Surfboardpack

Abstract

The invention provides an industry standard packaging design to ship and protect surfboards, wakeboards, snowboards, kiteboards, etc. in various sizes. It uses corrugated die-cut end caps, flexible straps, and foam and corrugated pads to provide enhanced fragility protection in an easy to assemble/disassemble and reusable package. This package makes it possible to ship expensive board products around the world safely and cost effectively for OEM Bulk and retail single/bulk deliveries.

1 . A packaging system for recreational board products (surfboards, kiteboards, wakeboards, snowboards) consisting of: 
 Specially designed internal die-cut corrugated “Caps” ( 40 ,  100 ) that secure board products in place such that they are not subjected to direct contact with the surface onto which the box is dropped or any objects brought into contact with it.    “straps” ( 60 ) made of various materials that allow for further flexibility of sizes and offers reusability as well as quick packing and unpacking times.    A telescoping box ( 80 , 90 ) made of corrugated that provides both protection in the form of cushioning and size flexibility by its ability to change sizes within a certain range.    Foam pads ( 35 ) which are perforated for easy tear off and assembly which provide indent load defection from side, top, or bottom impacts.    Corrugated pads ( 30 ), which provide stiffening protection for the foam pads to “push” against, to yield a “hard-soft” compression environment as well as further cushioning to the heavy board product upon impact.    
   
   
       2 . Within the packaging system in  claim 1 , there are features that allow for various shapes (length, width, and depth) of boards to fit into one size system. 
 The telescoping box ( 90 ) contains certain features that allow for size adjustments. The box is made in either two ( FIGS. 1 and 2 ) or three-pieces ( FIG. 3 ), with the outer box being a bit larger than the inner box, such that the two or three boxes can “telescope” or slide back and forth to create different lengths. The size can vary as the range of change desired.    A packaging component of  claim 1 , the end cap and mid cap ( 40 , 100 ), contain multiple die-cut “slots ( 55 ) and scores ( 70 ). The slots ( 55 ) allow for the Strap ( 60 ) to be placed in different places according to its width and the scores ( 70 ) allow it to bend around the board at different hinge points. This allows for a wide range of board thicknesses and widths to be placed in the same size pack. The end caps and side caps ( 40 , 100 ) can be made in various sizes to accommodate any size range the boards would be manufactured.    The Straps ( 60 ) are made of a flexible plastic film that enables it to stretch and thus conform to various sizes of board widths and thicknesses. In addition, the strap ( 60 ) acts as a security device, eliminating the need for tape or staples, and thus, allowing for recyclability and reusability.    
   
   
       3 . Within the packaging system in  claim 1 , there are features that allow for fragility protection: 
 Side Tabs ( 110 ) provide a stiffening member to resist a shocking force from the side of the telescoping box ( 80 , 90 ). The corrugation of the die-cut end and mid-cap ( 40 , 100 ), can be run either horizontal or vertical, which changes the strength of the side tab.    The Telescoping box ( 80 , 90 ) has an overlap in the center. This provides increased impact protection from the corrugations in the box. Corrugations provide impact protection from compression. Multiple thicknesses in the center of the board, which is the closest to the box sidewall ( 80 , 90 ), provide increased protection exactly in the area that will impact any side surface.    The End Caps ( 40 ) fill up the corners of the box and are shaped with multiple thicknesses such that they have tremendous compressive strength for stacking and provide excellent corner, end, and edge protection. Upon such impacts, the forces are kept away from the board by nature of the board shape. With all board products having drawn in tails from the middle of the board to the end, the empty space is strengthened by the end cap geometry, filling up that section with stiff corrugated members that create crush zones and keep the impact away from the board product it is housing.    Foam cushioning pads ( 35 ) offer thickness and indent load deflection, thereby giving the board a soft surface and extra distance to slow down its deceleration into impact.    Corrugated stiffening pads ( 30 ) offer thickness and a somewhat stiffer surface for the foam to press against and deflect. In addition, the corrugated has, by it nature, a stiffer cushion made up of corrugation that further aids in decellerating the boards upon impact.    Corrugation direction has been designed into this pack to provide stiffness where it is needed (vertical corrugation) and flexibility where it is needed (horizontal corrugation). Corrugation can be altered at the manufacturing level of all corrugated products.    
   
   
       4 . Within the packaging system in  claim 1 , there are certain materials used that makes the design affordable, shippable, light weight, strong, and recyclable: 
 Corrugated is used in the telescoping box ( 80 , 90 ) because it is strong, relatively inexpensive and easily manufacturable worldwide.    The strap ( 60 ) can use films from a variety of plastics, with thin-film urethane being the strongest and most desirable. However, PVC, Polyethylene, or other plastic films can be used. The fastening feature of the strap ( 60 ) can be by glue, locking retention, staples, or any other method of securance.    The foam pad ( 35 ) can be made from polyethylene, polypropylene, or any other foamed or blown plastic. In addition, cellulose paper or layered cardboard liners may be used.    
   
   
       5 . Within the packaging system in  claim 1 , there are certain materials and design features that aid in easy storage: 
 The Telescoping Box ( 80 , 100 ), because it is in two or three pieces, is able to store in either ½ or ⅓ its size, saving space.    Both the end caps and mid caps ( 40 , 100 ) utilize a snap-lock design that allows the caps to be easily disassembled and knocked down for flat storage.    The foam and corrugated pads ( 35 , 30 ) also flatten out for densification.    All of the components end up folding and storing in one of the pieces of the Telescoping box ( 80 , 90 ).    
   
   
       6 . Within the packaging system in  claim 1 , there are certain materials used and design features that aid in recylability: 
 The use of corrugated, which is curbside recylable worldwide, in the Telescoping box ( 80 , 90 ), the End and Mid Cap ( 40 , 100 ), and the corrugated pad ( 30 ).    The use of a plastic film strap ( 60 ) and polyethylene foam sheets ( 35 ), which due their overall weight volume, can be curbside recycled with the pack as a whole.    
   
   
       7 . Within the packaging system in  claim 1 , there are certain materials used and design features that aid in reusability: 
 The snap-lock design of the End Caps ( 40 ) enable this product to knock down flat and be reassembled with ease.    The use of flexible Straps ( 60 ), which eliminate the need for tape or staples, allow the End and Mid Caps ( 40 , 100 ) to be repeatedly reassembled.    The Telescoping Box ( 80 , 90 ) construction allows for multiple taping events due to its side and end flaps being FOL (Full Overlap), providing complete double thickness such that cutting the tape and retaping do not compromise the integrity of the box.