertical notches 184, 186 and 188 may have a width of ? inches.

[0036] The first bottom flap 176 has a top horizontal section 192 and a bottom horizontal section 194, the bottom horizontal section 194 having three notches 196, 198 and 200, the three notches creating four tabs 202, 204, 206 and 208. In an embodiment, the top and bottom horizontal section are delineated by horizontal fold indicators.

[0037] The second bottom flap 178 has a top horizontal section 210 and a bottom horizontal section 212, a vertical notch 214 extending downwardly from a top edge 216 of the top horizontal section 210 into the bottom horizontal section 212, and the bottom horizontal section 212 has two notches 218 and 220 extending up from a bottom edge 190 of the sheet 100, the two notches creating three tabs 222, 224 and 226. In an embodiment, the top and bottom horizontal section are delineated by horizontal fold indicators. Vertical notch 214 may have any suitable width. For example, vertical notch 214 may have a width of ? inches.

[0038] The third bottom flap 180 has top and bottom horizontal sections 228 and 230, respectively, notches 232, 234 and 236 creating four tabs 238, 240, 242 and 244 that mirror the first bottom flap 176. In an embodiment, the top and bottom horizontal section are delineated by horizontal fold indicators.

[0039] The fourth bottom flap 182 has top and bottom horizontal sections 246 and 248, respectively, a vertical notch 250 extending downwardly from a top edge of the top horizontal section 246 into the bottom horizontal section 248, and notches 252 and 254 creating three tabs 256, 258 and 260 that mirror the second bottom flap 178. In an embodiment, the top and bottom horizontal section are delineated by horizontal fold indicators.

[0040] No fillers are needed inside the packaging to protect the breakable print product. Rather, the breakable print product is elevated above a bottom surface of the packaging by various tabs of the bottom horizontal sections 194, 212, 230 and 248 of the bottom flaps 176, 178, 180 and 182, respectively, which interlock together in an interior space of the packing. In some embodiments, the tabs may to form an integrated cross cut section.

[0041] Preferably, the boundaries of the horizontal sections of the flaps are indicated with visible lines. Preferably, the boundaries of the horizontal sections of the flaps are not made to be more easily bendable (e.g., using perforations, micro-perforations, etc.), in order to provide more strength. However, the invention is intended to cover the packaging with or without lines and/or perforations.

[0042] In an embodiment, the sheet can include directions on various surfaces to assist with assembly. For example, in FIG. 12, section 166 of top flap 124 indicates how to orient the mug such that the mug handle with arrow points to where the handle is intended to be.

[0043] FIGS. 2-13 are photographs showing the sheet, including at various stages of creating packaging from the sheet.

[0044] FIGS. 2 and 3 show the sheet being weighed (in this case, 0.11 lbs), though the weight could be different based on the material used or through improvements in the material.

[0045] FIGS. 4 and 5 show the sheet folded in half with the bottom flaps on top, FIG. 4 having columns 108 and 106 visible and FIG. 5 having columns 104 and 102 visible.

[0046] FIG. 6 depicts the packaging in the process of being assembled from the sheet with column 102 visible after attaching the securing tab 116 to an inner surface of side 286 using, for example, an epoxy (preferably a bio-degradable epoxy).

[0047] FIG. 7A shows bottom flaps 176 and 180 being inserted into vertical notch 214 and vertical notch 250 of bottom flaps 178 and 182, forming a first half of the integrated cut cross section.

[0048] FIG. 7B shows the bottom of the packaging after inserting bottom flaps 176 and 180 from FIG. 7A, forming the second half of the integrated cut cross section (see FIG. 10) with horizontal sections 194 of bottom flap 176 and horizontal section 230 of bottom flap 180 visible.

[0049] FIG. 8 depicts the packaging after being flipped from FIG. 7 such that the top flaps are pointed up, with top flaps 120 and 118 visible.

[0050] FIG. 9 adds an 11 oz mug 300 to the scene of FIG. 8.

[0051] FIG. 10 is a top down view of the packaging from FIGS. 8 and 9 showing an example of the integrated cut cross section 302.

[0052] FIG. 11 shows the packaging from FIG. 10 after top-down placement of mug 300 on the integrated cut cross section 302, resulting in a bottom 304 of the mug being visible and handle 306 oriented toward securing tab 116.

[0053] FIG. 12 shows the packaging of FIG. 11 with the mug therein after assembling top flaps 124 and 120.

[0054] FIG. 13 shows the packaging of FIG. 12 after placement of top flaps 118 and 122, with sections 136 and 272 visible.

[0055] To create packaging from sheet 100 for an 11 oz mug (e.g., ceramic), a vertical fold is made between neighboring columns (e.g., columns 102 and 104), making three vertical folds, and the securing tab 116 is attached to an inner surface of side 286. The flaps of top row 110 will be used to form the top of the packaging, the four panels of the middle row 112 will be the four sides and the flaps of bottom row 114 will be used to form the bottom of the packaging as well as the integrated cut cross section.

[0056] After attaching securing tab 116 to an inner face of side 286, the sheet 100 is flipped over such that the bottom flaps are on top. Next, section 212 of flap 178 is folded inwardly at the boundary with section 210. Likewise, section 248 of flap 182 is folded inward at the boundary with section 246. Section 210 of flap 178 is folded inwardly at the boundary with middle row 112. Likewise, section 246 of flap 182 is folded inwardly, such that outer faces of sections 212 and 248 touch, forming half of the integrated cut cross section.

[0057] A similar process is performed for flaps 176 and 180. Section 194 of flap 176 is folded inwardly at the boundary with section 192. Likewise, section 230 of flap 180 is folded inwardly at the boundary with section 228. Next, section 192 of flap 176 is folded inwardly at the boundary with middle row 112. Likewise, section 246 of flap 182 is folded inwardly at the boundary with middle row 112, such that outer faces of sections 194 and 230 touch, forming the second half of the integrated cut cross section. It will be understood that the two halves of the integrated cut cross section need not be of equal length, depending on the particular breakable print product.

[0058] Flipping the packaging back upright, a standard 11 oz mug with handle (e.g., see FIGS. 9 and 11) is placed top down, as shown best in FIGS. 10 and 11, onto the integrated cut cross section with a handle of the mug positioned towards a corner nearest securing tab 116. Next, the top of the packaging is formed with top flaps 118, 120, 122 and 124. Section 148 of flap 120 and section 170 of flap 124 are folded inwardly, followed by folding inwardly section 150 of flap 120 and section 168 of flap 124. Next, section 152 of flap 120 and section 166 of flap 124 are folded inwardly at their respective boundaries with middle row 112, such that notches 154 and 172 can accommodate insertion of flaps 118 and 122. More specifically, section 134 of flap 118 and section 270 of flap 122 are folded inwardly at their respective boundaries with sections 136 and 272. The packaging is then completed by folding sections 136 and 272 inwardly at their respective boundaries with middle row 112, such that section 134 of flap 118 and section 270 of flap 122 are inserted through notches 154 and 172.

[0059] In one embodiment, the process to assemble the packaging for a 15 oz mug (e.g., ceramic), which is taller than the 11 oz mug, is the same for the bottom flaps. To accommodate the taller height, flap 124 is folded inwardly at its respective section boundaries and the boundary with middle row 112, such that the top edge of section 170 touches the side to which flap 124 is attached. The remainder of the top flaps are only folded at their respective boundaries with middle section 112. To clarify, flap 120 is folded inward first, then flaps 118 and 122 are folded on top of flap 120 in any order, i.e., flap 118, then flap 122 or flap 122 is first, followed by flap 118.

[0060] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms a, an, and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprise (and any form of comprise, such as comprises and comprising), have (and any form of have, such as has and having), include (and any form of include, such as includes and including), and contain (and any form of contain, such as contains and containing) are open-ended linking verbs. As a result, a method or device that comprises, has, includes, or contains one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of a device that comprises, has, includes, or contains one or more features possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a device or structure that is configured in a certain way is configured in at least that way, but may also be configured in ways that are not listed.

[0061] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below, if any, are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description set forth herein has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of one or more aspects set forth herein and the practical application, and to enable others of ordinary skill in the art to understand one or more aspects as described herein for various embodiments with various modifications as are suited to the particular use contemplated.