Field of the invention

The invention relates to a blank for forming an insert for a package. The insert is especially suitable for keeping the goods in position inside the package and/or for protecting the goods from mechanical impacts.

Technical Background

When designing an insert for a package it is often desirous to take into account a number of different design criteria. The insert should e.g. often be designed such that it makes efficient use of material, is easy to prepare for use, and provide a strong protective structure for placement in a package. It is often desirable that it is strong during handling and stable in an erected state.

It is common that inserts are made of corrugated cardboard. When corrugated cardboard is folded across the extension of the corrugations or flutes, a stable structure may be provided. To create an insert acting as a package bumper, it is common to combine a plurality of folded blanks of corrugated cardboard to make a functional insert. Packages made from cardboard are beneficial since they do not take up much space before they are erected, during for example transport.

There exist numerous attempts to address the above design criteria in connection to designing a package of cardboard material.

US 6,997,323 discloses a packaging system comprising a compressive and shock-absorbent packing insert. The insert comprises a main panel, a first end tube hingedly coupled to the main panel, a second end tube hingedly coupled to the main panel opposite the first end tube, a first side tube hingedly coupled to the main panel, the first side tube being adjacent to the first end tube and a second side tube hingedly coupled to the main panel, the second side tube being adjacent to the second end tube and opposite the first side tube wherein the first and second side tube panels and the first and second side tube panels include at least one cut-out to enhance the flexing capability of the packing insert. The bumper sections of the blank for forming the insert extends in four directions from the main panel. If the insert disclosed in US 6,997,323 would be made from a corrugated cardboard, two opposing tubes would be comparably strong since they would be folded along fold lines extending across the flutes whereas the two other opposing tubes would become comparably weak since they would be folded along fold lines extending along the flutes, thereby not making use of the material in an efficient manner.

JPH08230868 discloses a package and an insert formed by a single blank. The blank comprises four main panels, which are arranged one after the other and which are configured to form the four side walls of the insert. The bumper sections of the blank extend from the side walls of the package whereby all bumpers are formed by folding along fold lines extending across the flutes of the cardboard. However, the basic design of the blank makes it inefficient when it comes to the amount waste material that is cut away when the blank is manufactured, and also when it comes to transportation in flat- laid state. Moreover, it is difficult to fold and erect such a blank into an insert in a state ready to receive goods. The blank disclosed in JPH08230868 is designed to be partly folded and erected and thereafter receive a goods before the last bumper sections are folded.

It may be noted that none of the prior art documents discloses a package which adequately addresses the set of design criteria that the package should make efficient use of the material, be easy to transport to the point of use, be easy to erect, and provide a stable and strong protective structure.

Summary of the invention

In view of that stated above, the object of the present invention is to provide a package that addresses the design criterial that an insert for a package should be easy to erect, make efficient use of material, and provide a strong and stable protective structure.

To achieve at least one of the above objects and also other objects that will be evident from the following description, a blank for forming an insert for a package having the features defined in claim 1 is provided according to the present invention. Preferred embodiments of the device will be evident from the dependent claims.

According to a first aspect there is provided a blank for forming an insert for a package, the blank comprising: a first portion configured to form an outer portion of the insert, the first portion comprising: an outer floor panel, and two opposing end portions, each end portion comprising a set of a plurality of outer bumper panels consecutively arranged one after the other along a longitudinal direction, the plurality of outer bumper panels being connected to the outer floor panel and connected to each other about fold lines extending along a transverse direction extending across the longitudinal direction, wherein each of the two opposing end portions is arranged to be folded into a hollow structure by folding the plurality of outer bumper panels relative to each other about the fold lines and thereby form a bumper extending along the transverse direction on a respective longitudinal end of the outer floor panel, a second portion configured to form an inner portion of the insert, the second portion comprising: an inner floor panel, and two opposing end portions, each end portion comprising a set of a plurality of inner bumper panels consecutively arranged one after the other along the longitudinal direction, the plurality of inner bumper panels being connected to the inner floor panel and connected to each other about fold lines extending along the transverse direction, wherein each of the two opposing end portions is arranged to be folded into a hollow structure by folding the plurality of inner bumper panels relative to each other about the fold lines and thereby form a bumper extending along the transverse direction on a respective longitudinal end of the inner floor panel, a folding portion being formed within a perimeter of the inner floor panel, the folding portion having a triangular configuration with: a first side providing a foldable connection between a longitudinally extending transversal edge of the outer floor panel and a longitudinally extending transversal edge of the inner floor panel, a second side forming a cut through the blank, the second side extending into the perimeter of the inner floor panel, and a third side extending into the perimeter of the inner floor panel and forming an internal fold line within the perimeter of the inner floor panel, whereby the folding portion allows a rotational folding of the second portion relative to the first portion by folding the folding portion relative to the first portion and by folding the second portion about the folding portion such that the inner floor panel forms a double floor panel with the outer floor panel and such that the bumpers formed at the respective ends of the second portion thereby extends along the longitudinal direction.

Thus, it is facilitated to provide an insert which makes efficient use of material and which is easy to erect. The thus provided blank may form a sturdy insert for a package that is shock-resistant while still being easy to erect. All bumpers are folded in the same direction which makes it possible to make efficient use of flutes of a corrugated cardboard material and thereby provide sturdiness to the insert in both directions. By all bumpers being folded in the same direction, the assembly of the insert may be facilitated. The folding portion allows for the use of two floor panels being layered in a facilitated manner while at the same time providing the insert with a double flooring, adding to the shock-resistant capabilities of the insert. The provided blank may facilitate transportation of the insert in an unfolded state.

By the second portion being folded in a rotational movement to be placed on top of the first portion, the assembly of the insert is facilitated. The configuration further allows for all bumper panels to be folded in the same direction, whereas the rotational movement of the second portion realigns the bumpers such that they are aligned in two transversal directions.

It is preferred that the blank is made from a paper-based material, preferably a paper-based material comprising a corrugated layer in which flutes of the corrugated layer extends along the longitudinal direction. By this configuration, the bumpers of the outer panel and the bumpers of the inner panel may be folded such that the fold lines are transverse to the flutes. Accordingly, it is facilitated to provide a sturdy insert. Paper-based material is further an environmentally friendly material that can be recycled after use. Paper-based material is lightweight which facilitates transportation thereof.

The blank may comprise a top panel foldably connected to an outer most panel of the plurality of outer bumper panels, the top panel being configured to form a lid over the insert. By the blank comprising a lid, the shock-resistant capabilities of the insert increase since there is an added layer of material. The lid may prevent any object or product placed in the insert from falling out. Hence, the insert comprising a lid may act as a standalone package. Thus, it is possible to provide a package with an integrally formed insert, wherein such a package may be folded from a single blank.

The at least one of the set of outer bumper panels, preferably both sets of outer panels, may comprise four panels. Preferably, both sets of outer panels comprises exactly four panels.

The at least one of the set of inner bumper panels, preferably both sets of inner panels, may comprise four panels. Preferably, both sets of inner panels comprises exactly four panels.

By the set of bumper panels comprising four panels, the cross section of the hollow bumper may, when folded, be formed as a squared cross section, and the most outer panel may form an extra floor layer. By this configuration, a sturdy and stable insert for a package may be provided.

In association with at least one of the sets of outer bumper panels, and preferably in association with both sets of outer bumper panels, a locking flap may be provided in the outer floor panel or in one of the outer bumper panels, and a locking cut-out may be provided in another panel among the outer floor panel and outer bumper panels. The locking flap and locking cut-out may be positioned relative to each other such that the locking flap becomes in register with and is insertable into the locking cut-out when the outer bumper panels are folded relative to each other to form said bumpers.

By the provision of a locking flap and a locking cut-out to lock the bumpers of the first portion in a desired place, the insert may be erected and kept in desired form without the use of any adhesive, hence the assembly thereof may be facilitated.

The locking flap may be formed in the outer floor panel. The cut-out may be formed in an outer bumper panel being a fourth panel as counted from the outer floor panel. By this configuration, the locking flap may be arranged to be folded inwards from underneath the insert in an upward motion. Thus, the locking flap is easily accessible and may be pushed into the interior of the hollow structure of the bumper. Additionally, the underside of the insert will be even and thus the risk of unintentionally unfolding the locking flaps when handling the insert may be reduced. This configuration may further ensure that the bumper is folded as having a square cross section, which may increase the shock-resistant capabilities of the insert.

In association with at least one of the sets of inner bumper panels, and preferably in association with both sets of inner bumper panels, a locking flap may be provided in the inner floor panel or in one of the inner bumper panels, and a locking cut-out may be provided in another panel among the inner floor panel and inner bumper panels. The locking flap and locking cut-out may be positioned relative to each other such that the locking flap becomes in register with and is insertable into the locking cut-out when the inner bumper panels are folded relative to each other to form said bumpers. By the provision of a locking flap and a locking cut-out to lock the bumpers of the second portion the insert may be erected and kept in desired form without the use of any adhesive, hence the assembly thereof may be facilitated.

The locking flap may be formed in the inner floor panel. The cut-out may be formed in an inner bumper panel being a fourth panel as counted from the inner floor panel. It is to be understood that the insert may comprise one or more locking flaps and associated locking cut-outs. By this configuration, the locking flap may be arranged to be folded from underneath the insert in an upward motion. Thus, the locking flap is easily accessible may be pushed into the interior of the hollow structure of the bumper. Moreover, there is a reduced risk of unintentional unfolding of the locking flap during handling thereof. This since the flap after folding is inside the hollow bumper, out of reach when handling or carrying the insert. Additionally, the underside of the insert will be even and thus the risk of unintentional unfolding of the locking flaps when handling the insert may be reduced. This configuration may further ensure that the bumper is folded as having a square cross section, which may increase the shock-resistant capabilities of the insert.

The triangular folding portion may be asymmetrically positioned within the perimeter of the inner floor panel in the sense that it may be positioned closer to one of the sets of inner bumper panels that to the other set of inner bumper panels.

The inner floor panel may have an extension in the longitudinal direction such that a fold line between the inner floor panel and an inner most inner bumper panel of the set of inner bumper panels being farthest from the triangular folding portion is positioned farther away from the triangular folding portion than an inner most outer bumper panel of the adjacent set of outer bumper panels, and preferably farther away from the triangular folding portion than all the outer bumper panels of the adjacent set of outer bumper panels. This configuration makes it easy to make an efficient use of material for forming the blank. The configuration also allows for the optional feature that the blank also comprises a lid which does not need to extend outside the overall perimeter of the blank.

An intersection between the first side and the second side of the triangular folding portion may coincide with an intersection between a longitudinal cut between the first and second portions and a fold line between the inner floor panel and an inner most inner bumper panel of one of the sets inner bumper panels. It may be noted that coincide may in this context be a slight distance away from the geometrical intersection as seen in a flat-laid state in order to take into account that the blank is formed of a material that has a thickness and that a folding typically translates to a small movement or displacement having a size being anything from a fraction of up to about the same as the material thickness.

The invention may also in short be said to relate to a blank for forming an insert for a package, the blank comprising a first portion configured to form an outer portion of the insert, the first portion comprising: an outer floor panel, and two opposing end portions, each end portion comprising a set of a plurality of outer bumper panels, a second portion configured to form an inner portion of the insert, the second portion comprising: an inner floor panel, and two opposing end portions, each end portion comprising a set of a plurality of inner bumper panels, and a folding portion having a triangular configuration being formed within a perimeter of the inner floor panel, the folding portion allows a rotational folding of the second portion relative to the first portion by folding the folding portion relative to the first portion and by folding the second portion about the folding portion such that the inner floor panel forms a double floor panel with the outer floor panel.

Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to "a/an/the [element, device, component, means, step, etc]" are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated.

Brief Description of the Drawings

The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, where the same reference numerals will be used for similar elements, wherein:

Fig. 1 illustrates a blank for forming an insert.

Fig. 2 illustrates an insert in an assembled state.

Fig. 3 illustrates a rotational folding motion occurring when folding the blank into an insert.

Description of Embodiments

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

With reference to Figs. 1-3, a blank 1000 for forming an insert for a package is disclosed. Fig. 1 discloses a blank for forming the insert. Fig. 2 discloses the insert in an assembled state state. Fig. 3 discloses the insert during the folding of the insert, specifically during a rotational folding motion of the blank.

The blank 1000 comprises a first portion 100 configured to form an outer portion of the insert and a second portion 200 configured to form an inner portion of the insert. The blank 1000 extends in a longitudinal direction L and a transverse direction T, as seen in the flat laid state of the blank 1000.

The first portion 100 comprises an outer floor panel 102 and two opposing end portions. Each end portion comprises a set of a plurality of outer bumper panels 106. The plurality of outer bumper panels 106 are arranged consecutively one after another along the longitudinal direction L. The plurality of outer bumper panels 106 are connected to the outer floor panel 102 and connected to each other about fold lines extending along the transverse direction T extending across the longitudinal direction L. Each one of the two opposing end portions is arranged to be folded into a hollow structure by folding the plurality of outer bumper panels 106 relative to each other about the fold lines. Thereby a bumper extending along the transverse direction T is formed on a respective longitudinal end of the outer floor panel 102.

At least one of the set of outer bumper panels 106 may comprise four panels. Preferably both sets of outer bumper panels 106 comprises four panels. It is most preferred that both sets of outer bumper panels 106 comprises exactly four panels.

The second portion 200 comprises an inner floor panel 202 and two opposing end portions. Each end portion comprises a set of a plurality of inner bumper panels 206. The plurality of inner bumper panels 206 are arranged consecutively one after another along the longitudinal direction L. The plurality of inner bumper panels 206 are connected to the inner floor panel 202 and connected to each other about fold lines extending along transverse direction T extending across the longitudinal direction L. Each one of the two opposing end portions is arranged to be folded into a hollow structure by folding the plurality of inner bumper panels 206 relative to each other about the fold lines. Thereby a bumper extending along the transverse direction T is formed on a respective longitudinal end of the inner floor panel 202.

At least one of the set of inner bumper panels 206 may comprise four panels. Preferably both sets of inner bumper panels 206 comprises four panels. It is most preferred that both sets of inner bumper panels 206 comprises exactly four panels.

The blank 1000 may comprise a top panel 108. The top panel 108 may be foldably connected to an outer most panel of the plurality of outer bumper panels 106. The top panel 108 may be configured to form a lid over the insert.

The blank 1000 further comprises a folding portion 104. The folding portion is formed within a perimeter of the inner floor panel 202. The folding portion 104 has a triangular configuration having a first side, a second side, and a third side.

The first side provides a foldable connection between a longitudinally extending transversal edge of the outer floor panel 102 and a longitudinally extending transversal edge of the inner floor panel 202.

The second side forms a cut through the blank. The second side extends into the perimeter of the inner floor panel 202.

The third side extends into the perimeter of the inner floor panel 202 and forms an internal fold line within the perimeter of the inner floor panel 202.

The folding portion 104 is configured to allow a rotational folding of the second portion 200 relative to the first portion 100 by folding the folding portion 104 relative to the first portion 100 and by folding the second portion 200 about the folding portion 104 such that the inner floor panel 202 forms a double floor panel with the outer floor panel. By the folding motion, the bumpers formed at the respective ends of the second portion 202 thereby extends along the longitudinal direction L.

The triangular folding portion 104 may be asymmetrically positioned within the perimeter of the inner floor panel 202. By this, the folding portion 104 may be positioned closer to one of the sets of inner bumper panels 206 than to the other set of inner bumper panels 206. The folding portion 104 may be positioned such that the top panel does not extend outside the overall perimeters of the blank.

The inner floor panel 202 may have an extension in the longitudinal direction L such that a fold line between the inner floor panel 202 and an inner most inner bumper panel 206 of the set of inner bumper panels 206 being farthest from the triangular folding portion 104 is positioned farther away from the triangular folding portion 104 than an inner most outer bumper panel 106 of the adjacent set of outer bumper panels 106. It is preferred that said fold line is farther away from the triangular folding portion 104 than all the outer bumper panels 106 of the adjacent set of outer bumper panels 106. This may allow for the blank 1000 to comprise the top panel 108 without the perimeter of the top panel 108 sticking out from the outside of the overall perimeter of the blank 1000, as seen in the flat laid state of the blank 1000. By configuring the blank 1000 to comprise the top panel 108 as described, efficient use of material may be achieved.

An intersection between the first side and the second side of the triangular folding portion 104 may coincide with an intersection between a longitudinal cut between the first and second portions 100, 200 and a fold line between the inner floor panel 202 and an inner most inner bumper panel 206 of one of the sets inner bumper panels 206. It may be noted that coincide may in this context be a slight distance away from the geometrical intersection as seen in a flat-laid state in order to take into account that the blank 1000 is formed of a material that has a thickness and that a folding typically translates to a small movement or displacement having a size being anything from a fraction of up to about the same as the material thickness.

The first portion 100 may comprise a locking flap 110a, and a locking cut-out 112a, for locking one of the set of bumpers in the desired place. It is preferred that both set of bumpers may be locked with and provided with a locking flap 110a and a locking cut-out 112a. The locking flap 110a and the locking cut-out may accordingly be provided in association with the set of outer bumper panels 106. The locking flap 110a may be provided in one of the outer floor panel 102 or in one of the outer bumper panes 106. The locking cut-out may be provided in another one among the outer floor panel 102 and the outer bumper panels 106. The locking flap 110a and the locking cut-out 112a may be positioned relative to each other such that the locking flap 110a becomes in register with and is insertable into the locking cut-out 112a when the outer bumper panels 106 are folded relative to each other to form said bumpers.

It is preferred that the locking flap 110a is formed in the outer floor panel 102 and that the cut-out 112a is formed in an outer bumper panel 106 being a fourth panel as counted from the outer floor panel 102. In such an embodiment, the locking flap 110a may be reachable from an underside of the insert and can be pressed upwards into the hollow structure of the bumper where the locking flap 110a can be folded and thereby provide a desired locking mechanism for the bumper. The locking flap 110a will be protected by the hollow bumper. Accordingly, there is a reduced risk of any unintentional unfolding of said locking flap 110a. Said underside of the insert may be seen as an even underside. When the locking cut-out 112a is formed in the fourth outer bumper panel 106, and the locking cut-out is formed in the outer floor panel 102, the bumper will take the form of having a squared cross section. The squared cross section of the bumper may increase the shockabsorbing capabilities of the insert. The configuration may further provide a sturdy insert that is stable, and easy to place in any package or box.

The second portion 200 may comprise a locking flap 110b, and a locking cut-out 112b, for locking one of the set of bumpers in the desired place. It is preferred that both set of bumpers may be locked with, and provided with, a locking flap 110b and a locking cut-out 112b. The locking flap 110b and the locking cut-out 112b may accordingly be provided in association with the set of inner bumper panels 206. The locking flap 110b may be provided in one of the inner floor panel 202 or in one of the inner bumper panes 206. The locking cut-out may be provided in another one among the inner floor panel 102 and the inner bumper panels 206. The locking flap 110b and the locking cut-out 112b may be positioned relative to each other such that the locking flap 110b becomes in register with and is insertable into the locking cut-out 112b when the inner bumper panels 206 are folded relative to each other to form said bumpers.

It is preferred that the locking flap 110b is formed in the inner floor panel 202 and that the cut-out 112b is formed in an inner bumper panel 206 being a fourth panel as counted from the inner floor panel 202. In such an embodiment, the locking flap 110b may be reachable from an underside of the insert and can be pressed upwards into the hollow structure of the bumper where the locking flap 110b can be folded to provide a desired locking mechanism for the bumper. The locking flap 110a will be protected by the hollow bumper, and there is a reduced risk of any unintentional unfolding of said locking flap 110b. Said underside of the insert may be seen as an even underside. When the locking cut-out 112b is formed in the fourth inner bumper panel 206, and the locking cut-out is formed in the inner floor panel 202, the bumper will take the form of having a squared cross section. The squared cross section of the bumper may increase the shock-absorbing capabilities of the insert. The configuration may further provide a sturdy insert that is stable, and easy to place in any package or box.

The blank 1000 may be made of a paper-based material. It is preferred that the paper-based material comprises a corrugated layer in which flutes of the corrugated layer extends along the longitudinal direction L.

It will be appreciated that the present invention is not limited to the embodiments shown. Several modifications and variations are thus conceivable within the scope of the.

The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.

Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.