Suspension / retention packaging

Abstract

An improved suspension package system in which one or more suspension frames are used to suspend an article within a shipping container, wherein the suspension frame includes a suspension mechanism formed by a plurality of generally concentric cuts forming a plurality of suspension channel members, each cut being interrupted by one or more nicks. The nicks conjoin adjacent channel members, and conjoin an innermost channel member to an optional article platform, and conjoin an outermost channel member to an optional perimeter portion. Sidewalls give the suspension frame a 3-D shape and provide suspension clearance. The article can be sandwiched between two opposing suspension frames. The suspension frame can be formed as a monolithic piece of corrugated containerboard. Forming the suspension of corrugated containerboard improves the recyclability of the product, and reduces its manufacturing cost by eliminating the need for purchasing and assembling a plastic suspension sheet. The frame can also be configured as a retention frame.

1 . An apparatus comprising:
 a first suspension frame including,
 an article platform portion, 
 a perimeter portion, 
 a sidewall portion coupled to the perimeter portion to provide suspension clearance, and 
 a suspension portion coupling the article platform portion to the perimeter portion, 
   wherein the suspension portion includes a plurality of channels separated by a plurality of cuts, the cuts being interrupted by nicks.   
     
     
         2 . The apparatus of  claim 1  wherein:
 the suspension frame is constructed as a monolithic whole. 
 
     
     
         3 . The apparatus of  claim 2  wherein:
 the suspension frame is constructed of corrugated containerboard. 
 
     
     
         4 . The apparatus of  claim 1  further comprising:
 a box; and 
 a second suspension frame; 
 wherein the first and second suspension frames are disposed within the box so as to have their perimeter portions substantially abutting one another. 
 
     
     
         5 . A suspension frame for suspending an article within a shipping container, the suspension frame comprising:
 a suspension portion including a plurality of channels separated by a plurality of cuts, each cut being interrupted by a plurality of nicks, wherein the cuts enable the suspension portion to flex in a first direction; and   a sidewall portion coupled to the suspension portion and having a dimension in the first direction providing clearance for movement of the suspension portion.   
     
     
         6 . The suspension frame of  claim 5  further comprising:
 a perimeter portion coupling the suspension portion to the sidewall portion. 
 
     
     
         7 . The suspension frame of  claim 5  wherein:
 the sidewall portion comprises four sidewalls arranged in a generally rectilinear configuration about the suspension portion. 
 
     
     
         8 . The suspension frame of  claim 5  further comprising:
 an article platform portion disposed substantially at a center of the suspension portion. 
 
     
     
         9 . The suspension frame of  claim 8  wherein the article platform portion comprises:
 a void providing a perimeter for engaging the article. 
 
     
     
         10 . The suspension frame of  claim 8  wherein:
 the plurality of nicks are arranged in a regular pattern. 
 
     
     
         11 . A product produced by the process comprising:
 cutting a suspension frame from a sheet of material;   providing the suspension frame with a suspension portion having a plurality of cuts disposed about a location, each cut being interrupted by at least one nick, such that a plurality of suspension channels are formed, with adjacent suspension channels being conjoined by at least one nick; and   providing the suspension frame with means for facilitating subsequently folding the suspension frame into a 3-D configuration.   
     
     
         12 . The product by process of  claim 11  wherein the process further comprises:
 folding the suspension frame into the 3-D configuration. 
 
     
     
         13 . The product by process of  claim 11  wherein providing the means for facilitating subsequently folding comprises:
 providing the suspension frame with a perimeter portion adjacent to and conjoined with an outer perimeter of the suspension portion; and 
 providing the suspension frame with a plurality of sidewall portions adjacent to and conjoined with the perimeter portion. 
 
     
     
         14 . The product by process of  claim 13  wherein the process further comprises:
 providing the suspension frame with an article platform portion disposed within the suspension portion. 
 
     
     
         15 . The product by process of  claim 13  wherein the process further comprises:
 folding the suspension frame into the 3-D configuration by folding the sidewall portions to angles between 40 degrees and 140 degrees of perpendicular to the perimeter portion. 
 
     
     
         16 . An apparatus comprising:
 a corrugated containerboard box; and, disposed within the corrugated containerboard box,   a first suspension frame adjacent a bottom inner surface of the corrugated containerboard box; and   a second suspension frame adjacent a top inner surface of the corrugated containerboard box;   wherein each suspension frame comprises,
 a plurality of sidewalls having a vertical height providing suspension clearance, 
 a suspension portion coupled to the sidewalls so as to be dimensionally removed from the corrugated containerboard box by the vertical height of the sidewalls; 
   wherein the suspension portions of the first and second suspension frames provide suspension for an article placed therebetween.   
     
     
         17 . The apparatus of  claim 16  comprising:
 the article placed between the suspension portions of the first and second suspension frames. 
 
     
     
         18 . The apparatus of  claim 16  further comprising:
 a plurality of additional suspension frames disposed within the corrugated containerboard box.