Transport container with cushioning structure

Abstract

A cushioning structure is provided for safely transporting goods, comprising a main frame with at least one bearing surface, carrier foil bonded to the bearing surface, fully covering the at least one bearing surface, and covering the area between the bearing surfaces as a carrying surface for the goods, wherein the main frame comprises multiple foldable inner and outer side flaps able to be folded into multiple supporting elements to support the bearing surface with a height defined by the dimensions of the outer side flaps, wherein the carrier foil comprises a first foil, preferably an urethane foil, and a second foil, preferably an urethane foil, and an air cushion between the first and the second foils. Further, a container is provided configured to be reducible in size, comprising the cushioning structure, a method to load the goods into the container and a method to collapse the empty container.

1 - 17 . (canceled) 
     
     
         18 . A cushioning structure, comprising:
 a main frame comprising at least one bearing surface;   a carrier foil bonded to the bearing surface, wherein the carrier foil fully covers:
 the bearing surface; and 
 an area between bearing surfaces as a carrying surface for the goods, wherein the main frame comprises multiple foldable inner and outer side flaps able to be folded into multiple supporting elements to support the bearing surface with a height defined by dimensions of the outer side flaps, wherein the carrier foil comprises a first urethane foil, and a second urethane foil, and wherein an air cushion is disposed between the first urethane foil and the second urethane foil. 
   
     
     
         19 . The cushioning structure of  claim 18 , wherein the carrier foil is bonded to the bearing surface of the main frame by ultrasonic pressure bonding, and without additional adhesives. 
     
     
         20 . The cushioning structure of  claim 19 , wherein the carrier foil extends to the outer side flaps to increase a bonding strength. 
     
     
         21 . The cushioning structure of  claim 18 , wherein the carrier foil comprises reinforcement patches to locally support a carrying surface. 
     
     
         22 . The cushioning structure of  claim 21  wherein the reinforcement patches are disposed in each corner of the carrying surface near the bearing surface of the main frame. 
     
     
         23 . The cushioning structure of  claim 18 , wherein the bearing surface of the main frame comprises a rectangular shape with a first part, a second part, a third part, and a fourth part, wherein the first part is opposite to the third part and the second part is opposite to the fourth part, and wherein each part comprises one of the foldable inner side flaps facing towards the foldable side flap of the opposite part in a non-folded status, and wherein the inner side flaps comprise a triangular shape. 
     
     
         24 . The cushioning structure of  claim 23 , wherein the inner side flaps comprise a shape like a trapezium. 
     
     
         25 . The cushioning structure of  claim 22 , wherein the main frame comprises an L-shaped corner element that is fixed to the bearing surface of the main frame in each corner of the main frame to strengthen the main frame. 
     
     
         26 . The cushioning structure of  claim 18 , wherein rectangular areas of the outer side flaps are smaller than the areas of the inner side flaps. 
     
     
         27 . The cushioning structure of  claim 18 , wherein the supporting elements are established by the inner and outer side flaps, which are attached to each other by hook-and-loop fasteners, per corresponding inner and outer side flaps. 
     
     
         28 . The cushioning structure of  claim 18 , wherein neighboring outer side flaps are connected to each other by hook-and-loop fasteners, arranged on the outer surface of at least two outer side flaps. 
     
     
         29 . The cushioning structure of  claim 18 , wherein the support elements comprise a rectangular tubular profile. 
     
     
         30 . The cushioning structure of  claim 18 , wherein the main frame comprises pressed paperboard. 
     
     
         31 . A container for transporting goods, comprising:
 a bottom section;   a midsection as a container side wall fitting into the bottom section;   a first cushioning structure and a second cushioning structure, each comprising:
 a main frame comprising at least one bearing surface; 
 a carrier foil bonded to the bearing surface, wherein the carrier foil fully covers:
 the bearing surface; and 
 
 an area between bearing surfaces as a carrying surface for the goods, wherein the main frame comprises multiple foldable inner and outer side flaps configured to be folded into multiple supporting elements to support the bearing surface with a height defined by dimensions of the outer side flaps, wherein the carrier foil comprises a first urethane foil, and a second urethane foil, and wherein an air cushion is disposed between the first urethane foil and the second urethane foil, wherein the first cushioning structure comprises a bottom element fitting into the midsection and for being placed on top of the bottom section with the carrier foil facing upwards to carry good and with the second cushioning structure for being placed on top of the goods with the carrier foil facing downwards to sandwich the goods between the carrier foils of first and second cushioning structures, and a top section fitting on top of the midsection to close the container. 
   
     
     
         32 . The container of  claim 31 , wherein each of the bottom section, the top section and the midsection comprise pressed paperboard. 
     
     
         33 . The container of  claim 31 , wherein the midsection is configured to be foldable fitting into the bottom section in a collapsed status, wherein at least one hook-and-loop fastener is configured to be fixed to the first cushioning structure or the second cushioning structures. 
     
     
         34 . The container of  claim 31 , wherein the midsection comprises closing means configured to be fixed to the top section or the bottom section. 
     
     
         35 . A method for loading goods into a container, comprising:
 placing a midsection on top of a bottom section, wherein the container comprises:
 a bottom section; 
 a midsection as a container side wall fitting into the bottom section; 
 a first cushioning structure and a second cushioning structure, each comprising:
 a main frame comprising at least one bearing surface; 
 a carrier foil bonded to the bearing surface, wherein the carrier foil fully covers:
 the bearing surface; and 
 
 an area between bearing surfaces as a carrying surface for the goods, wherein the main frame comprises multiple foldable inner and outer side flaps configured to be folded into multiple supporting elements to support the bearing surface with a height defined by dimensions of the outer side flaps, wherein the carrier foil comprises a first urethane foil, and a second urethane foil, and wherein an air cushion is disposed between the first urethane foil and the second urethane foil, wherein the first cushioning structure comprises a bottom element fitting into the midsection and for being placed on top of the bottom section with the carrier foil facing upwards to carry good and with the second cushioning structure for being placed on top of the goods with the carrier foil facing downwards to sandwich the goods between the carrier foils of first and second cushioning structures, and a top section fitting on top of the midsection to close the container; 
 
 placing the first cushioning structure with folded support elements comprising reinforcement elements, into the midsection, and on top of the bottom section with the carrier foil facing upwards; 
 placing the goods on top of the carrier foil; 
 placing the second cushioning structure with folded support elements comprising reinforcement elements, into the midsection on top of the goods with the carrier foil facing downwards; 
 placing the top section over the second cushioning structure and the midsection in order to close the container; and 
 securing the closed containers by a securing strap. 
   
     
     
         36 . A method for transporting a container without loaded goods, comprising:
 collapsing a foldable midsection;   placing the collapsed foldable midsection on top of the bottom section;   collapsing a first cushioning structure and a second cushioning structure by unfolding the support elements;   placing the first cushioning structure and second cushioning structures on top of the bottom section or on top of the collapsed midsection together with reinforcement elements of the first cushioning structure or the second cushioning structure; and   placing the top section over the bottom section in order to close the container reduced in size, wherein the container comprises:
 a bottom section; 
 a midsection as a container side wall fitting into the bottom section; 
 a first cushioning structure and a second cushioning structure, each comprising:
 a main frame comprising at least one bearing surface; 
 a carrier foil bonded to the bearing surface, wherein the carrier foil fully covers:
 the bearing surface; and 
 
 an area between bearing surfaces as a carrying surface for the goods, wherein the main frame comprises multiple foldable inner and outer side flaps configured to be folded into multiple supporting elements to support the bearing surface with a height defined by dimensions of the outer side flaps, wherein the carrier foil comprises a first urethane foil, and a second urethane foil, and wherein an air cushion is disposed between the first urethane foil and the second urethane foil, wherein the first cushioning structure comprises a bottom element fitting into the midsection and for being placed on top of the bottom section with the carrier foil facing upwards to carry good and with the second cushioning structure for being placed on top of the goods with the carrier foil facing downwards to sandwich the goods between the carrier foils of first and second cushioning structures, and a top section fitting on top of the midsection to close the container.