Packaging insert

Abstract

An insert for a crate end cap is disclosed. The insert includes a substrate having a main body portion and a foldable tab extending from an edge of the main body portion. A plurality of support members is coupled to a surface of the substrate, at least one support member being coupled to the main body portion and at least one other support member being coupled to the foldable tab. The insert is removably received within a cavity of the crate end cap and maintained therein by a frictional engagement between the insert and the walls of the crate end cap forming the cavity thereof. The insert provides cushioning for objects placed in the cavity of the crate end cap.

1 . An insert for a crate end cap comprising;
 a substrate having a main body portion and a foldable tab extending from an edge of the main body portion;   a first support member coupled to the main body portion; and   a second support member coupled to the foldable tab, the insert removably received within a cavity formed in the crate end cap and maintained therein by a frictional engagement between the insert and a wall forming the cavity of the crate end cap.   
     
     
         2 . The insert according to  claim 1 , wherein the substrate is a corrugated material having a plurality of flutes formed therein. 
     
     
         3 . The insert according to  claim 2 , wherein the flutes of the corrugated material are substantially parallel to a longitudinal axis of the first support member. 
     
     
         4 . The insert according to  claim 2 , wherein the flutes of the corrugated material are substantially perpendicular to a longitudinal axis of the second support member. 
     
     
         5 . The insert according to  claim 1 , wherein at least one of the first support member and the second support member is formed from a paperboard material. 
     
     
         6 . The insert according to  claim 1 , further comprising an adhesive disposed between the substrate and the first support member and between the substrate and the second support member. 
     
     
         7 . The insert according to  claim 1 , further comprising a plurality of the first support members. 
     
     
         8 . A crate assembly comprising:
 a first end cap having a cavity formed therein;   a second end cap having a cavity formed therein, the second end cap spaced from the first end cap;   a base having one end disposed in the cavity formed in the first end cap and an opposite end disposed in the cavity formed in the second end cap;   an insert disposed in the cavity of each of the end caps, the insert including a substrate having a main body portion and a foldable tab extending from an edge of the main body portion, a first support member coupled to the main body portion, and a second support member coupled to the foldable tab, wherein the insert is maintained within the cavity of the end cap by a frictional engagement between the insert and a wall forming the cavity of the end cap; and   at least one tension band to urge the end caps toward one another and secure the base and the object therebetween, wherein the inserts are disposed between the end caps and the object.   
     
     
         9 . The crate assembly according to  claim 8 , further comprising an object having a first end disposed in the cavity formed in the first end cap and a second end disposed in the cavity formed in the second end cap, wherein the first insert is interposed between the first end cap and the first end of the object and the second insert is interposed between the second end cap and the second end of the object. 
     
     
         10 . The crate assembly according to  claim 8 , wherein the substrate of the insert disposed in the cavity of the first end cap abuts the wall forming the cavity therein and the first support member of the insert disposed in the cavity of the second end cap abuts the wall forming the cavity therein. 
     
     
         11 . The crate assembly according to  claim 8 , wherein the substrate of the insert is a corrugated material having a plurality of flutes formed therein and at least one of the first support member and the second support member is formed from a paperboard material. 
     
     
         12 . The crate assembly according to  claim 11 , wherein the flutes of the corrugated material are substantially parallel to a longitudinal axis of the first support member and substantially perpendicular to a longitudinal axis of the second support member. 
     
     
         13 . The crate assembly according to  claim 8 , further comprising an adhesive disposed between the substrate and the first support member and between the substrate and the second support member. 
     
     
         14 . A crate assembly comprising:
 a first end cap having a wall forming a cavity therein;   a second end cap having a wall forming a cavity therein, the second end cap spaced from the first end cap;   a base having one end disposed in the cavity formed in the first end cap and an opposite end disposed in the cavity formed in the second end cap;   a first insert disposed in the cavity formed in the first end cap and a second insert disposed in the cavity formed in the second end cap, each of the inserts including a substrate having a main body portion and a foldable tab extending from an edge of the main body portion, a first support member coupled to the main body portion, and a second support member coupled to the foldable tab, wherein the substrate of the first insert abuts the wall forming the cavity of the first insert and the first support member of the second insert abuts the wall forming the cavity of the second insert;   at least one sheet of material having a first end disposed in the cavity formed in the first end cap and a second end disposed in the cavity formed in the second end cap, wherein the first insert is interposed between the first end cap and the first end of the sheet of material and the second insert is interposed between the second end cap and the second end of the sheet of material; and   at least one tension band to urge the end caps toward one another and secure the base and the sheet of material therebetween.   
     
     
         15 . The crate assembly according to  claim 14 , wherein the substrate of the insert is a corrugated material having a plurality of flutes formed therein 
     
     
         16 . The crate assembly according to  claim 15 , wherein the flutes of the corrugated material are substantially parallel to a longitudinal axis of the first support member and perpendicular to a peripheral edge of the sheet of material. 
     
     
         17 . The crate assembly according to  claim 15 , wherein the flutes of the corrugated material are substantially perpendicular to a longitudinal axis of the second support member. 
     
     
         18 . The crate assembly according to  claim 14 , wherein at least one of the first support member and the second support member is formed from a paperboard material. 
     
     
         19 . The insert according to  claim 14 , further comprising a plurality of the first support members. 
     
     
         20 . The crate assembly according to  claim 9 , further comprising an adhesive disposed between the substrate and the first support member and between the substrate and the second support member.