PACKAGING BLANKS AND ASSEMBLIES WITH INTEGRATED SUSPENSION SLEEVE

Abstract

A packaging assembly may include: a bottom portion comprising a bottom surface and a plurality of sidewalls extending upwardly from the bottom surface, wherein the plurality of sidewalls and the bottom surface define a container defining an opening; a top portion foldably connected to at least one of the plurality of sidewalls for selectively covering the opening of the container; a sleeve foldably connected to at least one of the plurality of sidewalls, the sleeve defining an interior compartment for receiving an item, and the sleeve comprising at least one suspension tab, wherein the sleeve is foldable between: a deployed position and a stowed position; and at least one support tab configured to provide additional support between the sleeve and the at least one of the plurality of sidewalls.

Claims

1. A packaging assembly, comprising: a bottom portion comprising a bottom surface and a plurality of sidewalls extending upwardly from the bottom surface, wherein the plurality of sidewalls and the bottom surface define a container defining an opening; a top portion foldably connected to at least one of the plurality of sidewalls for selectively covering the opening of the container; a sleeve foldably connected to at least one of the plurality of sidewalls, the sleeve defining an interior compartment for receiving an item, and the sleeve comprising at least one suspension tab, wherein the sleeve is foldable between: a deployed position in which the sleeve is positioned at least partially outside of the container; and a stowed position in which the at least one suspension tab contacts an inner surface of the container and is configured to provide a gap between at least a portion of the sleeve and the bottom surface of the container such that the sleeve is at least partially suspended within the container; and at least one support tab configured to provide additional support between the sleeve and the at least one of the plurality of sidewalls.

2. The packaging assembly of claim 1, wherein: the packaging assembly is formed of a blank comprising a single sheet of material.

3. The packaging assembly of claim 1, wherein: the at least one suspension tab is foldable between: a deployed position in which the at least one suspension tab extends away from an outer surface of the sleeve; and a stowed position in which the at least one suspension tab is generally flush with the sleeve.

4. The packaging assembly of claim 1, wherein: the at least one support tab is integral with the sleeve and extends at least partially along a fold line between the sleeve a sidewall of the plurality of sidewalls such that the at least one support tab extends over a portion of the sidewall of the plurality of sidewalls.

5. The packaging assembly of claim 1, wherein: the sleeve is foldably connected to a first sidewall of the plurality of sidewalls; and the top portion is foldably connected to a second sidewall of the plurality of sidewalls, the second sidewall opposing the first sidewall.

6. The packaging assembly of claim 1, wherein: the sleeve is foldably connected to a first sidewall of the plurality of sidewalls at a first end of the sleeve, the first end defining a fold line of the sleeve; the sleeve comprises a flap foldably connected to a second end of the sleeve, the second end opposing the first end and defining a fold line of the flap; the flap comprises the at least one suspension tab, and the at least one suspension tab extends from the fold line of the flap in an opposing direction relative to the flap; and the flap is foldable between: a deployed position in which the flap and the at least one suspension tab extend outwardly from the sleeve, the at least one suspension tab is configured to contact the bottom surface of the bottom portion and provide a gap between at least a portion of the sleeve and the bottom surface of the bottom portion, and the flap is configured to contact a second sidewall of the plurality of sidewalls, the second sidewall opposing the first sidewall; and a stowed position in which the flap and the at least one suspension tab are generally flush with the sleeve.

7. The packaging assembly of claim 1, wherein: the sleeve comprises a first wall and a second wall arranged in an overlaid configuration; respective first ends of the first wall and the second wall are foldably connected to a first sidewall of the plurality of sidewalls; respective inner surfaces of the first wall and the second wall define the interior compartment; and in the deployed position, the first wall and the second wall are separable along respective second ends of the first wall and the second wall to provide access to the interior compartment, the respective second ends opposing the respective first ends.

8. The packaging assembly of claim 7, wherein: in the stowed position, the first wall is positioned more proximate to the bottom surface of the bottom portion than the second wall; the sleeve comprises at least one support tab extending from the second end of the first wall; and the at least one support tab is configured to provide additional support between the sleeve and the first sidewall.

9. The packaging assembly of claim 8, wherein: the at least one support tab is adhesively coupled to the first sidewall.

10. The packaging assembly of claim 7, wherein: a surface of at least one of the first wall or the second wall defines an opening.

11. A blank for forming a packaging assembly, the blank comprising: a bottom panel for forming a bottom surface of the packaging assembly; a plurality of sidewall panels foldably connected to the bottom panel for forming a plurality of sidewalls of the packaging assembly; a top panel foldably connected to at least one of the plurality of sidewall panels for forming a top portion of the packaging assembly; a sleeve panel foldably connected to a first sidewall panel of the plurality of sidewall panels; at least one sleeve panel flap foldably connected to the sleeve panel, the at least one sleeve panel flap being foldable relative to the sleeve panel for forming an interior compartment for receiving an item; a suspension tab, wherein the suspension tab is foldable between: an unfolded position in which the suspension tab is generally flush with the sleeve panel; and a folded position in which the suspension tab extends outwardly from the sleeve panel; and a support tab extending from the at least one sleeve panel.

12. The blank of claim 11, wherein: the sleeve panel is foldably connected to the first sidewall panel at a first end of the sleeve panel, the first end defining a fold line of the sleeve panel; the blank further comprises a suspension flap foldably connected to a second end of the sleeve panel, the second end opposing the first end and defining a fold line of the suspension flap; the suspension flap comprises the suspension tab; the suspension tab is defined by a cut line formed in at least one of the sleeve panel or the sleeve panel flap; and the suspension flap is foldable between: an unfolded position in which the suspension flap and the suspension tab are generally flush with the sleeve panel; and a folded position in which the suspension flap and the suspension tab extend outwardly from the sleeve panel.

13. The blank of claim 12, wherein: the at least one sleeve panel flap comprises a first sleeve panel flap and a second sleeve panel flap, wherein: the first sleeve panel flap is foldably connected to a third end of the sleeve panel, the third end defining a fold line of the first sleeve panel flap; the second sleeve panel flap is foldably connected to a fourth end of the sleeve panel, the fourth end opposing the third end and defining a fold line of the second sleeve panel flap; and the first sleeve panel flap and the second sleeve panel flap are foldable relative to the sleeve panel for forming the interior compartment.

14. The blank of claim 13, wherein: at least a portion of at least one of the first sleeve panel flap or the second sleeve panel flap comprises an adhesive layer for adhesively coupling the first sleeve panel flap with the second sleeve panel flap and forming the interior compartment.

15. The blank of claim 11, wherein: the support tab is integral with the at least one sleeve panel and at least a portion of the support tab comprises an adhesive layer.

16. The blank of claim 11, wherein: the sleeve panel is foldably connected to the first sidewall panel at a first end of the sleeve panel, the first end defining a fold line of the sleeve panel; the blank further comprises a suspension flap foldably connected to a second end of the sleeve panel, the second end opposing the first end and defining a fold line of the suspension flap; the suspension flap comprises the suspension tab; the at least one sleeve panel flap comprises a first sleeve panel flap and a second sleeve panel flap, wherein: the first sleeve panel flap is foldably connected to a third end of the sleeve panel, the third end defining a fold line of the first sleeve panel flap; and the second sleeve panel flap is foldably connected to a fourth end of the sleeve panel, the fourth end opposing the third end and defining a fold line of the second sleeve panel flap; the first sleeve panel flap and the second sleeve panel flap each comprise a support tab extending outwardly therefrom; and at least a portion of the support tab of the first sleeve panel flap and the second sleeve panel flap comprises an adhesive layer for adhesively coupling each support tab to the first sidewall panel.

17. The blank of claim 11, wherein: the sleeve panel comprises an opening defined by at least one cut line formed in the sleeve panel.

18. The blank of claim 11, wherein: the blank comprises a length of between about 30 inches and about 60 inches, a width of between about 20 inches and about 40 inches, and a thickness of about 0.05 inches to about 0.15 inches.

19. The blank of claim 11, wherein: the sleeve panel comprises a length of between about 5 inches and about 15 inches, and a width of between about 5 inches and about 20 inches.

20. The blank of claim 11, wherein: the blank comprises a sheet of cardboard.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] A further understanding of the nature and advantages of the disclosed technology may be realized by reference to the remaining portions of the specification and the drawings.

[0026] FIG. 1 depicts a packaging assembly in an erected orientation, according to some embodiments of the present invention.

[0027] FIGS. 2 depicts a packaging blank which may be erected to form a packaging assembly, according to some embodiments of the present invention.

[0028] FIGS. 3A-H depict steps of erecting the packaging blank of FIG. 2 into a packaging assembly, according to some embodiments of the present invention.

[0029] FIG. 4 depicts a blank for forming a packaging assembly, according to some embodiments of the present invention.

DETAILED DESCRIPTION

[0030] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

[0031] Embodiments of the present invention are directed to packaging blanks and packaging assemblies with one or more features for securing and protecting one or more items during shipment. For example, the packaging assemblies may include a sleeve foldably connected to the packaging assembly. The sleeve may be configured to receive and secure an item, and may reduce the risk of damage caused by movement of the item within the package during transit. The sleeve may be foldable between a deployed position and a stowed position. In the deployed position, the sleeve may be positioned at least partially outside of the container of the packaging assembly, allowing a user to insert the item within the sleeve. The sleeve may then be folded in the stowed position, in which the sleeve may be at least partially suspended within the container. This suspended state may protect the item by preventing direct contact with the inner surfaces of the container, thereby isolating the item from external impacts and vibrations. This may also eliminate the need for traditional cushioning materials, such as plastic air cushions or packing peanuts, which can otherwise increase cost, inefficiency, and environmental impact. To facilitate the suspended state, the sleeve may include at least one suspension tab, which may contact an inner surface of the container and maintain a gap between at least a portion of the sleeve and the inner surface of the container. Furthermore, the packaging assemblies may be erected from a packaging blank, such as a single packaging blank, which may facilitate assembly and reduce costs. The packaging blank may be erected from a lay flat configuration to an erected configuration (for receiving an item) via folding, gluing, and/or other securing steps.

[0032] FIG. 1 depicts a packaging assembly 100 in an erected or assembled orientation, according to some embodiments of the present invention. The packaging assembly 100 may include a bottom portion 102 and a top portion 106, and a sleeve 108. The bottom portion 102 may include a bottom surface 112 and a plurality of sidewalls 104a-d. The bottom surface 112 and the plurality of sidewalls 104a-d may together define a container 110. As will be made apparent by the following disclosure, the sleeve 108 may be configured to receive and secure an item when the sleeve 108 is in a deployed position (shown in FIG. 1), and the sleeve 108 may be at least partially suspended within the container 110 of the packaging assembly 100 when the sleeve 108 is in the stowed position (shown in FIG. 3F). This may reduce the risk of damage caused by movement of the item within the packaging assembly 100 during transit. The item may be any suitable item including but not limited to items prone to damage caused by movement within the packaging assembly 100 during transit, such as electronic devices, books, magazines, or other items.

[0033] As shown in FIG. 1, the bottom portion 102 may include the bottom surface 112 and four sidewalls 104a-d extending upwardly from respective ends of the bottom surface 112 to define the container 110. The container 110 may be sized and shaped to receive one or more additional components of the packaging assembly 100, such as the sleeve 108. While the bottom surface 112 and the sidewalls 104a-d are generally rectangular in shape and thereby define a generally rectangular shaped container 110, it should be appreciated that the number, shape, and arrangement of sidewall(s) 104a-d and/or bottom surface(s) 112 may depend on the desired size and shape of the container 110 and the packaging assembly 100, and such variations are contemplated within the scope of the present invention. For example, in some embodiments, the bottom surface 112 may be square-shaped, triangular, hexagonal, another polygonal shape, or other suitable shape, and the number, shape (including height) and arrangement of sidewalls 104a-d may be arranged to correspond to the size and shape of the bottom surface 112 and the desired size and shape of the container 110.

[0034] The top portion 106 may be foldably connected to at least one of the plurality of sidewalls 104a-d. This may allow the top portion 106 to cover an opening defined by the container 110 and thus facilitate closing of the packaging assembly 100 (shown in FIGS. 3H). As shown in FIG. 1, the top portion 106 is foldably coupled to sidewall 104b along a fold line 126 of the top portion 106. The top portion 106 is also arranged such that the top portion 106 and the sleeve 108 are foldably coupled to opposing sidewalls 104a-b. This may provide certain benefits, such as ease of designing, cutting, and assembly and/or ease of folding and unfolding the packaging assembly 100. However, it should be appreciated that the top portion 106 and/or the sleeve 108 may be arranged in a variety of different ways depending on the desired functionality and shape of the packaging assembly 100, and such variations are contemplated within the scope of the present invention.

[0035] The sleeve 108 may be foldably connected to at least one of the plurality of sidewalls 104. This may allow the sleeve 108 to be foldable between a deployed position (shown in FIG. 1) and a stowed position (shown in FIG. 3F). As shown in FIG. 1, the sleeve 108 is foldably coupled to sidewall 104a along a fold line 128. The sleeve 108 is also arranged such that the sleeve 108 and the top portion 106 are foldably coupled to opposing sidewalls 104a-b. However, as previously noted, the sleeve 108 and/or the top portion 106 may be arranged in a variety of different ways depending on the desired functionality and shape of the packaging assembly 100, and such variations are contemplated within the scope of the present invention.

[0036] The sleeve 108 may define an interior compartment 114 for receiving an item. For example, as shown in FIG. 1, the sleeve 108 may include a first wall 116 and a second wall 118 arranged in an overlaid configuration such that respective inner surfaces of the first wall 116 and the second wall 118 define the interior compartment 114. A respective end of the first wall 116 and the second wall 118 may be foldably connected to the sidewall 104a, and an opposing respective end of the first wall 116 and the second wall 118 may define an opening to provide access to the interior compartment 114. When the sleeve 108 is empty, respective inner surfaces of the first wall 116 and the second wall 118 may be in contact but are separable, allowing them to be separated to create the interior compartment 114 for sliding an item into the sleeve 108 through the opening. This may allow the item to be inserted and secured within the sleeve 108, which may reduce the risk of damage caused by movement of the item within the package during transit.

[0037] The sleeve 108 may be foldable between a deployed position (shown in FIG. 1) and a stowed position (shown in FIG. 3F) by rotating the sleeve 108 about the fold line 128. As shown in FIG. 1, when the sleeve 108 is in the deployed position, the sleeve 108 extends outwardly away from an inner region of the container 110 of the packaging assembly 100. This may allow a user to access an opening in the sleeve 108 between the first wall 116 and the second wall 118 and insert an item into the inner region or interior compartment 114 of the sleeve 108 through the opening, thus positioning the item within the sleeve 108. The sleeve 108 may then be folded in the stowed position and the packaging assembly 100 may be closed, as detailed further below with reference to FIGS. 3A-H.

[0038] When the sleeve 108 is in the stowed position, the sleeve 108 may be at least partially suspended within the container 110. This may protect the item by preventing or limiting direct contact with one or more inner surfaces of the container 110 (e.g., bottom surface 112), thereby isolating the item from external impacts and vibrations. To facilitate the suspended state when the sleeve 108 is in the stowed position, the sleeve 108 may include one or more suspension tabs 120, which may be configured to contact an inner surface of the container 110 (e.g., bottom surface 112) and provide a gap between at least a portion of the sleeve 108 and the inner surface of the container 110 (e.g., bottom surface 112).

[0039] For example, as shown in FIG. 1, the sleeve 108 includes two suspension tabs 120 located at an end of the sleeve 108 opposing the fold line 128. However, it should be appreciated that the number and/or arrangement of the suspension tabs 120 may vary depending on the desired functionality and/or shape of the packaging assembly 100, and such variations are contemplated within the scope of the present invention. Thus, for example, the sleeve 108 may include only one suspension tab 120 or more than two suspension tabs 120, and the one or more suspension tabs 120 may be arranged anywhere on the sleeve 108, depending on the desired functionality and/or shape of the packaging assembly 100. In some embodiments, the one or more suspension tabs 120 may extend from another portion of the packaging assembly 100, for example from a side wall or the bottom surface 112, while similarly prevent the sleeve 108 from being in contact with the inner surface of the container 110 (e.g. bottom surface 112).

[0040] The suspension tabs 120 may be foldable between a deployed position (shown in FIGS. 1 and 2F) and a stowed position (shown in FIG. 3F). As shown in FIG. 1, when the suspension tabs 120 are in the deployed position, the suspension tabs 120 extend away from an outer surface of the sleeve 108. This may allow the suspension tabs 120 to contact the bottom surface 112 of the container 110 when the sleeve 108 is folded in the stowed position, thereby providing a gap between at least a portion of the sleeve 108 and the bottom surface 112 and at least partially suspending the sleeve 108 within the container 110. However, it should be appreciated that the suspension tab(s) 120 may be configured to contact one or more other inner surfaces of the container 110, depending on the shape and arrangement of the suspension tab(s) 120, the sleeve 108, flap 122, and/or the packaging assembly 100. When the suspension tabs 120 are in the stowed position, the suspension tabs 120 may be generally flush with the sleeve 108.

[0041] The sleeve 108 may further include a flap 122 foldably connected at an end of the sleeve 108 opposing the fold line 128 of the sleeve 108, with the end defining a fold line 130 of the flap 122. The flap 122 may include the suspension tabs 120, and the suspension tabs 120 may extend from the fold line 130 of the flap 122 in an opposing direction relative to the flap 122. The flap 122 may be foldable between a deployed position (shown in FIGS. 1 and 2F) and a stowed position (shown in FIG. 3F). Thus, as shown in FIG. 1, when the flap 122 is in the deployed position, the flap 122 and the suspension tabs 120 extend outwardly from the sleeve 108. This may allow the suspension tabs 120 to contact the bottom surface 112 of the container 110 when the sleeve 108 is stowed in the stowed position, thereby providing a gap between at least a portion of the sleeve 108 and the bottom surface 112 and at least partially suspending the sleeve 108 within the container 110. Additionally, this may allow the flap 122 to contact the sidewall 104b when the sleeve 108 is stowed in the stowed position, which may utilize friction and/or exert a compressive force against the sidewall 104b to secure the sleeve 108 within the container 110. When the flap 122 is in the stowed position, the flap 122 and the extension tabs may be generally flush with the sleeve 108.

[0042] The sleeve 108 may include one or more support tabs (e.g., support tabs 218a-b shown and discussed in connection in FIGS. 2 and 3A). For example, as shown in FIG. 3A, the support tabs 218a-b may provide additional support between the sleeve and the one or more sidewalls that the sleeve is foldably connected with (e.g., sidewall 204a). Each support tab 218a-b may be integral with a respective sleeve panel flap 210a-b, or may be formed from a separate piece of material that is coupleable (e.g. adhered to) one or more of the sleeve panel flaps 210-b or sleeve panel 208. In some embodiments, the support tabs 218a-b may be defined in part by cut lines 252a-b along the sleeve panel flaps 210a-b. The support tabs 218a-b may extend from the respective sleeve panel flaps 210a-b such that the support tabs 218a-b extend over at least a portion of the sidewall 204a, and thus at least a portion of the fold line 212 between the sleeve (i.e., sleeve panel 208, the sleeve panel flaps 210a-b, and suspension flap 232) and the sidewall 204a. The support tabs 218a-b may therefore be configured to provide additional structural support along, and above and below the fold line 212 between the sidewall 204a and the sleeve. For instance, the support tabs 218a-b may provide structural support to reduce tearing along the fold line 218, reduce buckling or folding of the sidewall 204a, reduce separation between the sleeve and the sidewall 204a, and/or otherwise improve the structural stability of the sidewall 204a and the sleeve and thereby improve the function of the packaging assembly. However, it should be appreciated that the number and arrangement of support tab(s) (e.g., support tabs 218a-b) may vary depending on the arrangement of the sleeve 108 and/or the desired functionality of the packaging assembly 100, and such variations are contemplated within the scope of the present invention. Additionally, as will be described in more detail, the support tab(s) may be adhesively coupled to the sleeve 108 and/or the one or more sidewalls that the sleeve is foldably connected with (e.g., sidewall 104a). However, the support tab(s) may also be integral with the sleeve 108 and/or the one or more sidewalls, and may include but is not limited to a reinforced thicker section of material at and above and below the fold line 128 of the sleeve 108.

[0043] The sleeve 108 may include one or more openings (e.g., opening 124) for providing visual access to an item within the sleeve 108. The opening 124 may provide certain benefits, such as allowing a user to identify an item or to confirm the presence of an item within the sleeve 108 without removing the item from the sleeve 108 or otherwise moving the sleeve 108. For example, as shown in FIG. 1., the opening 124 is defined by a cutout in the first wall 116 of the sleeve 108. This may allow the opening 124 to be visually accessible when the sleeve 108 is folded in the stowed position. However, it should be appreciated that the number and arrangement of openings may depend on the desired functionality of the packaging assembly 100, and the opening 124 (and/or other openings) may be positioned on the second wall 118 and/or other locations on the sleeve 108. Additionally, the opening 124 may be shaped and positioned on the sleeve 108 to showcase a specific feature of the item, such as a logo, branding, or a unique design element. The opening 124 may be of any shape or size suitable for this purpose and is designed to maintain the structural integrity of the sleeve while providing a clear view of the contents. For example, the opening 124 may have a variety of different shapes, including a circle (shown in FIG. 1), a square, a rectangle, a triangle, an oval, an octagon, a custom shape, or other suitable shapes. Additionally, the opening 124 may have a diameter (or other lateral dimension) from between about 2 inches and about 8 inches, including but not limited to between about 2 inches to about 4 inches, between about 3 inches to about 5 inches, between about 4 inches to about 6 inches, between about 5 inches to about 7 inches, or between about 6 inches to about 8 inches.

[0044] The overall dimensions of the packaging assembly 100 may vary depending on the type of item to be secured and shipped within the packaging assembly 100. For example, the packaging assembly 100 may have a width of between about 5 inches and about 30 inches, including but not limited to between about 5 inches to 10 inches, between about 10 inches to 20 inches, between about 15 inches to 25 inches, or between about 20 inches to 30 inches. The packaging assembly 100 may have a depth of between about 5 inches and about 30 inches, including but not limited to between about 5 inches to 10 inches, between about 10 inches to 20 inches, between about 15 inches to 25 inches, or between about 20 inches to 30 inches. The packaging assembly 100 may have a height of between about 1 inch and about 10 inches, including but not limited to between about 1 inch to 3 inches, between about 3 inches to 6 inches, between about 4 inches to 8 inches, or between about 5 inches to 10 inches. However, such dimensions are merely intended to illustrate one example, and other dimensions of the packaging assembly 100 are contemplated within the scope of the present invention.

[0045] As will be made apparent by the following disclosure, the packaging assembly 100 may be formed of a single blank. The blank may be formed from a single sheet of material, which may include any suitable material for use in product packaging, including but not limited to a cardboard sheet, a paperboard sheet, a plastic sheet, sheets made of hybrid materials, or other suitable sheets. For example, in some embodiments, the packaging assembly 100 may be formed of a single sheet of cardboard. The single sheet of cardboard may be any suitable type of cardboard, including but not limited to corrugated cardboard having a burst strength of from about 200 #to about 350 #, and may have one or more flute types including but not limited to E-flute, B-flute, C-flute, or A-flute.

[0046] FIG. 2 depicts a single flat packaging blank 200 that may be erected or assembled into a packaging assembly (for example but not limited to the packaging assembly 100 depicted in FIG. 1), according to some embodiments of the present invention. The blank 200 may include any suitable material for use in product packaging, including those previously discussed. As will be made apparent by the following disclosure, the blank 200 may form a packaging assembly as discussed herein, including the various configurations, embodiments, and forms previously discussed, such as the packaging assembly 100 shown and discussed in connection with FIG. 1. It should be appreciated that the blank 200, the steps of assembling a packaging assembly, and the assembled packaging assembly shown in FIGS. 3A-H is merely intended to illustrate one example. The blank 200 may be adapted or reconfigured in numerous ways to achieve the desired packaging assembly. The number, shape, and arrangement elements of the blank 200, as well as the steps involved in the assembly process, may vary depending on the specific configuration of the blank 200. Such variations are contemplated within the scope of the present invention.

[0047] In some embodiments, the packaging blank 200 may be erected via machinery, as opposed to manually, which may reduce time and costs associated with erecting the packaging blank. The packaging blank may be folded and/or glued by the machinery. The packaging blank may be secured in the erected (or assembled) position via adhesives (i.e. gluing) and/or mechanical connections (e.g., mating features, frictional engagement, and the like).

[0048] As shown in FIG. 2, the blank 200 may include a bottom panel 202, sidewall panels 204a-d, a top panel 206, a sleeve panel 208, sleeve panel flaps 210a-b, and suspension flap 232. As will be made apparent by the following disclosure, the bottom panel 202 may form a bottom surface of the packaging assembly (e.g., bottom surface 112 of FIG. 1); the sidewall panels 204a-d may form sidewalls of the packaging assembly (e.g., sidewalls 104a-d of FIG. 1); the top panel 206 may form a top portion of the packaging assembly (e.g., top portion 106 of FIG. 1); and the sleeve panel 208, the sleeve panel flaps 210a-b, and suspension flap 232 may form a sleeve of the packaging assembly (e.g., sleeve 108 of FIG. 1).

[0049] The sidewall panels 204a-b may be foldably connected to the bottom panel 202 at opposing ends of the bottom panel 202 and along fold lines 216a-b.

[0050] The sidewall panels 204c-d may be foldably connected to the bottom panel 202 along respective fold lines 216c-d of the sidewall panels 204c-d.

[0051] The top panel 206 may be foldably connected to sidewall panel 204b at an end of the top panel 206 and along fold line 250 of the top panel 206.

[0052] The sleeve panel 208 may be foldably connected to sidewall panel 204a at an end of the sleeve panel 208 and along fold line 212 of the sleeve panel 208.

[0053] The sleeve panel flaps 210a-b may be foldably connected to the sleeve panel 208 at opposing ends of the sleeve panel 208 and along respective fold lines 214a-b of the sleeve panel flaps 210a-b. The sleeve panel flaps 210a-b may include respective support tabs 218a-b, and the support tabs 218a-b may extend from the respective sleeve panel flaps 210a-b such that they overlap a portion of the sleeve panel 208, the fold line 212, and at least a portion of the sidewall 204a. The support tabs 218a-b may include respective fold lines 224a-b that are generally colinear with fold line 212 of the sleeve panel 208.

[0054] The suspension flap 232 may be foldably connected to the sleeve panel 208 and the sleeve panel flaps 210a-b along an end of the sleeve panel 208 and the sleeve panel flaps 210a-b and along fold line 234 of the suspension flap 232. The suspension flap 232 may include suspension tabs 236. The suspension flap 232 and suspension tabs 236 may extend in opposite directions relative to the fold line 234. Additionally, the suspension tabs 236 may be defined by cut lines formed in the sleeve panel 208 and/or the sleeve panel flaps 210a-b. The suspension tabs 236 formed in the sleeve panel flaps 210a-b may be sized and arranged such that they overlay with corresponding suspension tabs 236 in the sleeve panel 208 when the sleeve panel flaps 210a-b are folded inwardly about fold lines 214a-b.

[0055] The sidewall panels 204a-b may include flaps 220 foldably connected to opposing ends of each sidewall panel 204a-b, with the opposing ends defining respective fold lines 222 of the flaps 220.

[0056] The sidewall panels 204c-d may include flaps 228 foldably connected to opposing ends of each sidewall panel 204c-d, with the opposing ends defining respective fold lines 226 of the flaps 228.

[0057] The top panel 206 may include side flaps 238 foldably connected to opposing ends of the top panel 206, with the opposing ends defining respective fold lines 240 of the side flaps 238. The top panel 206 may also include a top flap 242 foldably connected to an end of the top panel 206 and along fold line 244 of the top flap 242. The top flap 242 may include side tabs 246 foldably connected to opposing ends of the top flap 242, with the opposing ends defining respective fold lines 248 of the side tabs 246.

[0058] The sleeve panel 208 may include a cutout 258 that defines an opening (e.g., opening 124 of FIG. 1) for providing visual access to an item within the sleeve of the erected or assembled packaging assembly. As previously explained, the opening formed by the cutout 258 may provide certain benefits, such as allowing a user to identify an item or to confirm the presence of an item within the sleeve without removing the item from the sleeve or otherwise moving the sleeve. It should be appreciated that while the cutout 258 is formed in the sleeve panel 208, the cutout 258 also may be formed in other locations, such as one or more of the sleeve panel flaps 210a-b.

[0059] FIGS. 3A-H depict steps of erecting the packaging blank 200 of FIG. 2 into a packaging assembly, according to some embodiments of the present invention. As shown in FIG. 3A, the sleeve panel flaps 210a-b may be folded inwardly about the respective fold lines 214a-b to form a sleeve 254 of the packaging assembly (e.g., sleeve 108 of FIG. 1). The sleeve panel flaps 210a-b may partially overlap when fully folded, and the sleeve panel flaps 210a-b may be adhesively coupled together at the overlapping portion. Further, the support tabs 218a-b may extend over a portion of the sidewall panel 204a when the sleeve panel flaps 210a-b are folded, and the support tabs 218a-b may be adhesively coupled to a portion of the sidewall panel 204a and/or the sleeve panel 208 (adhesive not shown but may be positioned in some embodiments as depicted in FIG. 4). This may provide additional support between the sleeve (e.g. sleeve 108) defined by the sleeve panel 208 and the sleeve panel flaps 210a-b and the sidewall panel 204a. In the lay flat and erected position (depicted in FIG. 2), the fold lines 224a-b of the support tabs 218a-b are generally colinear with fold line 212 between the sleeve panel 208 and the sidewall panel 204a. When the sleeve panel flaps 210a-b are folded along fold lines 214a-b as shown in FIG. 3A, the fold lines 224a-b of the support tabs 218a-b overlay and align with fold line 212 between the sleeve panel 208 and the sidewall 204a. This may allow the support tabs 218a-b to rotate, move, or fold about fold line 212 (shown in FIG. 3F), while providing support to the sleeve 254 comprising the sleeve panel flaps 210a-b. The support tabs 218a-b may also each include one or more cutouts 256a-b (shown in FIG. 3A). The cutouts 256a-b may be generally aligned with and/or at least partially pass through the fold lines 224a-b. The cutouts 256a-b may provide for ease of movement when the sleeve 254 is rotated or folded along the fold line 212. Additionally, as mentioned earlier, the suspension tabs 236 formed in the sleeve panel flaps 210a-b may be sized and arranged such that they overlay with corresponding suspension tabs 236 in the sleeve panel 208 when the sleeve panel flaps 210a-b are folded inwardly about fold lines 214a-b. This may allow the suspension tabs 236 extend toward the inner region of the container 330 when the suspension flap 232 is folded outwardly about the fold line 234 (shown in FIG. 3E).

[0060] As shown in FIG. 3B-E, the sidewall panels 204a-b may be folded inwardly about the respective fold lines 216a-b (shown in FIG. 3B); the flaps 220 may be folded inwardly about the respective fold lines 222 (shown in FIG. 3C); the sidewall panels 204c-d may be folded inwardly about the respective fold lines 216c-d (shown in FIG. 3D); and the flaps 228 may be folded inwardly about the respective fold lines 226, thus forming a container 230 of the packaging assembly (shown in FIG. 3E). To secure the flaps 228 in place, the flaps 228 may include one or more tabs 260 (shown in FIG. D) that fit into respective openings 266 (shown in FIG. 3B) formed in the bottom panel 202. However, other suitable methods may be used for securing the flaps 228 in place, including but not limited to adhesives (e.g., glue, tapes) or other suitable coupling methods.

[0061] Additionally, as shown in FIGS. 3D and 3E, the suspension flap 232 may be folded about the fold line 234 between an unfolded position and a folded position. In the unfolded position (shown in FIG. 3D), the suspension flap 232 and the suspension tabs 236 are generally flush with the formed sleeve. FIG. 3E depicts the suspension flap 232, and thereby the suspension tabs 236 in the folded position in which it has been rotated generally perpendicular to the sleeve 254. In the folded position (shown in FIG. 3E), the suspension flap 232 and the suspension tabs 236 extend outwardly from the formed sleeve 254, such that the suspension flap 232 are no longer parallel with the sleeve 254 and the suspension tabs 236, which are generally aligned and overlapping, also are no longer parallel with sleeve 254. This orientation of the suspension flap 232 may orient the suspension tabs 236 such that when the sleeve 254 is positioned in the stowed position, with the sleeve 254 folded inwardly about the fold line 212 and stowed within the container 230 (shown in FIG. 3F), the suspension tabs 236 contact the bottom panel 202. The suspension tabs 236 may thereby suspend the sleeve 254 within the container such that the sleeve is not contacting the bottom panel 202. The suspension of the sleeve 254 within the container may reduce damage to an item positioned within the sleeve 254 during shipment. For example, by reducing damage due to dropping or other movements that could otherwise damage an item that is free to move within the container or positioned adjacent or contacting the bottom panel 202. As shown in FIG. 3F, the size, shape, and orientation of the suspension flap 232 may also cause the suspension flap 232 to contact and be frictionally engaged with the sidewall panel 204b when the formed sleeve 254 is stowed within the container 230. Though FIGS. 1-3H depict a packaging assembly and a blank that has two suspension tabs 236, more or fewer suspension tabs may be used. For example, FIG. 4 depicts an embodiment in which a single suspension tab 436 is used. Some or all of the remaining features of the blank of FIG. 4 may correspond to the features described herein with respect to the embodiment of FIGS. 1-3H.

[0062] As shown in FIG. 3F, the formed sleeve 254 may be folded inwardly about the fold line 212 until suspension tabs 236 contact the bottom panel 202 and the formed sleeve 254 is stowed within the container 230. Thus, as shown in FIGS. 3E-F, the formed sleeve 254 may be articulated between the stowed and deployed position by rotating the formed sleeve 254 about the fold line 212 located between the formed sleeve and the sidewall 204a. Additionally, because the suspension flap 232 extends outwardly from the formed sleeve 254 when the suspension flap 232 is folded in the folded position (shown in FIG. 3E), the contact between the suspension flap 232 and the sidewall panel 204b may utilize friction and/or exert a compressive force against the sidewall panel 204b to aid in securing the formed sleeve 254 within the container 230. Similarly, because the suspension tabs 236 extend outwardly from the formed sleeve 254 when the suspension flap 232 is folded in the folded position (shown in FIG. 3E), the contact between the suspension tabs 236 and the bottom panel 202 may provide a gap between at least a portion of the formed sleeve 254 and bottom panel 202, thus at least partially suspending the formed sleeve 254 within the container 230. This suspended state may protect an item stored within the formed sleeve 254 by preventing direct contact with the inner surfaces of the container 330, thereby isolating the item from external impacts and vibrations during transit.

[0063] Additionally, the formed sleeve 254 may include one or more side tabs 262 along one or more sides of the formed sleeve 254 which may contact one or more sidewall panels 204a-d. For example, as shown in FIGS. 3E-F, the formed sleeve 254 has a pair of side tabs 262 located on respective sides of the formed sleeve 254 and configured to contact sidewall panels 204c-d when the formed sleeve is in the stowed position (shown in FIG. 3F). The side tabs 262 may utilize friction and/or exert a compressive force against the respective sidewall panels 204c-d, which may further secure the formed sleeve 254 within container 230. As shown in FIGS. 2-3A, the side tabs 262 may be formed by cutouts 264 formed within the respective sleeve panel flaps 210a-b, with the side tabs 262 extending from the respective fold lines 214a-b. This may allow the side tabs 262 to remain outwardly extended from the respective fold lines 214a-b when the sleeve panel flaps 210a-b are folded inwardly about the fold lines 214a-b to form the sleeve 254. However, it should be appreciated that the side tabs 262 may be formed in other ways, and may be separately attached to the sleeve panel flaps 210a-b, the sleeve panel 208, or other portion of the formed sleeve 254. Such variations are contemplated within the scope of the present invention.

[0064] Additionally, when the formed sleeve 254 is in the stowed position, the opening formed by the cutout 258 may be visible and may therefore provide visual access to an item within the formed sleeve 254. As previously explained, the opening formed by the cutout 258 may provide certain benefits, such as allowing a user to identify an item or to confirm the presence of an item within the sleeve 254 without removing the item from the sleeve 254 or otherwise moving the sleeve 254.

[0065] As shown in FIGS. 3G-H, the side flaps 238 may be folded inwardly about the respective fold lines 240, the top panel 206 may be folded inwardly about the fold line 250 to cover an opening defined by the container 230, the top flap 242 may be folded inwardly about the fold line 244, and the side tabs 246 may be folded inwardly about the respective fold lines 248. To fully close the packaging assembly (shown in FIG. 3H), the side flaps 238 may be inserted within a gap formed between at least a portion of the formed sleeve and the sidewall panels 204c-d, and the side tabs 246 may be inserted within a gap formed between the sidewall panels 204c-d the flaps 220. This may prevent the top panel 206 from opening and exposing the container 230, thus allowing the packaging assembly to remain closed during transit. The fully closed packaging assembly shown in FIG. 3H may be sealed using an adhesive, such as glue (hot melt or cold), tape, other suitable adhesive, or combination thereof (adhesive not shown but may be positioned in some embodiments as depicted in FIG. 4). Thus, a single blank (e.g., blank 200) may be folded and erected, for example using mating features of the blank and a limited amount of adhesive, to form a packaging assembly (e.g., packaging assembly 100) that provides for a sleeve suspended within a container. The single blank may be folded and glued using standard machinery as opposed to manual assembly, thereby reducing costs associated with assembly.

[0066] FIG. 4 depicts a blank 400 for forming a packaging assembly, according to some embodiments of the present invention. The blank 400 may be analogous to those previously discussed, such as the blank 200 shown and discussed in connection with FIG. 2, and may include some or all of the elements of the blank 200. For example, while the blank 400 may not include some elements as discussed in connection with FIG. 2 (e.g., side tabs 262), it should be appreciated that such elements may be included in blank 400, and other elements of blank 400 may be omitted and/or reconfigured depending on the desired packaging assembly.

[0067] As previously explained, the blank 400 may be formed from a single sheet of material, such as a cardboard sheet or other suitable sheet. For example, the blank 400 may be formed into a predefined shape, such as that shown in FIG. 4, using die-cutting methods or other suitable methods. This process may involve stamping or cutting the material with any suitable tool, such as a die that has the desired pattern for the blank 400, including the necessary panels, flaps, and tabs (e.g., suspension flap 432, suspension tabs 436). Once cut, fold lines (e.g., fold lines 416a-d) may be created on the blank 400 to allow the material to be easily folded into its final three-dimensional shape. Fold lines may be formed by scoring or creasing the material along specific locations, ensuring that the folds are precise and durable. The resulting blank 400 may then be folded and assembled into the final packaging assembly, for example, by performing the steps discussed in connection with FIGS. 3A-H.

[0068] The blank 400 may form a packaging assembly as discussed herein, including the various configurations, embodiments, and forms previously discussed, such as the packaging assembly 100 shown and discussed in connection with FIG. 1. It should be appreciated that the blank 400 shown in FIG. 4 is merely intended to illustrate one example. For reasons previously explained, the blank 400 may be adapted or reconfigured in numerous ways to achieve the desired packaging assembly, and the number, shape, and arrangement elements of the blank 400 may vary depending on the specific configuration of the blank 400. Such variations are contemplated within the scope of the present invention. For instance, while panels or other elements of the blank 400 are shown in FIG. 4 as having an elongate rectangular shape for achieving a rectangular shaped packaging assembly (e.g., shown in FIG. 3H), such elements may be reconfigured in other shapes and sizes, such as squares, circles, triangles, or other suitable shapes of varying sizes.

[0069] As shown in FIG. 4, the blank 400 may include a bottom panel 402, sidewall panels 404a-d, a top panel 406, a sleeve panel 408, sleeve panel flaps 410a-b, and suspension flap 432. As will be made apparent by the following disclosure, the bottom panel 402 may form a bottom surface of the packaging assembly (e.g., bottom surface 112 of FIG. 1); the sidewall panels 404a-d may form sidewalls of the packaging assembly (e.g., sidewalls 104a-d of FIG. 1); the top panel 406 may form a top portion of the packaging assembly (e.g., top portion 106 of FIG. 1); and the sleeve panel 408, the sleeve panel flaps 410a-b, and suspension flap 432 may form a sleeve of the packaging assembly (e.g., sleeve 108 of FIG. 1).

[0070] The sidewall panels 404a-b may be foldably connected to the bottom panel 402 at opposing ends of the bottom panel 402, with the opposing ends defining respective fold lines 416a-b of the sidewall panels 404a-b.

[0071] Sidewall panels 404c-d may be foldably connected to the bottom panel 402 at opposing ends of the bottom panel 402, with the opposing ends defining respective fold lines 416c-d of the sidewall panels 404c-d.

[0072] The top panel 406 may be foldably connected to sidewall panel 404b at an end of the top panel 406 that defines a fold line 450 of the top panel 406.

[0073] The sleeve panel 408 may be foldably connected to sidewall panel 404a at an end of the sleeve panel 408 that defines a fold line 412 of the sleeve panel 408. As previously discussed, the sleeve panel 408 may include a cutout that forms opening 430, which may provide visual access to an item within the sleeve of the packaging assembly.

[0074] The sleeve panel flaps 410a-b may be foldably connected to the sleeve panel 408 at opposing ends of the sleeve panel 408, with the opposing ends defining respective fold lines 414a-b of the sleeve panel flaps 410a-b. The sleeve panel flaps 410a-b may include respective support tabs 418a-b, and the support tabs 418a-b may extend outwardly from the respective sleeve panel flaps 410a-b. The support tabs 418a-b may include respective fold lines 424a-b that are generally colinear with fold line 412 of the sleeve panel 408.

[0075] The suspension flap 432 may be foldably connected to the sleeve panel 408 and the sleeve panel flaps 410a-b at an end of the sleeve panel 408 and the sleeve panel flaps 410a-b and along fold line 434 of the suspension flap 432. The suspension flap 432 may include suspension tabs 436. The suspension flap 432 and suspension tabs 436 may extend in opposite directions relative to the fold line 434. Additionally, the suspension tabs 436 may be defined by cut lines formed in the sleeve panel 408 and/or the sleeve panel flaps 410a-b. The suspension tabs 436 formed in the sleeve panel flaps 410a-b may be sized and arranged such that they overlay with corresponding suspension tabs 436 in the sleeve panel 408 when the sleeve panel flaps 410a-b are folded inwardly about fold lines 414a-b.

[0076] The sidewall panels 404a-b may include flaps 420 foldably connected to opposing ends of each sidewall panel 404a-b, with the opposing ends defining respective fold lines 422 of the flaps 420.

[0077] The sidewall panels 404c-d may include flaps 428 foldably connected to opposing ends of each sidewall panel 404c-d, with the opposing ends defining respective fold lines 426 of the flaps 428.

[0078] The top panel 406 may include side flaps 438 foldably connected to opposing ends of the top panel 406, with the opposing ends defining respective fold lines 440 of the side flaps 438. The top panel 406 may also include a top flap 442 foldably connected to an end of the top panel 406 and along fold line 444 of the top flap 442. The top flap 442 may include side tabs 446 foldably connected to opposing ends of the top flap 442, with the opposing ends defining respective fold lines 448 of the side tabs 446.

[0079] At least a portion of the sleeve panel flap 410a, the sleeve panel flap 410b, and/or the suspension flap 432 may include an adhesive layer 452 for adhesively coupling the panel flaps 410a-b when folded about the respective fold lines 414a-b to form the interior compartment. For example, as shown in FIG. 4, the sleeve panel flap 410b and the suspension flap 432 includes the adhesive layer 452 applied along a respective end of the sleeve panel flap 410b and the suspension flap 432 that opposes the fold line 414b. Additionally, at least a portion of the support tabs 418a-b may include an adhesive layer 454 for adhesively coupling the support tabs 418a-b to a portion of the sidewall panel 404a and/or the sleeve panel 408. For example, as shown in FIG. 4, the support tabs 418a-b include the adhesive layer 454 applied on an entire upwardly facing surface of the support tabs 418a-b. It should be appreciated that the adhesive layers 452 and 454 are merely intended to illustrate one example; the adhesive layers 452 and 454 may be applied at other locations on the sleeve panel flap 410a, the sleeve panel flap 410b, and/or the suspension flap 432 based on the design or functional requirements of the packaging assembly, and such variations are contemplated within the scope of the present invention. The adhesive layers 452 and 454 may include the same type of adhesive or may be different, and may include any suitable type of suitable adhesive, including but not limited to as glue, tape, other suitable adhesive, or combination thereof. For example, the adhesive layer 452 may include a glue and the adhesive layer 454 may include tape, or vice versa.

[0080] The dimensions of the blank 400 may vary depending on the desired shape and size of the packaging assembly, which may vary depending on the type of item to be secured and shipped within the packaging assembly. For example, the blank 400 may have a length (X) of between about 30 inches and about 60 inches, including but not limited to between about 30 inches and about 40 inches, between about 35 inches and about 50 inches, between about 40 inches and about 55 inches, or between about 50 inches and about 60 inches. The blank 400 may have a width (Y) of between about 20 inches and about 40 inches, including but not limited to between about 20 inches and about 25 inches, between about 25 inches and about 30 inches, between about 30 inches and about 35 inches, or between about 35 inches and about 40 inches. The blank 400 may have a thickness of about 0.05 inches to about 0.15 inches, including but not limited to between about 0.05 inches and about 0.08 inches, between about 0.08 inches and about 0.12 inches, or between about 0.12 inches and about 0.15 inches.

[0081] In some embodiments, the thickness of the blank 400 may depend on the type of material selected, which may have pre-determined thicknesses. For example, a blank 400 may be formed from cardboard of a pre-determined thickness, such as corrugated cardboard having a thickness ranging from about 0.1 inches to about 0.15 inches, depending on the grade (e.g., single-wall, double-wall, or triple-wall construction). It should be appreciated that the selection of material and thickness may depend on the required durability and strength of the packaging assembly, which may depend on the size, weight, and/or type of the item being shipped.

[0082] The sleeve panel 408 (and thus the formed sleeve) may have a length (X) of between about 5 inches and about 15 inches, including but not limited to between about 5 inches and about 10 inches, between about 8 inches and about 12 inches, and between about 10 inches and about 15 inches. The sleeve panel 408 (and thus the formed sleeve) may have a width (Y) of between about 5 inches and about 30 inches, including but not limited to between about 5 inches and about 15 inches, between about 10 inches and about 20 inches, and between about 15 inches and about 30 inches. However, such dimensions are merely intended to illustrate one example, and other dimensions of the blank 400 are contemplated within the scope of the present invention.

[0083] The methods, systems, and devices discussed above are examples. Some embodiments were described as processes depicted as flow diagrams or block diagrams. Although each may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process may have additional steps not included in the figure. It will be further appreciated that all testing methods described here may be based on the testing standards in use at the time of filing or those developed after filing.

[0084] Having disclosed several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the embodiments. Additionally, a number of well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present technology. Accordingly, the above description should not be taken as limiting the scope of the technology.

[0085] As used herein and in the following claims, the singular forms a, an, and the include plural references unless the context clearly dictates otherwise. Thus, for example, reference to an element includes a plurality of such elements, and reference to the aperture includes reference to one or more apertures and equivalents thereof known to those skilled in the art, and so forth.

[0086] Further, as used herein and in the following claims, the term generally is used to describe a characteristic, relationship, or condition that is broadly applicable or approximate, without requiring absolute precision or exact conformity unless explicitly stated. The term is intended to encompass reasonable variations or deviations while still reflecting the overall essence or intended scope of the described feature, structure, or relationship. For example, generally may refer to shapes, orientations, or alignments that deviate by a range of 20% from a specified description, depending on the context and functional requirements.

[0087] Further, as used herein and in the following claims, the term proximate is intended to encompass both being at a particular location and being near or in close proximity to a particular location. It should therefore be appreciated that the specific meaning of proximate may vary depending on the context of the invention, and it is not limited to an exact location unless explicitly stated. For example, proximate may refer to a location within a defined range, such as within a few millimeters, centimeters, or meters in physical distance, or within a defined percentage range of a particular parameter. By way of illustration, proximate may include being within 20% of a specified distance or measurement, depending on the application. Such ranges are provided as examples and should not be considered limiting unless explicitly stated. The scope of proximate should be understood in accordance with the principles and objectives of the invention as described herein.

[0088] Further, as used herein and in the following claims, the words comprise(s), comprising, contain(s), containing, include(s), and including are intended to specify the presence of stated features, integers, components, or operations, but they do not preclude the presence or addition of one or more other features, integers, components, operations, acts, or groups.