DESC:FIELD OF THE INVENTION:
The present invention relates to cardboard packaging units and more particularly to a modular packaging unit for all components of ceiling fans.
BACKGROUND OF THE INVENTION:
Packaging units or boxes are widely used for varied purposes such as packaging and shipping goods, storing goods of various sizes and the like. Depending on the size of the goods to be packaged, the size and shape of the boxes also vary. Further, the type of material used also varies. Material such as corrugated cardboard sheets, blister packs, card sheets and the like are commonly used in the Packaging industry. The mechanism of packaging goods also varies depending on the type of goods to be packaged. For example, circular shaped goods require a different type of packaging in contrast to cuboid goods. More elaborate packaging options, often used for collectible or premium cards, and can include features like embossing, foil stamping, or unique material choices.
Key considerations made during packaging include product protection, visual appeal, branding, functionality and cost of manufacturing. The packaging must be such that it safeguards the product from damage from external factors. Further, the design and material should attract and convey the quality of the product when the packaging is also to be displayed. Also, the packaging should be relatively easy to open but should have certain sealing mechanisms as well. Apart from these points, the manufacturing such packaging units should also be cost effective.
Ceiling fans are commonly packaged using cardboard boxes, which include protective inserts made from thermocol, sponge, or bubble wrap to safeguard the components during transit. Traditionally, the packaging involves two separate boxes: one smaller box houses the hub, motor, hub casing, canopy, remote, and other accessories, while a second box contains the blades. After purchasing a ceiling fan, customers typically receive two separate boxes. This dual-box system is cumbersome for both retailers and consumers, adding to the complexity of handling and increasing the likelihood of misplacement or damage during transit.
Alternatively, all components may be packed together in a single large box. However, this method often results in significant redundant space within the packaging, leading to inefficient use of volume during shipping. This inefficiency not only increases transportation costs but also poses challenges in ensuring the safe transit of the ceiling fans. The excessive empty space within the box can cause the components to shift during transport, increasing the risk of damage. Additionally, the larger single-box approach does not effectively address the organizational needs of the various components, often resulting in a cluttered and insecure packing scenario.
Furthermore, issues arise when components like the hub and blades are packed together in different colors, leading to potential mismatches and complications during packaging. Such mismatches can cause confusion for both retailers and customers, affecting the overall customer satisfaction and increasing the chances of returns or exchanges. The transport process becomes even more challenging due to the movement of components within the box, increasing the risk of damage.
The Canadian Patent Application CA2338136A1 to Charles E. Bucher, et al., discloses a folding fan that includes ready to hand ceiling fans where the whole fan is enclosed in a single packaging. However, transport of the folding fan is tedious and required additional space.
The Chinese Patent CN216035653 to Zong Tongzu, et al., discloses a paper-plastic packaging structure for a multi-lamp ceiling fan. This patent includes a container to store various parts of a ceiling fan. However, the packaging structure of this patent is not fit for transport as the upper part of the central portion of the ceiling fan remains exposed, leading to possibilities of damage and wear and tear.
There is a need of a packaging for ceiling fans that comes in a single packaging. Further, there is a need for a packaging unit for ceiling fans that is able to enclose all of its elements in a single location during transport with minimal hassle and high cost efficiency.
SUMMARY OF THE INVENTION:
The present invention discloses a packaging unit for ceiling fans, enclosing all components of a disassembled ceiling fan in a single packaging, including an outer shell having a first flat configuration as a blank and a second standing configuration as a standing three-dimensional container. The outer shell is formed of at least one blank having fold lines defining a plurality of panels. Further, an elongated insert is disposed along a sidewall of the interior compartment and the elongated insert includes at least one storage groove and at least one storage niche that are configured to hold batteries, a remote, nuts, tools, and blades of the ceiling fan. Furthermore, a triangular insert is positioned adjacent to the elongated insert, such that the triangular insert includes at least one aperture and at least one retention tab adapted to secure a canopy and canopy rod of the ceiling fan. Also, a container receives a motor of the disassembled ceiling fan and a base is positioned below the container to support the motor, wherein the combination of the inserts and the container occupying substantially all free space within the interior compartment, thereby reduce redundant volume and preventing component movement during transport.
The outer shell of the packaging unit is formed from a pair of blanks and is attached along predefined tabs to form the standing configuration. Further, the outer shell is formed from a single blank including main panels, secondary panels, and integral flaps that are folded and adhered and define the standing configuration. Also, the outer shell includes at least one perforation that defines a handle for manual carrying. It is noted that the packaging unit is made of corrugated cardboard of B flute or C flute grade.
The elongated insert includes a first main panel and a second main panel that define a tray portion. The elongated insert also includes a plurality of foldable flaps configured to close the tray and at least one groove and at least one niche that are integrally formed by slits and tearable portions to secure accessories. The triangular insert includes a triangular panel, a plurality of folding panels that enclose the canopy, and at least one aperture having flaps configured to retain the canopy within the insert. Further, the container includes a quadrilateral main panel and a plurality of flaps that are foldable upward to form a bowl-shaped receptacle.
The outer shell in standing configuration includes a cuboid when paired with a second identical packaging unit positioned adjacent along their longest trapezoidal sides. The outer shell, elongated insert, triangular insert, container, and base are machine-pasted or die-cut to fit to dimensions of the ceiling fan components. Further, the base is configured to conform to the shape of the container to prevent movement of the motor during transport. The standing configuration includes externally sealable flaps that are joined by at least one sealing means selected from the group including of adhesive tape, glue, staples, and heat sealing and the like.
The arrangement of two packaging units along their respective diagonals form a single cuboid unit allowing efficiency in stacking of the units for transport. The length of the blank of the outer shell is approximately 1443.38mm and the width being approximately 371.58mm. Further, the length of the elongated insert is approximately 582mm and the width is approximately 180mm. Furthermore, the length of the triangular insert is approximately 442.24mm and the width is approximately 106mm. It is noted that the main panel of the base is a quadrilateral including one acute angle such that when folded, the base fits into the gap remining within the packaging unit after the elongated insert and the triangular insert are positioned in the outer shell.
A process of assembly of the packaging unit from the first flat configuration to a second standing configuration includes five phases. A first phase being a connecting phase that includes connecting the first blank to the second blank through tabs, forming a hollow cylindrical structure or connecting a tab to a second end of the single blank, forming a hollow cylindrical structure. A second phase, being a positioning phase that includes positioning the main panels such that the respective main panels are parallel to each other forming an approximate three-dimensional structure. A third phase, being a folding phase that includes folding the plurality of side flaps and long flaps and forming an initial structure of the packaging unit. A fourth phase, being sealing phase that includes sealing the long flaps externally by sealing means such as adhesive tape, glue, staples, and heat sealing and the like, thereby forming the outer shell of the packaging unit and a fifth phase being a receiving phase that includes the outer shell inserts in an order, including inserting the elongated insert, followed by the triangular insert, followed by the base and then the container.
The process for the assembly of the elongated insert including four cycles. A first cycle being a connecting cycle that connects the second tab to the first main panel and connecting and attaching the second main panel to the first tab forming an initial insert structure. A second cycle being a positioning cycle that positions the main panels such that the respective main panels being parallel to each other forming an approximate three-dimensional structure. A third cycle being a folding cycle, for folding the plurality of side flaps forming the tray portion of the elongated insert packaging unit. A fourth cycle being a sealing cycle, for sealing the long flaps externally by sealing means such as adhesive tape, glue, staples, and heat sealing and the like, thereby forming the outer shell of the packaging unit.
The process for assembly of the triangular insert including three cycles. A first cycle, being a folding cycle, for folding the plurality of flaps forming an initial approximate three-dimensional structure of the triangular insert. A second cycle, being a positioning cycle, for positioning the flaps for receiving canopy of the disassembled fan and the tabs being pushed inwards, forming the suspension means for retaining the rod of the disassembled fan. A third cycle, being an insertion cycle, for inserting the triangular insert within the outer shell without requiring any sealing means.

BRIEF DESCRIPTION OF DRAWINGS:
The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,
FIG. 1 shows a front perspective view of a pair of the packaging units for ceiling fans of the present invention;
FIG. 2A shows a front perspective view of a single packaging unit for ceiling fans of FIG. 1;
FIG. 2B shows a top view of a first blank of a flat configuration of an outer shell of the packaging unit for ceiling fans of FIG. 1;
FIG. 2C shows a top view of a second blank of the flat configuration of the outer shell the packaging unit for ceiling fans of FIG. 1;
FIG. 2D shows a top view of a single blank of the flat configuration of the outer shell of the packaging unit for ceiling fans of FIG. 1;
FIG. 3A shows a top perspective view of the opened packaging unit for ceiling fans of FIG. 1;
FIG. 3B shows perspective view of inner components of the packaging unit for ceiling fans of FIG. 1;
FIG. 3C shows an exploded view of the packaging unit for ceiling fans of FIG. 1;
FIG. 4A shows a top view of a blank of an elongated insert of the packaging unit for ceiling fans of FIG.1;
FIG. 4B shows a perspective view of the elongated insert of the packaging unit for ceiling fans of FIG.1;
FIG. 5A shows a top view of a blank of an triangular insert of the packaging unit for ceiling fans of FIG.1;
FIG. 5B shows a perspective view of the triangular insert of the packaging unit for ceiling fans of FIG.1;
FIG. 6A shows top view of a blank of a base of the packaging unit for ceiling fans of FIG.1;
FIG. 6B shows a perspective view of the base of the packaging unit for ceiling fans of FIG.1;
FIG. 7A shows a top view of a blank of a container of the packaging unit for ceiling fans of FIG.1;
FIG. 7B shows perspective view of the container of the packaging unit for ceiling fans of FIG.1;
FIG. 8A shows a top view of a blank of a second embodiment of the packaging unit for ceiling fans of FIG. 1;
FIG. 8B shows a perspective view of the second embodiment of the packaging unit for ceiling fans of FIG. 1;
FIG. 9A shows a top view of a first blank of a flat configuration of a third embodiment of the packaging unit for ceiling fans of FIG. 1;
FIG. 9B shows a top view of a second blank of a flat configuration of the third embodiment of the packaging unit for ceiling fans of FIG. 1;
FIG. 9C shows a top view a single blank of the flat configuration of the third embodiment of the packaging unit for ceiling fans of FIG. 1;
FIG. 9D shows a perspective view of the third embodiment of the packaging unit for ceiling fans of FIG. 1; and
FIG. 10 shows an exploded view of the third embodiment of the packaging unit for ceiling fans of FIG. 1.
DESCRIPTION OF THE INVENTION:
References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.
The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching.
The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the disclosure. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.
Referring to FIG. 1, a pair of packaging units for a ceiling fan in accordance with the present invention is described. Each packaging unit for a ceiling fan being referred to hereinafter as ‘packaging unit’. A pair of such packaging units (100) are positioned besides each other to form a cuboid unit. The pair of packaging units (100) include a first packaging unit (104) and a second packaging unit (108). In accordance with the present invention, each of the packaging units (104, 108) have two configurations- a first flat configuration and a second standing configuration. In the first flat configuration, the unit (104, 108) is a blank with predefined slots and holes. Whereas, the second configuration is three dimensional and accommodates various parts of the fan in dissembled condition.
It is noted that each of the single unit (104, 108) is preferably trapezoidal in shape. Two trapezoidal packaging units (104, 108) when arranged together, along their longest side, form a cuboid unit of the present invention. The cuboid units allow for stacking of multiple packaging units with disassembled fans on top of each other without damaging the disassembled fans itself. Further, the packaging of the present invention is transported in the flat configuration in the form of a blank.
Referring to FIG. 2A, a first configuration of the packaging unit (104) in accordance with the present invention is described. The standing configuration of the present invention includes a single packaging unit (104) with preferably a trapezoidal shape. The packaging unit (104) includes a single slope that is diagonally positioned, mimicking an approximate cut made to a cuboid unit or container. Further, the packaging unit (104) includes a total of six panels.
A first panel (204) (NOT SEEN) of the unit (104) is a planar side and is an approximate square. The first panel (204) is parallel to a second panel (208), wherein the second panel (208) is an approximate narrow rectangle. Further, the first panel (204) and the second panel (208) are exactly opposed sides. A third panel (212) (NOT SEEN) connects the first panel (204) and the second panel (208) and is positioned exactly perpendicular to the two panels (204, 208). Further, a fourth panel (216) is positioned at an acute angle, relative to the first panel (204) such that the fourth panel (216) connects the first panel (204) and second panel (208).
The positioning of the fourth panel forms a diagonal slope, that is distinctive of the packaging unit (104). Also, the third panel (212) and the fourth panel (216) are opposed panels. A fifth panel (220) and a sixth panel (224) (NOT SEEN) are positioned such that they connect each of the other sides respectively to form the trapezoidal packaging unit (104) of the present invention.
It is noted that each packaging unit of the present invention is assembled from either a pair of blanks or a single blank. The blanks are folded and pasted together in a predefined manner to assemble each packaging unit. In the preferred embodiment of the present invention the packaging unit (104) is formed from two blanks (110, 110A) (NOT SEEN). Each of the two blanks are connected in a predefined manner to form the outer shell of the packaging unit (104). The standing configuration is shaped by folding the blank in the flat configuration at predefined fold lines. In accordance with the present invention, the fifth panel (220) and sixth panel (224) further includes a pair of flaps (228). Each of the flaps (228) are vertical and connect to each other at the approximate center of the two panels (220,224). The pair of flaps (228) are externally sealed together by a sealing means. In this preferred embodiment, the sealing means used is a cello tape. However, other embodiments of the present invention, may include other sealing means such as glue, staples, hot press sealing and the like.
The second panel (208) further includes a pair of perforations (232) that include a handle. This allows for ease in transport of the packaging unit (104) when in the standing configuration.
In accordance with the present invention, removing the sealing from the flaps (228) opens the packaging unit (104) and allows access to the disassembled fan components stored inside. Further, the packaging unit (104) of the present invention is preferably made of material such as corrugated sheets that is of the B or C flute type. However, a person skilled in the art will appreciate that in other embodiments, material such as corrugated sheets of other categories such as A flute, E flute, card sheets and the like may be used.
Referring to FIG. 2B and 2C the two parts of a blank of the packaging unit for ceiling fans is described. The packaging unit (104) may either be assembled from a pair of blanks (110, 110A) or a single blank (110B). The first blank (110) of the pair of blanks includes a first central panel (236), an side panel (240) and a first tab (244). The first blank (110) further includes a first pair of side flaps (248) and a first pair of long flaps (252).
The first central panel (236) is elongated and its shorter end connected to the side panel (240) by a fold line (236’). Further, a pair of fold lines (252’) connects the first pair of long flaps (252) to the first central panel (236). The pair of long flaps (252) are connected along the length of the first central panel (236). Further, a pair of fold lines (248’) connects the first pair of side flaps (248) to the side panel (240). The first tab (244) is further connected to the side panel (240) by a fold line (244’). Further, the side panel includes the pair of perforation (232) that allow attachment of a handle. It is noted that the first central panel (236) forms the third panel (212) of the packaging unit (104) when in standing configuration. Similarly, the side panel (240) forms the second panel (208) of the packaging unit (104) when in standing configuration.
The second blank (110A) includes a second central panel (260), a second tab (256), and a second side panel (264). The second blank (110A) also includes a second pair of long flaps (268) and a second pair of side flaps (272).
In accordance with the present invention, the second central panel (260) is elongated and its shorter end connected to the second side panel (264) by a fold line (260’). Further, the second pair of long flaps (268) are connected to the second central panel (260) by a pair of fold lines (268’). The pair of long flaps (268) are connected along the length of the second central panel (260). Further, the second pair of side flaps (272) are connected to the second side panel (264) by a pair of fold lines (260’). Furthermore, the second tab (256) is further connected to the second side panel (264) by a fold line (256’). Further, the second side panel (264) and the second pair of side flaps (272) include a crease line (264A) running across them. This crease line (264A) allows for folding of the second side panel (264) when the packaging unit (104) is in a standing configuration. In the present embodiment, the tabs (244, 256) are preferably glue tabs. However, in other embodiments of the present invention, the tabs (244, 256) may include other sealing means such as tape, hot press sealing and the like.
It is noted that the second central panel (260) forms the fourth panel (216) of the packing unit (104) when in standing configuration. Further, the second side panel (264) form the first panel (204) of the packing unit (104) when in standing configuration. In accordance with the present invention, the first pair of long flaps (252) forms the fifth panel (220) and the second pair of long flaps (268) form the sixth panel (224) of the packaging unit when in standing configuration.
In accordance with the present invention, the total length of the first blank (110) is approximately 674.88mm and the width is approximately 368.78mm. Further, the length of the first central panel (236) is approximately 604.88mm. Whereas, the total length of the second blank (110A) is approximately 798.5mm and the width is approximately 371.58mm. Further, the length of the second central panel (260) is approximately 588.5mm. Furthermore, the length of both the tabs (244, 256) is approximately 187mm. However, a person skilled in the art will appreciate that the dimensions of each blank (110, 110A) may vary depending on the size of the ceiling fan that is to be packaged within it. Further, it is noted that the blanks (110, 110A) shape the outer shell (302) of the packaging unit (104).
Now referring to FIG. 2A, 2B, 2C, 2D and 3A, the assembly of the packaging unit (104) from a flat configuration to a standing configuration is described. In a first step, the second tab (256) is attached onto the edge of a first central panel (236) of the first blank (110). This allows a single elongated blank to be formed. In other embodiments, a single blank may be formed, bypassing the second tab (256). However, this single tab requires complex and big machinery that may increase the cost of the product as a whole. In a second step, the first tab (244) is pasted onto the edge of the second central panel (260) of the second blank(110A). This leads to formation of a hollow cylinder-like structure from the blanks (110, 110A). In a third step, the flaps (248, 272) are folded inwards along respective fold lines (248’, 272’). Further, the panels (240, 264) are also folded inwards along respective fold lines (236’, 244’, 260’, 256’). In a fourth step, each of the long flaps (252, 268) are folded inwards along the respective fold line (252’, 268’). This forms the packaging unit (104) in its standing configuration.
In another embodiment, the packaging unit (104) is formed from a single blank (110B). The blank (110B) includes a first main panel (276), a second main panel (280), a first pair of long flaps (284) and a second pair of long flaps (288). Further, the blank (110B) includes a connecting panel (289) and a first pair of flaps (290). There also includes an upper panel (291) a second pair of flaps (292) and a tab (293).
The connecting panel (289) connects the first and the second main panel (276, 280) by fold lines (276’, 280’) respectively. Further, the first pair of flaps (290) are connected to the connecting panel (289) by a pair of fold lines (289’). Further, the first pair of long flaps (284) are connected along the length of the second main panel (280) through a pair of fold lines (284’). Whereas, the second pair of long flaps (288) are connected along the length of the first main panel (282) through a pair of fold lines (288’). This forms the main panel portion of the packaging unit (104) of the present invention.
Further, the upper panel (291) is connected to the second end of the first main panel (276) by a fold line (291’). Also, the second pair of flaps (292) are connected to the free ends of the upper panel (291) by a pair of fold lines (292’). The tab (293) is connected to the upper panel (291) through a fold line (293’). Further, the upper panel (291) and the second pair of flaps (292) include a crease line (291A) running across them. This crease line (291A) allows for folding of the upper panel (191) when the packaging unit (104) is in a standing configuration.
It is noted that the second main panel (280) forms the fourth panel (216) of the packing unit (104) when in standing configuration. Further, the upper panel (291) form the first panel (204) of the packing unit (104) when in standing configuration. In accordance with the present invention, the first pair of long flaps (284) forms the fifth panel (220) and the second pair of long flaps (288) form the sixth panel (224) of the packaging unit when in standing configuration.
In accordance with the present invention, the total length of the blank (110B) is approximately 1443.38and the width is approximately 371.58mm. Further, the length of each of the main central panels (276, 280) is approximately 588.5mm. Further, the length of the tab (293) is approximately 187mm. However, a person skilled in the art will appreciate that the dimensions of the blank (110B) may vary depending on the size of the ceiling fan that is to be packaged within it.
Now, assembly of the packaging unit (104) from the single blank is described. In a first step, the tab (293) is pasted onto the edge of a second central panel (280). In a second step, the flaps (290, 292) are folded inwards along respective fold lines (290’, 292’). Further, the upper panel (291) is also folded inwards along respective fold lines (291’). In a fourth step, each of the long flaps (284, 288) are folded inwards along the respective fold line (284’, 288’). This forms the packaging unit (104) in its standing erect configuration.
Referring to FIG. 3A, 3B and 3C, the packaging unit (104) in the standing and assembled configurations along with its inner packaging components is described. The assembled packaging unit (104) includes a plurality of inner packaging components that hold various disassembled parts of a fan in them. The assembled packaging unit (104) includes the outer shell (302), an elongated insert (304), a triangular insert (308), a container (312) and a base (316). The outer shell (302) is formed from either a pair of blanks or a single blank as per the machinery available. An elongated insert (304) is positioned parallelly along the inner wall of the third panel (212) of the packaging unit (104). It is also noted that the elongated insert (304) stores the blades, battery, nuts, tool and the remote of the disassembled fan within it. The triangular insert (308) is positioned exactly next to the elongated insert (304). Further, the second side of the triangular insert (308) runs parallelly along the inner wall of the fourth panel (216) of the packaging unit (104). The triangular insert (308) preferably stores the canopy and canopy rod of the disassembled fan within it.
Further, the container (312) is an open cuboid container that is positioned in the gap formed after the positioning of the elongated insert (304) and the triangular insert (308). The container (312) is further positioned on the base (316). It is noted that the container (312) holds the motor parts of the disassembled fan within it. The base (316) is an approximate cuboid that has the exact same shape as that of the base of the container (312). The base (316) is positioned within the gap formed after the positioning of the elongated insert (304) and the triangular insert (308). It is noted that the base (316) provides support to the motor stored within the container (312), thereby preventing damage and wear and tear to the motor of the disassembled fan. All of the inner packaging components of the packaging unit (104) allow efficient storage of all disassembled fan components. Further, the handle positioned on the second panel (208) of the packaging unit (104) allows for ease in manual transport.

Now referring to FIG. 4A and 4B, a blank and standing configuration of the elongated insert (304) of the packaging unit (104) is described. The elongated insert (304) includes a first main panel (404), a second main panel (408) and a first connecting panel (412). Further, the elongated insert (404) also includes a second connecting panel (416), a first tab (420) and a second tab (424). The first connecting panel (412) connects the first main panel (404) to the second main panel (408) through a pair of fold lines (412’) along the length of their first end. Further, each of the main panels (404, 408) include a pair of side flaps (428, 432) attached to their width respectively. The pair of side flaps (428, 432) are each connected to the main panels (404, 408) by a pair of fold lines (428’, 432’) respectively.
The second connecting panel (416) connects the second end of the first main panel (404) to the first tab (420). It is noted a fold line (404’) connects the second connecting panel (416) to the first main panel (404). Further, a fold line (416’) connects the second end of the second connecting panel (416) to the first tab (420). In the preferred embodiment of the present invention the first tab (420) is a glue tab. Also, a fold line (420’) connects the second tab (424) to the first tab (420). In accordance with the present invention, the second tab (424) includes a crease line (424A) that divides the second tab (424) into two parts such that the first tab part (424a) is connected to the first tab (420) and the second part (424b) has two tapered ends. Further, preferably, the second part (424b) is a glue tab. There also includes a pair of side flaps (436) that are attached to the remaining two free ends of the second connecting panel (416) through a pair of fold lines (436’). This forms the blank of the elongated insert (304).
In accordance with the present invention, the blank of the elongated insert includes a plurality of cuts and slits that when assembled form grooves, slots and niches that hold several components of a disassemble fan. The second panel (408) includes a first slit (440’), a first cut (444’), a second slit (448’) and a notch (452’). Further, the connected pieces of the first panel (404), the second connecting panel (416), the first tab (420) and the second tab (424) define a single connected portion (304A). A plurality of slits and cuts are etched out onto this connected portion (304A). Further, this connected portion (304A) includes a third slit (440’’) and a second cut (444’’). It is noted that the third slit (440’’) and the second cut (444’’) are cut onto the connected portion (304A) such that it corresponds to the first slit (440’) and the first cut (444’) respectively. Further the connected portion (304A) includes a first tearable portion (448’’) and second tearable portion (452’’). The first and second tearable portions (448’’, 452’’) are positioned such that they correspond to the second slit (448’) and the notch (452’) respectively. It is also noted that the second tab (424) includes a pair of slots (448’’) that correspond to the first tearable portion (448’’) and the second slit (448’) respectively.
In accordance with the present invention, the total length of the elongated insert (304) is approximately 582mm and the approximate width of the elongated insert is 180mm. However, a person skilled in the art will appreciate that the dimensions of the elongated insert (304) and subsequently its blank shall differ depending upon the size and shape of the packaging unit (104) and the fan itself.
Now, the assembly of the elongated insert (304) of the packaging unit (104) is described. In a first step, the second part (424b) of the second tab (424) is folded and glued onto the edge of first main panel (404) and the crease line (424A) is folded. In a next step, the second main panel (408) is folded onto the first main panel (404) such that the second tab (420) is attached onto the edge of the second main panel (408). The second main panel (408) is positioned such that it is parallel to the first main panel (404). This leads to formation of a tray portion (456) that is able to store other fan components as well. In a next step, the side flaps (436) are folded inwards. The two pairs of side flaps (428, 432) are then folded inwards to form a box like shape of the elongated insert (304).
In a next step, the first slit (440’) and the second slit (440’’) now correspond together to form a groove (440). Further, the first cut (444’) and the third slit (444’’) now correspond together to form a depression (444) that is open from the side of the main panel (408). In a next step, the first tearable portion (448’’) is torn sideways and the third slit (448’) is positioned such that it corresponds to the first tearable portion (448’’). The torn parts of the first tearable portion (448’’) are tucked into the gap formed with the tray portion (456) to form a first niche (448). In a final step, the second tearable portion (452’’) is torn sideways and the notch (452’) is positioned such that it corresponds to the second tearable portion (452’’). The torn parts of the second tearable portion (452’’) are tucked into the gap formed with the tray portion (456) to form a second niche (452).
In accordance with the present invention, the groove (440), the first niche (448) and the second niche (452) are storage cells that hold several components of the disassembled fan. In the preferred embodiment of the present invention, the groove (440) holds the batteries of the disassembled fan, the first niche (448) holds the remote that controls the fan. Further, the second niche (452) holds the various nuts and tools of the disassembled fan.

Referring to FIG. 5A and 5B, a blank and standing configuration of the triangular insert (308) of the packaging unit (104) is described. The triangular insert (308) a triangular panel (504), a first panel (508), a second panel (512) and a third panel (516). A fold line (508’) connects the triangular insert (504) to the first panel (508). Further, a fold line (512’) connects the triangular insert (504) to the second panel (5012), whereas a fold line (516’) connects the triangular insert (504) to the third panel (516). It is noted that the second panel (512) is connected to the longest side of the triangular panel (504) and the third panel (516) is connected to the shortest side of the triangular panel (504). Further, the second panel (512) is approximately a pentagon.
An aperture (520) is positioned on the broad portion of the triangular panel (504). The aperture (520) is positioned approximately on the left side of the triangular panel when positioned on the X axis. Further, the aperture (520) is approximately an octagon wherein each side of the octagon includes a triangular flap (524). Each of the triangular flaps (524) are positioned such that the aperture (520) is covered. In accordance with the present invention, the first panel (508) includes a pair of tabs (528) that are equidistant from one another. The pair of tabs (528) are preferably D-shaped tabs that are positioned approximately centrally on the first panel (508). Further, each of the tab (528) includes an opening (532). The openings (532) are also D shaped and approximately centrally positioned on the tabs (528). The openings (532) further define a suspension means (532) that hold the rod of a disassembled fan. When the tabs (528) are folded inwards, the width of the opening (532) accommodates the width of a rod of a disassembled fan. It is also noted that the third panel (516) is connected to a pair of side flaps (536) through a pair of fold lines (536’).
In accordance with the present invention, the total length of the triangular insert (308) is approximately 442.24mm and the approximate width of the triangular insert (308) is 106mm. However, a person skilled in the art will appreciate that the dimensions of the triangular insert (308) and subsequently its blank shall differ depending upon the size and shape of the packaging unit (104) and the fan itself.
Now the assembly of the triangular insert (308) of the packaging unit (104) is described. In a first step, the first panel second panel (508, 512) are folded inwards onto the triangular panel (504). In a next step, the side flaps (536) of the third panel (516) inwards. Further, the third panel (516) is folded inwards along the fold line (516’) such that the side flaps (536) are tucked within the walls of the first panel (508) and the second panel (512). In a next step, the tabs (528) on the first panel (508) are folded inwards such that a rod of the disassembled fan may be held within the openings (532) of the tabs (528). In a final step, the triangular flaps (524) on the aperture (520) are pushed inwards to accommodate the canopy of the disassembled fan within the packaging unit. This provides a stable storage space for the canopy and rod of the disassembled fan without requiring any additional packaging components.

Referring to FIG. 6A and 6B, a blank and standing configuration of the base (316) of the packaging unit (104) is described. The base (316) includes a main panel (604), a left panel (608) and a right panel (612). The base (316) also includes a plurality of connecting panels, glue tabs and side flaps. A first connecting panel (616) connects the main panel (604) to the right panel (612). Further, a fold line (616’) connects the main panel (604) to the first connecting panel (616) and a fold line (612’) subsequently connects the right panel (612) to the first connecting panel (616). A second connecting panel (620) connects the main panel (604) to the left panel (608). Further, a fold line (620’) connects the main panel (604) to the second connecting panel (620) and a fold line (608’) subsequently connects the left panel (608) to the first connecting panel (620).
In accordance with the present invention, a third connecting panel (624) connects the right panel (616) to a first tab (632). A fold line (624’) connects the third connecting panel (624) to the right panel (616) and a fold line (632’) connects the third connecting panel (624) to the tab (632). Further, a fourth connecting panel (628) connects the left panel (608) to a second tab (636). A fold line (628’) connects the fourth connecting panel (628) to the left panel (608) and a fold line (636’) connects the fourth connecting panel (628) to the second tab (636). It is noted that a pair of side flaps (640) are connected to the main panel (604) by a fold line (640’).
The main panel (604) is preferably a quadrilateral that includes one acute angle. The shape of the main panel (604) is such that when folded, the base (316) fits into the gap remining within the packaging unit after the elongated insert (304) and the triangular insert (308) are positioned within it. The total length of the base (316) is approximately 118mm. However, a person skilled in the art will appreciate that the dimensions of the base (316) and subsequently its blank shall differ depending upon the size and shape of the packaging unit (104) and the fan itself.

Referring to FIG. 7A and 7B, a blank and standing configuration of the container (312) of the packaging unit (104) is described. The container (312) includes a main panel (704) and a plurality of flaps (708). Each side of the main panel (704) is connected to one flap (708) through a fold line (708’). Further, each flap (708) includes rounded edges. The assembly of the container (312) includes folding of the flaps (708) in an upwards direction, resembling a bowl. The main panel (704) is preferably a quadrilateral that includes one acute angle. The shape of the main panel (704) is such that when the container is assembled, the container (312) fits onto the base (316) of the packaging unit (104). In accordance with the present invention, the approximate length of the container (312) is 118mm.
Referring to FIG. 8A and 8B, a blank and standing configuration of a second embodiment of the packaging unit (800) of the present invention is described. The blank of the second embodiment of the packaging unit (800) includes a first main panel (804), a second main panel (808) and a connector panel (812). The blank also includes a plurality of side panels, plurality of tabs, notches and flaps. The connector panel (812) connects the first main panel (804) to the second main panel (808) through a pair of fold lines (804’, 808’) respectively. A first pair of long panels (816) are connected along the length of the first main panel (804) through a pair of fold lines (816’). Whereas, a second pair of panels (832) are connected to the second main panel (808) through a pair of fold lines (832’).
Further, three side panels (820, 824, 828) are positioned adjacent to the first pair of long panels and the first main panel (804). The second side panel (824) is positioned between the first side panel (820) and the third side panel (828) such that the second side panel is connected to the first main panel (804). Each of the side panels (820, 824, 828) are connected to the main panel (804) through fold lines (824’). Also, each of the side panels (820, 824, 828) includes a crease line (824A) that allows folding of the side panels (820, 824, 828).
In accordance with the present invention, the second side panel (824) is connected to a tab (836) through a fold line (836’). The tab (836) is preferably a glue tab. Further, the first and the third side panels (820, 828) are connected each to a pair of flaps (840) through a fold line (840’). Also, a pair of side flaps (852) are connected to the free ends of the connector panel (812). It is noted that the first pair of long panels (816) each include a pair of tabs (844). Each of the tabs (844) is equidistant to the other and include an aperture within them. Further, two pairs of notches (848) are positioned between the second pair of long flaps (832) and the second main panel (808). The tabs (844) and the notches (848) slot into one another when the packaging unit (800) is assembled, forming a locking mechanism.
Now, the assembly of the standing configuration of the second embodiment of the packaging unit (800) is described. In a first step, the second main panel (808) is folded onto the first main panel (804) such that the two panels (804, 808) are parallel to one another. In a next step, the tab (826) is glued onto the second main panel (808). In a next step, the long panels (816, 832) and the side flaps (852) are folded inwards followed by the flaps (840) of the side panels (820, 828). In a final step, the tabs (844) on the first pair of long panels (816) are inserted into the corresponding notches (848) to lock the packaging unit (800). It is noted that first pair of long panels (816) form the top panel (852) and bottom panel of the packaging unit (800) in the standing configuration. Further, the first main panel (804) and the second main panel (808) form the side panels (856) of the packaging unit (800) in the standing configuration. Similarly, the connector panel (812) forms the front panel (860) and the three side panels (820, 824, 828) form the rear panel of the packaging unit (800) in the standing configuration.
Referring to FIG. 9A, 9B, 9C and 9D, a blank and standing configuration of a third embodiment of the packaging unit (900) is described. The packaging unit (900) may either be made from a pair of blanks (910, 910A) or a single blank (910B). The first blank (910) of the pair of blanks (910, 910A) includes a first central panel (904), a right panel (908) and a left panel (912). Further, the blank (910) includes a first pair of long flaps (916), a first tab (924) and a pair of side flaps (928). The first central panel (904) is connected to the right panel (908) and left panel (912) on respective side by fold line (908’) and fold line (912’) respectively.
Further, the first pair of long flaps (920) are connected to the free sides of the first central panel (904) by a fold line (916’). Furthermore, a fold line (924’) connects the left panel (912) to the first tab (924). Also, the first pair of side flaps (928) are connected to the left panel (912) by a pair of fold lines (928’). In accordance with the second embodiment of the present invention, the first pair of long flaps (916) includes a pair of diagonal cuts (920) on their right side. The cuts (920) and the right panel (908) allow for assembly of the packaging unit (800) in accordance with this embodiment. Further, the left panel (912) includes a pair of perforations (932) that allow a handle to be positioned within it for transport of the packaging unit (800).
The second blank (910A) of the pair of blanks (910, 910A) includes a second central panel (936), a side panel (940), a second pair of long flaps (944), a pair of side flaps (948) and a second tab (952). A pair of fold lines (944’) connect the second pair of flaps (948) to the second central panel (936). Further, a fold line (940’) connects the second central panel (936) to the side panel (940). Also, a pair of fold lines (948’) connect the pair of side flaps (948) to the side panel (940). In accordance with the present embodiment, a crease line (940A) cuts across the side panel (940) and the pair of side flaps (948) that allows the side panel (940) and side flaps (948) to fold when the packaging unit (900) is assembled. Further, a fold line (952’) connects the second tab (952) to the side panel (940).
In another embodiment, the packaging unit (900) is formed from a single blank (910B). The single blank (910B) includes a first main panel (956), a second main panel (960) and a connector panel (972). The single blank (910B) further includes a first pair of long flaps (964), a second pair of long flaps (968), a side panel (984), a pair of side flaps (976) and a tab (988). The connector panel (972) connects the first main panel (956) and the second main panel (960) through a fold line (956’) and a fold line (960’) respectively. Further, a fold line (984’) connects the side panel (984) to the first main panel (956). Furthermore, the pair of side flaps (976) are connected to the connector panel (972) through a fold line (976’). Also, the first pair of long flaps (964) and the second pair of long flaps (968) are connected to the first main panel (956) and second main panel (960) by a pair of fold lines (964’, 968’). The tab (988) is connected to the side panel (984) by a fold line (988’). In accordance with the present embodiment, a crease line (972A) runs across the connector panel (972) and the side flaps (976). This allows for folding of the connector panel (972) when the packaging unit (900) is assembled.
In accordance with the third embodiment, the shape of the packaging unit (900) is such that an additional side is formed, allowing for additional space within the packaging unit (900) for storing disassembled fans. Further, it is noted that two packaging units (900) of the third embodiment when arranged along their diagonal do not form a cuboid unit.
Now, the assembly of the packaging unit (900) is described. In a first step, second tab (952) is attached to the right panel (908). Preferably, the second tab (952) is a glue tab. In a second step, the first tab (924) is then attached to the second central panel (936). In a next step, the first pair of long flaps (916) and the second pair of long flaps (944) are folded inwards. Next, the pair of side flaps (948) are folded inwards. In a final step, the cuts (920) are folded inwards to form the packaging unit (900) of the present embodiment.
Now referring to FIG. 10, an exploded view of the packaging unit (900) is described. The packaging unit (900) includes an outer shell (990), an elongated insert (992), a triangular insert (994), a container (996) and a base (998). The outer shell (990) is formed from either a pair of blanks (910, 910A) or a single blank (910B) as per the requirement of the user. The outer shell (990) encloses the various components of the packaging that hold the disassembled fan components within it. The elongated insert (991) includes 2 slots (993) that hold components such as the remote and batteries of the fan. Further, the blades of the fan are inserted from the sides of the elongated insert (992). The triangular insert (994) includes 2 apertures (992, 993) that hold the canopy of the disassembled fan. Further, the triangular insert (994) is broad and also holds the rod of the disassembled fan. Further, the base (998) is positioned in the gap remaining between the elongated insert (992) and the triangular insert (994). The container (996) is positioned atop the base (998) and holds the motor of the disassembled fan.
Advantageously, the packaging unit of the present invention eliminates the redundant space, reduces the risk of damage during transport, and simplifies the handling process for both retailers and customers. Further, machine-pasted or die-punched inserts are be customized to fit the specific dimensions and shapes of the ceiling fan components, ensuring they remain securely in place throughout the transportation process. The present invention advantageously improves the safety and reliability of the packaging and also contributes to a more streamlined and cost-effective logistics process. Also, by adopting a single-box packaging solution, the ceiling fan industry advantageously significantly enhances the protection of the product, reduce transportation costs, and improve customer satisfaction.
The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.
It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.
,CLAIMS:We claim:
1. A packaging unit (104) for ceiling fans, enclosing all components of a disassembled ceiling fan in a single packaging, comprising:
an outer shell (302) being configured, to have a first flat configuration as a blank and a second standing configuration as a standing three-dimensional container;
the outer shell (302) being formed of at least one blank having fold lines defining a plurality of panels;
an elongated insert (304) being disposed along a sidewall of the interior compartment, the elongated insert (304) including at least one storage groove (440) and at least one storage niche (448, 452) being configured to hold batteries, a remote, nuts, tools, and blades of the ceiling fan;
a triangular insert (308) being positioned adjacent to the elongated insert (304), the triangular insert (304) including at least one aperture (520) and at least one retention tab (528) being adapted to secure a canopy and canopy rod of the ceiling fan;
a container (312) receiving a motor of the disassembled ceiling fan; and
a base (316) being positioned below the container (312) to support the motor; wherein the combination of the inserts (304, 308) and the container (312) occupying substantially all free space within the interior compartment, thereby reducing redundant volume and preventing component movement during transport.
2. The packaging unit (104) as claimed in claim 1, wherein the outer shell (302) being formed from a pair of blanks (110, 110A) being attached along predefined tabs (244, 256) to form the standing configuration.
3. The packaging unit (104) as claimed in claim 1, wherein the outer shell (302) being formed from a single blank (110B) including main panels (276, 280), secondary panels (289, 291), and integral flaps (290, 292) being folded and adhered defining the standing configuration.
4. The packaging unit (104) as claimed in claim 1, wherein the outer shell (302) including at least one perforation (232) defining a handle for manual carrying.
5. The packaging unit (104) as claimed in claim 1, wherein the outer shell (302) including corrugated cardboard of B flute or C flute grade.
6. The packaging unit (104) as claimed in claim 1, wherein the elongated insert (304) including a first main panel (404) and a second main panel (408) defining a tray portion (456); a plurality of foldable flaps (428, 436) being configured to close the tray (456); at least one groove (440) and at least one niche (448, 452) being integrally formed by slits (440’, 440’’) and tearable portions (448’’, 452’’) to secure accessories.
7. The packaging unit (104) as claimed in claim 1, wherein the triangular insert (308) including a triangular panel (504), a plurality of folding panels (508, 512, 516) enclosing the canopy, and at least one aperture (520) having flaps (524) being configured to retain the canopy within the insert (308).
8. The packaging unit (104) as claimed in claim 1, wherein the container (312) including a quadrilateral main panel (704) and a plurality of flaps (708) being foldable upward to form a bowl-shaped receptacle.
9. The packaging unit (104) as claimed in claim 1, wherein the outer shell (302) being in standing configuration including a cuboid when paired with a second identical packaging unit (104) positioned adjacent along their longest trapezoidal sides.
10. The packaging unit (104) as claimed in claim 1, wherein the outer shell (302), elongated insert (304), triangular insert (308), container (312), and base (316) being machine-pasted or die-cut to fit to dimensions of the ceiling fan components.
11. The packaging unit (104) as claimed in claim 1, wherein the base (316) being configured to conform to the shape of the container to prevent movement of the motor during transport.
12. The packaging unit (104) as claimed in claim 1, wherein the standing configuration including externally sealable flaps (228) being joined by at least one sealing means selected from the group including of adhesive tape, glue, staples, and heat sealing and the like.
13. The packaging unit (104) as claimed in claim 1, wherein the arrangement of two packaging units (104, 108) along their respective diagonals forming a single cuboid unit (100) allowing efficiency in stacking of the units for transport.
14. The packaging unit (104) as claimed in claim 1, wherein the length of the blank (110B) of the outer shell (302) being approximately 1443.38mm and the width being approximately 371.58mm.
15. The packaging unit (104) as claimed in claim 1, wherein the length of the elongated insert (304) being approximately 582mm and the width being approximately 180mm.
16. The packaging unit (104) as claimed in claim 1, wherein the length of the triangular insert (308) being approximately 442.24mm and the width being approximately 106mm.
17. The packaging unit (104) as claimed in claim 1, wherein the main panel (604) of the base (316) being a quadrilateral including one acute angle such that . when folded, the base (316) fitting into the gap remining within the packaging unit (104) after the elongated insert (304) and the triangular insert (308) are positioned in the outer shell (302).
18. A process of assembly of the packaging unit (104) from the first flat configuration to a second standing configuration comprising five phases:
a first phase, the first phase being a connecting phase including connecting the first blank (110) to the second blank (110A) through tabs (244, 256), forming a hollow cylindrical structure or connecting a tab (293) to a second end of the single blank (110B), forming a hollow cylindrical structure;
a second phase, the second phase being a positioning phase including positioning the main panels (236, 260, 276, 280) such that the respective main panels being parallel to each other forming an approximate three-dimensional structure;
a third phase, the third phase being a folding phase including folding the plurality of side flaps (248, 264, 290, 292) and long flaps (252, 268, 284, 288) forming an initial structure of the packaging unit (104);
a fourth phase, the fourth phase being sealing phase including sealing the long flaps externally by sealing means such as adhesive tape, glue, staples, and heat sealing and the like, thereby forming the outer shell (302) of the packaging unit (104); and
a fifth phase, the fifth phase being a receiving phase including the outer shell (302) inserts in an order, including inserting the elongated insert (304), followed by the triangular insert (308), followed by the base (316) and then the container (312).
19. The process for assembly of the packaging unit (104) as claimed in claim 18, the assembly of the elongated insert (304) comprising four cycles:
a first cycle, the first cycle being a connecting cycle, connecting the second tab (424) to the first main panel (404) and connecting and attaching the second main panel (408) to the first tab (420) forming an initial insert structure;
a second cycle being a positioning cycle, positioning the main panels (404, 408) such that the respective main panels being parallel to each other forming an approximate three-dimensional structure;
a third cycle being a folding cycle, folding the plurality of side flaps (428, 432, 436) forming the tray portion (256) of the elongated insert (304) packaging unit (104); and
a fourth cycle being a sealing cycle, sealing the long flaps externally by sealing means such as adhesive tape, glue, staples, and heat sealing and the like, thereby forming the outer shell (302) of the packaging unit (104).
20. The process for assembly of the packaging unit (104) as claimed in claim 18, the assembly of the triangular insert (308) comprising three cycles:
a first cycle, the first cycle being a folding cycle, folding the plurality of flaps (508, 512, 516)) forming an initial approximate three-dimensional structure of the triangular insert (308);
a second cycle, the second cycle being a positioning cycle, positioning the flaps (524) for receiving canopy of the disassembled fan and the tabs (528) being pushed inwards, forming the suspension means for retaining the rod of the disassembled fan; and
a third cycle, the third cycle being an insertion cycle, inserting the triangular insert (308) within the outer shell (302) without requiring any sealing means.

Dated this 06th day of July 2024.
For Parksons Packaging Ltd.,

Mahurkar Anand Gopalkrishna
IN/PA-1862
(Agent for Applicant)