Foam Buffer Device for Packaging

Abstract

A packaging apparatus comprising a foam buffer that provides protection of a computer system component during transit, provides ease of use during pre-packing and packing of the component for transport, does not require the need for additional packing components in combination with the packaging assembly, provides shock and vibration protection during transport, and the foam buffer is configured for ease of manufacture, for reduced manufacturing time and for reduced cost. The foam buffer comprises a foam block formed at least in part from a nonplanar foam extrusion to protect the computer system components during transport. A component socket is provided in the foam block for the reception of the component, and the geometry of the foam surrounding the received computer is configured to provide protection and for ease of manufacture. An exterior of the foam block comprises alternating bands of curvilinear ribs and grooves to provide the desired buffering and shock characteristics, and to reduce manufacturing time by promoting air or gas passage from the foam. Alternate embodiments of the nonplanar foam extrusion can comprise a “U” and an “L” shaped foam extrusion, and the foam block can be assembled from a single continuous piece of a foam extrusion or an assembly of multiple extrusions.

1 . A foam buffer device for protecting a computer system component during transport, the foam buffer device comprising:
 a foam block configured to protect the computer system component, the foam block comprising:
 a socket extending into a top of the foam block and configured to engage an end of the computer system component inserted within, the socket having at least one wall extending vertically into the block from the top with a horizontal floor at right angles to a bottom of the at least one vertical wall; and 
 at least one bumper extending outwardly away from the foam block to prevent the computer component from directly contacting a surface other than the at least one vertical wall and the floor of the socket, and 
 a nonplanar foam extrusion having a length and a first end and a second end, the nonplanar foam extrusion comprising at least a portion of the foam block and in contact with at least a portion of the computer system component. 
   
   
   
       2 . The foam buffer device of  claim 1  wherein the foam extrusion is “U” shaped in cross section, and further comprises a second vertical wall extending from the floor parallel to the first vertical wall with an inner slot therebetween, the inner slot extending along the length of the “U” shaped nonplanar foam extrusion to comprise at least a portion of the socket. 
   
   
       3 . The foam buffer device of  claim 2  wherein the foam buffer device further comprises an end piece attached to each end of the “U” shaped nonplanar foam extrusion, wherein each attached end piece is an end portion of the socket. 
   
   
       4 . The foam buffer device of  claim 2  wherein the “U” shaped nonplanar foam extrusion has end portions configured to be folded such that the floor of the folded end portions define ends of the socket. 
   
   
       5 . The foam buffer device of  claim 4  wherein the foldable end portions of the “U” shaped nonplanar foam extrusion are configured to fold at a “V” notch adjacent to each end of the foam extrusion, wherein the “V” notch extends downwardly at each end of the “U” shaped nonplanar foam extrusion with the widest portion of the “V” notch at the top of the least one foam block. 
   
   
       6 . The foam buffer device of  claim 4  wherein the end portions of the “U” shaped nonplanar foam extrusion have hinges at a sharp of the “V” and the hinges are at the external corners of the folded ends. 
   
   
       7 . The foam buffer device of  claim 1  wherein the nonplanar foam extrusion is “L” shaped in cross section and is configured to fold into a rectangular shaped foam block with the socket extending downwardly therein, the at least one wall forming a vertical perimeter around the rectangular shaped foam block and the floor extending horizontally inward from a bottom of the at least one wall. 
   
   
       8 . The foam buffer device of  claim 7  wherein the “L” shaped nonplanar foam extrusion has a rectangular opening extending therethrough surrounded by the inwardly extending floor. 
   
   
       9 . The foam buffer device of  claim 7  wherein the “L” shaped nonplanar foam extrusion is configured to fold into the a rectangular shaped foam block along a of a plurality of “V” notches cut into the “L” shaped nonplanar foam extrusion. 
   
   
       10 . The foam buffer device of  claim 7  wherein at least the first end and the second end of the L″ shaped nonplanar foam extrusion are secured together 
   
   
       11 . The foam buffer device of  claim 1  wherein the at least one bumper extends outwardly from the extrusion along the length thereof. 
   
   
       12 . The foam buffer device of  claim 1  wherein the at least one bumper has an arcuate surface. 
   
   
       13 . The foam buffer device of  claim 1  wherein the at least one bumper is configured progressive rate geometry wherein the at least one foam bumper becomes stiffer the more it is are deflected. 
   
   
       14 . The foam buffer device of  claim 1  wherein the at least one bumper extends outwardly from the at least one vertical wall to form a perimeter around the rectangular shaped foam block. 
   
   
       15 . The foam buffer device of  claim 1  wherein the at least one bumper extends downwardly from the at least one horizontal floor. 
   
   
       16 . The foam buffer device of  claim 1  wherein the at least one bumper extends downwardly and outwardly from an intersection of the at least one vertical wall and the horizontal floor. 
   
   
       17 . The foam buffer device of  claim 1  wherein the foam extrusion further comprises at least one gas outlet feature to encourage the passage of gas from the foam during extrusion. 
   
   
       18 . A foam buffer device for protecting a computer system component during transport, the foam buffer device comprising: a nonplanar foam extrusion having at least one vertical wall and at least one horizontal wall extending at a right angle to a bottom of the vertical wall, the nonplanar foam extrusion foldably configured to form a socket from the least one vertical wall and at least one horizontal wall, the socket sized for the reception of a computer system component within, 
   
   
       19 . The foam buffer device of  claim 1  wherein the nonplanar extrusion has an “L” shaped profile formed from the least one vertical wall and at least one horizontal wall, and the “L” shaped nonplanar foam extrusion is folded with the vertical wall forming an outer rectangular perimeter with the horizontal wall extending inwardly from a bottom of the vertical wall. 
   
   
       20 . The foam buffer device of  claim 1  wherein the nonplanar extrusion has a second vertical wall extending upwardly from the to define a “U” shaped extrusion with the vertical wall and the horizontal wall, and the “U” shaped extrusion is foldably configured to fold upwardly at each end to define a socket therebetween