Foam packaging apparatus

Abstract

A foam packaging pad for enclosing and packaging an article includes a single sheet of material having a top section, a bottom section, a plurality of wall sections, and at least one first extended section configured to extend from one of the plurality of wall sections toward a side of the bottom section connected to the one of the plurality of wall sections. The single sheet of material includes a plurality of cutting portions cut through an entire thickness of the material and a plurality of connecting hinge portions connected between the plurality of wall sections and the bottom section such that each of the plurality of wall sections is positioned in an angle relative to the bottom section. Further, the wall sections are configured to be folded substantially perpendicular to the bottom section to form a container for receiving the article.

What is claimed is: 
     
         1 . A foam packaging pad for enclosing and packaging an article, the foam packaging pad comprising:
 a single sheet of material including:   a top section;   a bottom section; and   a plurality of wall sections,   wherein the single sheet of material further includes a plurality of cutting portions cut through an entire thickness of the material and a plurality of connecting hinge portions connected between each of the plurality of wall sections and the bottom section such that each of the plurality of wall sections is positioned in an angle relative to the bottom section.   
     
     
         2 . The foam packaging pad of  claim 1 , wherein the single sheet of material further includes at least one first extended section configured to extend from one of the plurality of wall sections toward a side of the bottom section connected to the one of the plurality of wall sections. 
     
     
         3 . The foam packaging pad of  claim 1 , wherein the single sheet of material further includes at least one second extended section configured to extend from one of the plurality of wall sections toward a side of the top section connected to the one of the plurality of wall sections. 
     
     
         4 . The foam packaging pad of  claim 1 , wherein, in a folded configuration, each of the plurality of wall sections is configured to be folded substantially perpendicular to the bottom section to form a container for receiving the article. 
     
     
         5 . The foam packaging pad of  claim 4 , wherein, in the folded configuration, the top section is configured to be folded substantially perpendicular to one of the wall sections to form a lid for covering an opening of the container. 
     
     
         6 . The foam packaging pad of  claim 2 , wherein, in a folded configuration, an extended length of the at least one first extended section from one of the wall sections is substantially the same as a thickness of the single sheet of material. 
     
     
         7 . The foam packaging pad of  claim 2 , wherein, in a folded configuration, each of the plurality of wall sections is configured to retain its folded position due to the at least one first extended section separated from the bottom section and coupled to a side surface of the bottom section. 
     
     
         8 . The foam packaging pad of  claim 7 , wherein, in the folded configuration, the bottom section includes at least one first aperture configured to receive a pad block such that the pad block inserted into the at least one first aperture is configured to support the position of the plurality of wall sections. 
     
     
         9 . The foam packaging pad of  claim 5 , wherein, in the folded configuration, the top section includes at least one second aperture configured to receive a pad block such that the pad block inserted into the at least one second aperture is configured to support the position of the top section in a closed state. 
     
     
         10 . The foam packaging pad of  claim 1 , wherein the single sheet of material includes a first layer and a second layer attached to each other, and the first layer is thicker than the second layer. 
     
     
         11 . The foam packaging pad of  claim 10 , wherein, in a folded configuration, the second layer has the plurality of connecting hinge portions configured to be bend to form a container and/or a lid. 
     
     
         12 . The foam packaging pad of  claim 1 , wherein the single sheet of material further includes at least one locking aperture formed in a side of the top section and at least one locking extended section extending from one of the plurality of wall sections opposite from one of the plurality of wall sections connected to the top section. 
     
     
         13 . The foam packaging pad of  claim 12 , wherein, in a folded configuration, the at least one locking extended section is engaged with the at least one locking aperture of the top section such that the top section is releasably locked with a container formed by the bottom section and the plurality of wall sections. 
     
     
         14 . A foam packaging pad for receiving a portion of an article, the foam packaging pad comprising:
 a single sheet of material including:
 a first section; 
 a second section; 
   a wall section disposed between the first section and the section,   wherein the single sheet of material includes a plurality of cutting portions cut through an entire thickness of the material and a plurality of connecting hinge portions connected between the wall section and each of the first and second sections such that the wall section is positioned in an angle relative to each of the first and second sections.   
     
     
         15 . The foam packaging pad of  claim 14 , wherein the single sheet of material further includes at least one first extended section configured to extend from the first section toward the wall section and at least one second extended section configured to extend from the second section toward the wall section. 
     
     
         16 . The foam packaging pad of  claim 14 , wherein in a folded configuration, the foam packaging pad has an open side receiving the portion of the article to provide a cushioning protection. 
     
     
         17 . The foam packaging pad of  claim 14 , wherein the single sheet of material further includes a protective layer selectively attached to a surface of the first section and configured to protect a surface of the article. 
     
     
         18 . The foam packaging pad of  claim 14 , further comprising a second wall section connected to a side of the first section, the second wall section including a locking aperture to receive a locking extended section extending from a side of the second section. 
     
     
         19 . The foam packaging pad of  claim 18 , wherein, in a folded configuration, the locking extended section of the second section is engaged with the locking aperture of the second extended section such that the second section is releasably locked with the second wall section to receive and protect a corner of the article. 
     
     
         20 . The foam packaging pad of  claim 18 , wherein the single sheet of material includes at least one second extended section configured to extend from the first section toward the second wall section and the second wall section is positioned in an angle relative to the first section.