Reconfigurable Packaging Material and Packages

Abstract

Packaging materials are disclosed which are reconfigurable into two different shipping configurations: one for bulk shipment of electronic products, and one for individual shipment of the same electronic products.

1 . Method comprising:
 receiving a plurality of electronic products packaged for bulk shipment in which a plurality of configurable bodies of energy absorbing foam material are disposed as caps in pairs each engaging a corresponding one electronic product, the pairs of bodies and corresponding electronic products being interleaved with others of like electronic products;   unpacking the electronic products;   reconfiguring a single pair of the configurable bodies to engage a single one of the electronic products as a pair of caps and to provide three dimensional projecting portions which cushion the engaged electronic product against shock loads; and   packaging the engaged single electronic product and reconfigured bodies for shipment to an end user.   
   
   
       2 . Method according to  claim 1  wherein the reconfiguring of each body comprises folding the body about fold lines formed therein. 
   
   
       3 . Method according to  claim 1  wherein the reconfiguring of each body comprises removing a portion of each body by separating the body along tear lines formed therein. 
   
   
       4 . Method according to  claim 1  wherein said electronic product has a rectilinear configuration in elevation and plan and has a width dimension which is a fraction of the height and length dimensions thereof. 
   
   
       5 . Method according to  claim 1  further comprising assembling each configurable body as a plurality of layers of energy absorbing foam material, a central layer having smaller dimensions than outer layers to form with the outer layers a pocket for receiving an engaged electronic product and further wherein the outer layers of the body have fold lines formed therein enabling reconfiguration of the body from bulk packaging configuration to single unit packaging configuration. 
   
   
       6 . Method comprising:
 disposing a plurality of configurable bodies of energy absorbing foam material as top and bottom caps in pairs each engaging a corresponding one server blade, the pairs of bodies and corresponding electronic products being interleaved with a plurality of server blades packaged for bulk shipment;   unpacking the server blades;   reconfiguring a single pair of the configurable bodies to engage a single one of the server blades as a pair of side caps and to provide three dimensional projecting portions which cushion the engaged server blade against shock loads; and   packaging the engaged single server blade and reconfigured bodies for shipment to an end user.   
   
   
       7 . Method according to  claim 6  further comprising assembling each configurable body as a plurality of layers of energy absorbing foam material, a central layer having smaller dimensions than outer layers to form with the outer layers and in both configurations a pocket for receiving an engaged server blade and further wherein the outer layers of the body have fold lines formed therein enabling reconfiguration of the body from bulk packaging configuration to single unit packaging configuration. 
   
   
       8 . Apparatus comprising:
 a configurable body of energy absorbing foam material used as protective packaging for electronic components and having lines scored therein;   said body being configurable into a first packaging configuration with a like companion body as one of a pair of caps engaging an electronic product and interleaved among a plurality of similarly capped electronic products packaged for bulk shipment; and   said body being reconfigurable by manipulation along the scored lines into a second packaging configuration with a like companion body as one of a pair of caps engaging an electronic product and providing three dimensional projecting portions which cushion against shock loads when the engaged electronic product and the reconfigured body are packaged as a single unit for shipment to an end user.   
   
   
       9 . Apparatus according to  claim 8  wherein said body is composed of a plurality of layers of energy absorbing foam material, a central layer having smaller dimensions than outer layers and defining with the outer layers a pocket receiving an engaged electronic product and further wherein said outer layers have fold lines formed therein for pivoting portions thereof between bulk packaging configuration and single unit packaging configuration. 
   
   
       10 . Apparatus according to  claim 9  wherein said central layer is sandwiched between two outer layers and further wherein, when disposed in the bulk packaging configuration, the body is three layers thick and, when disposed in the single unit packaging configuration, the body is five layers thick. 
   
   
       11 . Apparatus according to  claim 9  wherein said outer layers are configured with a plurality of reliefs regulating the energy absorption characteristics of the body and the shock cushioning effectiveness thereof. 
   
   
       12 . Apparatus according to  claim 8  wherein said body is composed of a plurality of layers of energy absorbing foam material, a central layer having smaller dimensions than outer layers and defining with the outer layers a pocket receiving an engaged electronic product and further wherein said outer layers have tear lines formed therein for removing portions thereof between bulk packaging configuration and single unit packaging configuration. 
   
   
       13 . Apparatus comprising:
 a carton;   a server blade disposed within said carton; and   a pair of reconfigured bodies of energy absorbing foam material engaging said blade and said carton and cushioning said blade against shock loads possibly exerted on said carton during shipment, said bodies having been reconfigured from a first condition into an arrangement having three dimensional portions interposed between said blade and an inner wall of said carton by folding along fold lines scored in the material of said sheet.   
   
   
       14 . Apparatus comprising:
 a carton;   a plurality of server blades disposed within said carton; and   a plurality of pairs of reconfigurable bodies of energy absorbing foam material, each pair engaging a corresponding one of said blades and said carton and cushioning said corresponding blade against shock loads possibly exerted on said carton during shipment, said plurality of server blades and pairs of bodies being interleaved one with another within said carton.