Overbox packaging system
View Patent ↗An overbox packaging system for a high aspect ratio inner box includes an outer box, at least four modular packaging inserts, and tape to seal the outer box closed. Four modular packaging inserts are adapted to a width of the high aspect ratio inner box by selective removal of zero or more first tear-away pieces and are adapted to a difference in a second dimension of the outer box in the inner box by selective removal of zero or more second tear-away pieces of at least two of the four modular packaging inserts. A second module of additional modular packaging inserts is removed, leaving a first module which is adapted to the width of the high aspect ratio inner box by selective removal of zero or more first tear-away pieces and placed in the outer box with its slot holding a section of the inner box.
1. A modular packaging insert comprising:
a first module comprising:
a first substantially rectangular cuboid portion positioned on a first end of the insert;
a second substantially rectangular cuboid portion positioned on a second end of the insert opposite of the first end; and
a third substantially rectangular cuboid portion connected to the first portion of the first module and the second portion of the first module to form a top surface of the first module and to form a slot in a bottom of the first module extending from a first side of the first module to the second side of the first module opposite of the first side;
the slot defined by a first inner face of the first portion of the first module, a second inner face of the second portion of the first module, and a third inner face of the third portion of the first module, wherein a distance from the first inner face to the second inner face defines a first width of the slot and a distance from the third inner face to the bottom of the first module defines a first depth of the slot;
the first portion of the first module further comprising a first tear-away piece that includes the first inner face, the first tear-away piece removably attached to a remaining section of the first portion and configured to expose a first new surface of the first portion of the first module once the first tear-away piece is removed;
the second portion of the first module further comprising a second tear-away piece that includes the second inner face, the second tear-away piece removably attached to a remaining section of the second portion and configured to expose a second new surface of the second portion of the first module once the second tear-away piece is removed, wherein a distance from the first new surface to the second new surface defines a second width of the slot; and
the third portion of the first module further comprising a third tear-away piece that includes the third inner face, the third tear-away piece removably attached to a remaining section of the third portion and configured to expose a third new surface of the third portion of the first module once the third tear-away piece is removed, wherein a distance from the third new surface to the bottom of the first module defines a second depth of the slot; and
a second module having a first thickness, the second module removably attached to the first side of the first module and covering at least a portion of one open side of the slot.
2. The insert of claim 1 , the first portion of the first module further comprising a fourth tear-away piece that includes the first new surface, the fourth tear-away piece removably attached to a residual section of the first portion and configured to expose a fourth new surface of the first portion of the first module once the fourth tear-away piece is removed; and
the second portion of the first module further comprising a fifth tear-away piece that includes the second new surface, the fifth tear-away piece removably attached to a residual section of the second portion and configured to expose a fifth new surface of the second portion of the first module once the fifth tear-away piece is removed, wherein a distance from the fourth new surface to the fifth new surface defines a third width of the slot.
3. The insert of claim 1 , the third portion of the first module further comprising a sixth tear-away piece that includes the third new surface, the sixth tear-away piece removably attached to a residual section of the third portion and configured to expose a sixth new surface of the third portion of the first module once the sixth tear-away piece is removed, wherein a distance from the sixth new surface to the bottom of the first module defines a third depth of the slot.
4. The insert of claim 1 , the second module comprising:
a first portion having the first thickness and a length extending from the first end of the first module to the second end of the first module; and
a second portion attached to a first side of the first portion of the second module and extending out from the side of the first portion of the second module parallel to the first side of the first module, the second portion of the second module having a width about equivalent to the first width of the slot.
5. The insert of claim 4 , the second portion of the second module having the first thickness.
6. The insert of claim 4 , the first portion of the second module including a notch on a side which is removably attached to the first module and extending from the first side of the first portion of the second module to a second side of the first portion of the second module opposite of the first side of the first portion of the second module, the notch having a width equal to or greater than the first width of the slot, and a depth of between 5% and 50% of the first thickness.
7. The insert of claim 6 , the second portion of the second module having a thickness about equal to the first thickness minus the depth of the notch.
8. The insert of claim 4 , the first portion of the second module including placement indentations on a side opposite of the side which is removably attached to the first module, the placement indentations positioned to mark a position of attachment for the second portion of the second module.