Box divider unit and method for its manufacture

Abstract

The invention provides a foamed-elastomer collapsible box divider for dividing a box into at least six cushioned compartments when extended, and when collapsed having the form of an elongated component stepped on four edges as viewed from a side. The steps being formed by two face-to-face central elongated leaves, in combination with a short top and a short bottom leaf, and at least a first and a second leaf of intermediate length. The first intermediate leaf being disposed between the short top leaf and the central elongated leaves, and the second intermediate leaf being disposed between the short bottom leaf and the central elongated leaves, each leaf being separate along a major portion of its length from adjacent leaves and being transversely cut through part of its thickness at a pitch corresponding to the width of one of the compartments, each elongated and intermediate leaf being joined to adjacent leaves by at least one narrow connecting line adjacent to the transverse cut, the connecting line being formed by the remaining uncut material adjacent to the transverse cut.

1 . A foamed-elastomer collapsible box divider for dividing a box into at least six cushioned compartments when extended, and when collapsed having the form of an elongated component stepped on four edges as viewed from a side, said steps being formed by two face-to-face central elongated leaves, in combination with a short top and a short bottom leaf, and at least a first and a second leaf of intermediate length, said first intermediate leaf being disposed between said short top leaf and said central elongated leaves, and said second intermediate leaf being disposed between said short bottom leaf and said central elongated leaves, each leaf being separate along a major portion of its length from adjacent leaves and being transversely cut through part of its thickness at a pitch corresponding to the width of one of said compartments, each elongated and intermediate leaf being joined to adjacent leaves by at least one narrow connecting line adjacent to said transverse cut, said connecting line being formed by the remaining uncut material adjacent to said transverse cut.  
   
   
       2 . The box divider as claimed in  claim 1 , wherein when extended, said short cut appears as a square-section hollow prism located at the center of any array comprising four compartments arranged in a square configuration.  
   
   
       3 . The box divider as claimed in  claim 1 , wherein the height of the divider is built up by stacking multiple sheets of foamed elastomer, each sheet being bonded to each adjacent sheet.  
   
   
       4 . The foamed elastomer collapsible box divider, wherein said elastomer is a rubber.  
   
   
       5 . A method for manufacturing a foamed-elastomer collapsible box divider, comprising the following steps: 
 providing a foamed-elastomer sheet, if available of thickness equal to the height of the desired box divider;    alternatively bonding together a plurality of foamed-elastomer sheets, the total height of the stack being equal to the height of the required box divider; and    blanking the stepped form, and executing the long cuts and the short cuts by means of a single-element press-mounted ply-wood based steel-rule die.