Protective package for an automobile part

A method of forming a protective package for shipping a part comprising:

• (a) providing a shipping carton with a generally rectangular shape for the protective package;
• (b) shaping the carton with rear dust flaps mounted thereon;
• (c) shaping a first side rail to have a first part receiving slot and a second side rail to have a second part receiving slot;
• (d) fitting the first side rail and the second side rail into the carton on opposing sides thereof;
• (e) spacing the first side rail and the second side rail from the respective opposing sides of the carton with a side spacer;
• (f) placing a first rear insert in the first side rail;
• (g) placing a second rear insert in the second side rail;
• (h) inserting the part into the carton in contact with the first side rail, the second side rail into the first rear insert and the second rear insert;
• (i) placing a first front insert in the first side rail and in contact with the part;
• (j) placing a second front insert in the second side rail and in contact with the part;
• (k) closing the carton;
• (l) having the first rear insert being similar in shape the second rear insert;
• (m) folding a rear die-cut flat to form the first rear insert;
• (n) inserting a larger jaw angle cut spacer into the first rear insert;
• (o) inserting a foldable tongue from the rear die-cut flat into the larger jaw angle cut spacer;
• (p) having the first front insert being similar in shape to the second front insert;
• (q) forming the first front insert from a corrugated front insert die-cut flat;
• and
• (r) placing a front foam support in the first front insert.

A protective package for shipping a part comprising:

• a carton having a packing assembly therein;
• the packing assembly including a first side rail support and a second side rail support adapted to position the part in the carton;
• the packing assembly including a first rear support in the first side rail in the carton to support a rear portion of the part;
• the packing assembly including a second rear support in the second side rail in the carton to support the rear portion of the part;
• the carton being a seamed carton or a fold over carton;
• the packing assembly including a first front support in the second side rail in the carton to support a front portion of the part;
• the packing assembly including a second front support in the second side rail in the carton to support the front portion of the part;
• a first slot being present in the first side rail support;
• a second slot being present in the second side rail support;
• the first slot receiving the first rear support and the first front support;
• the second slot receiving the second rear support and the second front support;
• a first spacer pad being inserted between the carton and the first side rail;
• a second spacer pad being inserted between the carton and the second side rail;
• the first spacer pad, the second spacer pad, the first rear support, the first front support, the second rear support and the second front support cooperating to support the part within the carton and at least minimize damage to the part;
• the first spacer pad forcing the first side rail inwardly to provide additional support for the part;
• the second spacer pad forcing the second side rail inwardly to provide additional support for the part;
• the first spacer pad and the second spacer pad forming part of the packing assembly;
• the first front support and the second front support being substantially similar in appearance;
• the first front support being formed from a corrugated front insert die-cut flat with a front foam support mounted therein;
• the front foam support having a front jaw slot;
• and
• the front jaw slot being adapted to receive and partially support the part.