Retaining Flap for Shipping Cartons

The present invention generally relates to cartons for shipping or transporting delicate items, such as floral groupings, and more specifically to retaining flaps which are interposed between and among the delicate items, in order to substantially immobilize the delicate items within the shipping carton to thereby prevent damage to the delicate items by movement.

FIG. 1 is a perspective view of a flexible retaining wrap constructed in accordance with the present invention.

FIG. 2 is a perspective view of another flexible retaining flap constructed in accordance with the present invention.

FIG. 3 is a perspective view of a retaining flap comprising a rigid material and constructed in accordance with the present invention.

FIG. 4 is a perspective view of another retaining flap comprising a rigid material and constructed in accordance with the present invention.

FIG. 5 is a perspective view of the flexible retaining flap shown in FIG. 1 disposed about a plurality of floral grouping assemblies.

FIG. 6 is a perspective view of two flexible retaining flaps, similar to the retaining flap shown in FIG. 2, disposed about a plurality of floral grouping assemblies.

FIG. 7 is a side view of the flexible retaining flap shown in FIG. 1, disposed about a plurality of floral grouping assemblies.

FIG. 8 is a side view of the retaining flap and floral grouping assemblies shown in FIG. 7, disposed in a carton.

FIG. 9 is a perspective view of the retaining flap shown in FIG. 3 disposed about a plurality of floral grouping assemblies.

FIG. 10 is a perspective view of two retaining flaps, similar to the retaining flap shown in FIG. 4, disposed about a plurality of floral grouping assemblies.

FIG. 11 is a side view of the retaining flap shown in FIG. 3, disposed about a plurality of floral grouping assemblies.

FIG. 12 is a side view of the retaining flap and floral grouping assembly shown in FIG. 11, disposed in a carton.

Shown in FIG. 1 is a retaining flap constructed in accordance with the present invention and designated by the general reference numeral 10. The flap 10 is constructed of a flexible sheet of material 12 having an upper surface 14, a lower surface 16, a first end 15, a second end 17, a first side 19 and a second side 21. A bonding material is disposed in strips of bonding material, one strip of bonding material being shown and designated with the reference numeral 20, the strips of bonding material, such as bonding material strip 20, extending generally from the first end 15 to the second end 17 of the sheet of material 12.

The sheet of material 12 is constructed from any suitable flexible material that is capable of being formed in accordance with the present invention, as will be explained below. Preferably, the flexible sheet material 12 is constructed of a material selected from a group of materials consisting of paper, metal foil, cloth (natural or synthetic), denim, burlap or polymer film or combinations thereof.

The term "polymer" as used herein means any polymer film. For example, but not by way of limitation, one polymer film is a polypropylene film. Another example of a polymer film, is cellophane.

The sheet of material 12 has a thickness in a range from about 0.1 mils to about 30 mils. Preferably, the sheet of material has a thickness in a range from about 0.1 mils to about 5 mils. The sheet of material 12 may be of any shape and a rectangular shape is shown in FIG. 1 only by way of example. The sheet of material, for example, may be square, circular, or any other geometric shape. The sheet of material 12 may be constructed of a single layer of material or a plurality of layers of the same or different types of materials. Any thickness of the sheet of material 12 may be utilized with the present invention as long as the sheet of material is capable of being formed in accordance with the present invention. The layers of material comprising the sheet of material 12 may be connected together or laminated or may be separate layers.

The term "bonding material" as used herein means a pressure sensitive adhesive, preferably a pressure sensitive adhesive, or a cohesive. Where the bonding material is a cohesive, a similar cohesive material must be placed on the adjacent surface for bondingly contacting and bondingly engaging with the cohesive material. The term "bonding material" as used herein means any type of material or thing which can be used to effect the bonding or connecting of the two adjacent portions of the material or sheet of material as described herein.

Shown in FIG. 2 is a flap 10a constructed of a flexible sheet of material 12a, and having an upper surface 14a, a lower surface 16a, a first end 15a, a second end 17a, a first side 19a, and a second side 21a. The flexible sheet of material 12a, as shown in FIG. 2, has bonding material 18 disposed generally across the upper surface 14a and the lower surface 16a of the sheet of material 12a.

Shown in FIG. 3 is a retaining flap 10b constructed in accordance with the present invention. The flap 10b is constructed of a rigid sheet of material 22b. The rigid sheet of material 22b comprises any material that can be formed in accordance with the present invention. Examples of materials from which the rigid sheet of material 22b can be constructed include, solely by way of illustration and not by way of limitation, cardboard, metal foil, such as aluminum foil, and plastic sheet, such as polyethylene sheet. The rigid sheet of material 22b includes an upper surface 24b, a lower surface 26b (not shown) a first end 25b, a second end 27b, a first side 29b, and the second side 31b.

The rigid sheet of material 22b also comprises at least two panels, the rigid sheet of material 22b shown in FIG. 3 comprising a first panel 28b, a second panel 34b, a third panel 40b, and a fourth panel 46b.

The first panel 28b extends generally from the first end 25b to the fold line 30b. A fold line 32b is separated a distance from the fold line 30b and the second panel extends from the fold line 32b to the fold line 36b. A fold line 38b is separated a distance from the fold line 36b, and the third panel 40b extends from the fold line 38b to a fold line 42b. The fold line 44b is separated a distance from the fold line 42b and the fourth panel 46b extends generally from the fold line 44b to the second end 27b of the rigid sheet of material 22b. As shown in FIG. 3, the panels 28b, 34b, 40b, and 46b, are generally the same size, but in other embodiments of the invention, the size of the panels comprising a sheet of material 22d can vary.

The rigid sheet of material 22b additionally has strips of bonding material 20 disposed on the upper surface 24b and the lower surface 26b (not shown). One strip of bonding material is designated generally by the reference numeral 20.

FIG. 4 shows a retaining flap 10c constructed of a rigid sheet of material 22c. The rigid sheet of material 22c has a upper surface 24c, a lower surface 26c (not shown). A first end 25c, a second end 27c, and a first side 29c and a second side 31c. The retaining flap 10c will comprise at least two panels. The retaining flap 10c shown in FIG. 4 comprises a first panel 28c, a second panel 34c, a third panel 40c and a fourth panel 46c. The first panel 28c extends generally from the first end 25c to a fold line 30c. A fold line 32c is separated a distance from the fold line 30c, and the second panel 34c extends from the fold line 32c to a fold line 36c. A fold line 38c is separated a distance from the fold line 36c, and the third panel 40c extends from the fold line 36c to a fold line 42c. The fold line 44c is separated a distance from the fold line 42c and a fourth panel 46c extends from the fold line 44c to the second end 27c of the flexible or rigid sheet of material 22c. A bonding material 18 is disposed generally on the panels, such as the panels 28c, 34c, 40c and 46c shown in FIG. 4, on the first side 24c and the second side 26c of the rigid sheet of material 22c.

FIG. 5 is a perspective view of a retaining flap 10, constructed in accordance with the present invention, disposed about a plurality of floral grouping assemblies 50. As shown in FIG. 5, the floral grouping assemblies 50 are oriented to be disposed in a carton or carton 56 having an inner surface 58 defining a receiving space. A first layer of floral grouping assemblies is comprised of the floral grouping assemblies 50a through 50f. A second layer of floral grouping assemblies is comprised of the floral grouping assemblies 50g through 50l (50l not shown), and a third layer of floral grouping assemblies is comprised of the floral grouping assemblies 50m through 50r. Floral grouping assembly 50a is a representative of the floral grouping assemblies 50 shown in FIG. 5. The floral grouping assembly 50a comprises a floral grouping having a bloom end 52a and a stem end, which is generally encompassed by a floral grouping wrap 54. The present invention can also be used with a floral grouping without the floral grouping wrap 54. In that event, the bonding material disposed on the retention flap, such as the retention flaps 10 or 10a, will comprise an adhesive. Floral groupings, in general, possess the characteristic of being of delicate construction, and are subject to crushing and tearing when a plurality of floral grouping assemblies 50 are placed in a carton, such as the carton 56. The floral grouping assemblies 50 may be compressed or torn when additional floral grouping assemblies 50 are placed in the carton 56, or as a result of movement of the floral groupings assemblies 50 within the carton 56 unless the floral grouping assemblies 50 are essentially immobilized.

As shown in FIG. 5, the first end 15 and the upper surface 14 of the flexible sheet of material 12 is placed generally underneath the first layer of floral grouping assemblies 50a to 50f. The bonding strips, such as bonding strip 20, releasably connect to a portion of the floral grouping wrap comprising part of a floral grouping assembly, such as the floral grouping wrap 54 comprising part of the floral grouping assembly 50a.

The sheet of material 22 is then fed over the first layer of floral grouping assemblies 50a to 50f so the first surface 14 of the sheet of material 12 releasably connects to additional portions of the floral wrap comprising part of the floral grouping assemblies 50a to 50f. The second layer of floral grouping assemblies 50l is placed on a portion of the lower surface 16 of the sheet of material 12 so that a portion of the floral wrap comprising the floral grouping assemblies 50g through 50l is releasably connected to the lower surface 16 of the sheet of material 12 via the bonding strips, such as the bonding strip 20. The sheet of material is then folded over the second layer of floral grouping assemblies 50g through 50l so that an additional portion of the lower surface 16 of the sheet of material 12 comes in contact, via the bonding strips, with additional portions of the floral wrap comprising part of the floral grouping assemblies 50g through 50l. Finally, a third layer of floral grouping assemblies 50m through 50r is disposed on the upper surface 14 on an additional portion of the upper surface 14 of the sheet of material 12, a portion of the floral wrap comprising the floral grouping assemblies 50m through 50r coming in contact with the bonding strips disposed on the upper surface 14 of the sheet of material 12. The sheet of material 12 is folded over the third layer of floral grouping assemblies 50m through 50r so an additional portion of the bonding strips disposed on the upper surface 14 of the sheet of material 12 comes in contact with an additional portion of the floral wrap comprising the floral grouping assemblies 50m through 50 r.

It is understood that the general size of the sheet of material 12 will be determined by the number of floral grouping assemblies 50 to be disposed in the carton 56. Three layers of floral grouping assemblies 50 are shown in FIG. 5, but additional layers, or fewer layers, can be used, consistent with the present invention. Generally, however, it is contemplated that at least a first layer of floral grouping assemblies 50 and a second layer of floral grouping assemblies 50 will be used in accordance with the present invention.

FIG. 6 shows a perspective view of two retaining flaps, designated generally as retaining flaps 10' and 10", constructed in accordance with the present invention. As shown in FIG. 6, the flaps 10' and 10" are interwoven among a first layer of floral grouping assemblies 50a to 50f, a second layer of floral grouping assemblies 50m and 50l, and a third layer of floral grouping assemblies 50m and 50r, in exactly the same manner as the flap 10 shown in FIG. 5. However, the flap 10 shown in FIG. 5 is sized to generally fit within the cross sectional space defined by the inner surface 58 of the carton 56, whereas two flaps 10' and 10" performing the same function but occupying less space, are shown in FIG. 6. It is understood that, in a particular embodiment of the invention, additional flaps, such as flaps 10' and 10", or since flap 10' can be used in accordance with the invention. The flaps 10' and 10" have bonding material 18' or 18" disposed on the surfaces thereof, the bonding material 18' or 18" releasably connecting to a portion of the floral wraps of the floral grouping assemblies 50a to 50r to hold the floral groupings 50a to 50r essentially immobile when the floral groupings 50a to 50r and disposed in the carton 56.

Shown in FIG. 7, is a side view of a flap 10 disposed about a first layer of floral grouping assemblies 50a to 50f, a second layer of floral grouping assemblies 50g to 50l, and a third layer of floral grouping assemblies 50m through 50r. As shown in FIG. 7, the flap 10 operates to hold the floral grouping assemblies 50 essentially immobile and in a fixed orientation relative to each other.

Shown in FIG. 8 are the floral grouping assemblies 50a through 50r shown in FIG. 7, with the retaining flap 10 shown in FIG. 7 disposed about the floral grouping assemblies 50a to 50r, the floral grouping assemblies 50a to 50r being disposed in the receiving space of a carton 56. As shown in FIG. 8, the lower surface 16 of the sheet of material 22 is located generally adjacent a portion of the inner surface 58 of the carton 56, and the upper surface 14 of the sheet of material 22 is disposed generally under a first layer of floral grouping assemblies 50a through 50f. A portion of the bonding strips disposed on the sheet of material 22 (not shown), located on the lower surface 16 of the sheet of material 22 comes in contact with a portion of the inner surface 58 of the carton 56, thereby holding the portion of the sheet of material 22 in contact with a portion of the inner surface 58 of the carton 56 generally immobile within the carton 56. In turn, portions of the floral wrap comprising a portion of the floral grouping assemblies 50a through 50f is in contact with at least a portion of the bonding strips disposed on the upper surface 14 of the sheet of material 12, causing the floral grouping assemblies 50a through 50f to be held generally immobile on a portion of the sheet of material 12.

The sheet of material 12 is generally held against an additional posts of the inner surface 58 of the carton 56 at other contact points, such as the contact point 60. The sheet of material 12 therefor cooperates with the carton 56 to hold the floral grouping assemblies 50 generally immobile within the carton 56.

Shown in FIG. 9 is the retaining flap 10b shown in FIG. 3 disposed about a plurality of floral grouping assemblies 50a to 50r. The retaining flap 10b comprises a first panel 28b, which is disposed generally underneath a first layer of floral grouping assemblies 50a to 50f, a second panel 32b, disposed generally between the first layer of floral grouping assemblies 50a to 50f and a second layer of floral grouping assemblies 50h through 50l, the first panel 28b and the second panel 34b cooperating to form a first retention pocket 29b, generally encompassing the first layer of floral grouping assemblies 50a to 50f.

The third panel 40b extends generally above the second layer of floral grouping assemblies 50g through 50l forming a second retention pocket 37b and the fourth panel extending generally above the third layer of floral grouping assemblies 50m through 50r forming, with the second panel, a third retention pocket 45b.

The effect of folding the first panel 28b, the second panel 34b, the third panel 40b and the fourth panel 46b as shown in FIG. 9 is to create three retention pockets 29b, 37b and 45b, the retention pockets each securing a portion of the floral grouping assemblies 50a through 50r.

As shown in FIG. 9, the retaining flap 10b comprises on a first surface 24b and a second surface 26b a plurality of bonding strips, one of the bonding strips being shown and denominated by the reference numeral 20b. The bonding strips contact portions of the floral grouping assemblies 50a to 50r, thereby cooperating with the structure of the retaining flap 10b to hold the floral grouping assemblies 50a to 50r essentially immobile when the floral grouping assemblies 50a to 50r are disposed within the carton 56.

Shown in FIG. 10 are two retaining flaps 10c' and 10c". The retaining flaps 10c' and 10c" operate in exactly the same manner as the retaining flap 10b shown in FIG. 9, except that the retaining flap 10b, when disposed around the floral grouping assemblies 50a to 50r generally encompasses the floral grouping assemblies, whereas the retaining flaps 10c' and 10c" each encompass only a portion of the floral grouping assemblies 50a' to 50r". Additionally, the bonding material 18 disposed on the retaining flaps 10c' and 10c" in this embodiment of the invention, comprise a cohesive. For that reason, the floral wrap comprising a portion of the floral grouping assemblies 50a' through 50r" must be at least partially covered with a cohesive, as shown in FIG. 10. Additionally, the carton 56', shown disposed below the first layer of floral grouping assemblies 50a' through 50f', the second layer of floral grouping assemblies 50g' through 50l' and the third layer of floral grouping assemblies 50m' through 50r' has cohesive disposed in the form of cohesive strips across at least a portion of the interior 56' of the carton 58'. One of the cohesive strips is designated by the numeral 64. In operation, the cohesive disposed on the retaining flaps 10c' and 10c" will releasably connect to a portion of the cohesive strips, such as the cohesive strip 64, disposed on the interior surface 58' of the carton 56', cooperating to hold the retaining strips 10c' and 10c" essentially mobile within the carton 56'. In turn, the cohesive on the retaining flaps 10c' and 10c" will releasably connect to the cohesive disposed on a portion of the floral grouping assemblies 50a' through 50r' to hold the floral grouping assemblies 50a' through 50r' essentially immobile within the retaining flaps 10c' and 10c" when the retaining flaps 10c' and 10c" are disposed within the carton 56'.

Shown in FIG. 11 is a side view of the retaining flap 10b shown in FIG. 3, disposed about a first layer of floral grouping assemblies 50a through 50f, a second layer of floral grouping assemblies 50g through 50l, and a third layer of floral grouping assemblies 50m through 50r. The first panel 28b and the upper surface 24b of the second panel 34b generally encompass the first layer of floral grouping assemblies 50a through 50f, the lower surface 26b of the second panel 34b in the lower surface 26b of the third panel 40b generally encompass the second level of floral grouping assemblies 50g through 50l, and the upper surface 24b of the third panel 40b and the upper surface 24b of the fifth panel 46b generally encompass the third level of floral grouping assemblies 50m through 50r. As shown in FIG. 11, the first and second panels cooperate to form a first floral grouping retention pocket 29b, the second and third panels cooperate to form a second floral grouping retention pocket 37b, and the third and fourth panels cooperate to form a third floral grouping retention pocket 45b.

When placed in a carton 56 as shown in FIG. 12, the bonding strips disposed on a portion of the retaining flap 10b (not shown) releasably connect to a portion of the interior surface 58 of the carton 56, in order to hold the retaining flap 10b essentially immovable within the carton 56. Additionally, portions of other bonding strips disposed on the retaining flap 10b releasably connect with portions of the floral grouping assemblies 50a to 50r, thereby cooperating with the rigidity of the first panel 28b, the second panel 34b, the fourth panel 40b and the fifth panel 46b to hold the floral grouping assemblies 50a to 50r essentially immobile when the floral grouping assemblies 50, disposed within the retaining flap 10b, are inserted and encompassed by the carton 56.

Changes may be made in the embodiments of the invention described herein or in parts or elements of the embodiments described herein or in the steps or in the sequence of steps of the methods described herein without departing from the spirit and scope of the invention as defined in the following claims.