Light weight product cushioning device

Abstract

Disclosed is a unitary product cushioning device for supporting shock sensitive products during transport in an exterior container, comprising a product support region having a platform; a flap hingedly connected on either side of the product support region for folding upwards and towards the product support region; a plurality of ribs on each flap and product support region, the ribs defining product-supporting cavities therebetween for receiving and supporting the products; a cutout between each flap and product support region. Fold stops may hingedly connect each flap and product support region, the fold stop being angled to facilitate folding of the flap towards the product support region to form a generally “U” shape in the exterior container.

1 . (canceled) 
     
     
         2 . The device of  claim 12 , further comprising fold stops hingedly connecting each flap and product support region at a location between outer edges of the device, the fold stop being angled to facilitate folding of the flap towards the product support region to form a generally “U” shape in the exterior container. 
     
     
         3 . The device of  claim 12 , wherein the fold stops are angled at 45°. 
     
     
         4 . The device of  claim 12 , wherein the ribs are generally triangular in shape terminating at an apex at the top. 
     
     
         5 . The device of  claim 4 , wherein the underside of each rib defines a shock absorbing air space therein. 
     
     
         6 . The device of  claim 12 , further comprising a lid to place on top of the device after the products have been loaded, the lid comprising a plurality of corresponding ribs to support the products. 
     
     
         7 . The device of  claim 12 , wherein outermost ribs terminate at an angled portion to facilitate folding of the flap towards the product support region. 
     
     
         8 . (canceled) 
     
     
         9 . The device of  claim 12 , wherein the device is thermoformed using a moldable plastic. 
     
     
         10 . The device of  claim 9 , wherein the plastic is 0.045 medium density polyethylene. 
     
     
         11 . The device of  claim 12 , wherein there are two product support regions each flanked by flaps, the flaps being hingedly connected to respective support regions to form two rows of product support. 
     
     
         12 . A unitary product cushioning device for supporting shock sensitive products during transport in an exterior container, comprising:
 a product support region having a platform;   a flap connected on either side of the product support region, each flap being connected to the product support region by a hinge to permit each flap to fold about a fold line upwards and towards the product support region;   a plurality of ribs on each flap and product support region, the ribs defining product-supporting cavities therebetween for receiving and supporting the products; and   wherein a portion of each hinge is removed to define cutouts extending along a major portion of said fold line, such that the overall material of the unitary product cushioning device is reduced.