PACKAGING SYSTEM

Abstract

A packaging system includes a base box with a plurality of walls and a tray with a primary panel and a plurality of flaps extending therefrom. The primary panel includes a recess that extends at least partially into an interior space of the base box. The plurality of flaps are attached to exterior surfaces of the plurality of walls.

Claims

1. A packaging system comprising: a base box having a plurality of walls defining an interior space, the plurality of walls having exterior surfaces; and a tray attached to the base box, the tray comprising: a primary panel with a recess that extends at least partially into the interior space of the base box; and a plurality of flaps extending from the primary panel and attached to the exterior surfaces of the plurality of walls.

2. The packaging system of claim 1, wherein the tray comprises an underside, the underside having a groove formed therein between the primary panel and each of the plurality of flaps.

3. The packaging system of claim 2, wherein each groove comprises opposing walls that are angled relative to one another.

4. The packaging system of claim 3, wherein the opposing walls are angled relative to one another at an angle that enables the plurality of flaps to be folded to a predetermined angle relative to the primary panel.

5. The packaging system of claim 1, wherein opposing ends of each of the plurality of flaps comprises a chamfer.

6. The packaging system of claim 5, wherein the chamfers are angled to enable the ends of adjacent flaps to form a seam such that the adjacent flaps are oriented at a predetermined angle relative to one another.

7. The packaging system of claim 1, wherein the tray is a monolithic component.

8. The packaging system of claim 1, wherein the tray is formed of a moldable material.

9. The packaging system of claim 1, wherein the each of the plurality of flaps has a dimension that is substantially equal to a dimension of the plurality of walls.

10. The packaging system of claim 9, wherein the dimension of the flaps is a distance between a groove formed in the tray and an outer edge of the flap and the dimension of the wall is a height of the exterior surface of the wall.

11. The packaging system of claim 1, wherein the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels.

12. A packaging system comprising: a base box assembly, comprising: a base box having a plurality of walls defining an interior space, each of the plurality of walls has an exterior surface and an upper edge; and a monolithic molded tray attached to the base box, the tray comprising: a primary panel comprising: a planar portion that rests on the upper edges of the plurality of walls of the base box; and a recess that extends at least partially into the interior space of the base box; a plurality of flaps extending from the primary panel and attached to the exterior surfaces of the plurality of walls; and a plurality of folds formed between the primary panel and the plurality of flaps; and a lid having a top panel and a plurality of wall panels that cooperate to form and interior space, the interior space of the lid being configured to receive the base box assembly at least partially therein.

13. The packaging system of claim 12, wherein the tray comprises a groove formed therein between the primary panel and each of the plurality of flaps.

14. The packaging system of claim 13, wherein the grooves facilitate forming the plurality of folds.

15. The packaging system of claim 12, wherein the recess is configured to receive a product therein for packaging within the packaging system.

16. The packaging system of claim 12, wherein the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels.

17. A method for forming a packaging system comprising: providing a base box having a plurality of walls that define an interior space and have exterior surfaces; providing a tray having a primary panel and a plurality of flaps extending from the primary panel, the primary panel having a recess; and attaching the tray to the base box so that the protruding portion extends at least partially into the interior space and the plurality of flaps are attached to the exterior surfaces.

18. The method of claim 17, further comprising forming a plurality of grooves in the tray between the primary panel and the plurality of flaps.

19. The method of claim 17, further comprising forming chamfers on opposing ends of each of the plurality of flaps.

20. The method of claim 17, wherein providing the tray comprising forming the tray with a moldable material and a molding process.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Features, aspects, and advantages of the presently disclosed technology may be better understood concerning the following description, appended claims, and accompanying drawings. A person skilled in the relevant art will understand that the features shown in the drawings are purposes of illustration, and variations, including different or additional features and arrangements thereof, are possible.

[0006] FIG. 1 shows an exploded view of a packaging system according to an example embodiment.

[0007] FIG. 2 shows an underside of a packaging system tray according to an example embodiment.

[0008] FIG. 3 shows a closeup view of a portion of the underside of a packaging system tray according to an example embodiment.

[0009] FIG. 4 shows another underside view of a packaging system tray with adhesive added thereto according to an example embodiment.

[0010] FIG. 5 shows a base box and a packaging system tray being associated with one another according to an example embodiment.

[0011] FIGS. 6 and 7 show flaps of a packaging system tray being attached to a base box according to an example embodiment.

[0012] FIG. 8 shows a closeup view of a portion of a packaging system tray after being attached to a base box according to an example embodiment.

[0013] FIG. 9 shows a closeup view of the attachment between a packaging system tray and a base box according to an example embodiment.

[0014] FIG. 10 shows a partial cross-sectional view of the attachment between a packaging system tray and a base box according to an example embodiment.

[0015] FIG. 11 shows a method of forming a packaging system according to an example embodiment.

[0016] The drawings are to illustrate example implementations and are not drawn to scale. It is understood that the inventions are not limited to the arrangements and instrumentalities shown in the drawings.

DETAILED DESCRIPTION

[0017] A better understanding of different embodiments of the disclosure may be had from the following description read with the drawings in which like reference characters refer to like elements.

[0018] While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are in the drawings and are described below. The dimensions, angles, and curvatures represented are to be understood as examples for purposes of illustration and are not necessarily shown in proportion.

[0019] It should be understood, however, there is no intention to limit the disclosure to the specific embodiments disclosed, but on the contrary, the intention covers all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure.

[0020] The labels used herein that indicate or suggest particular orientations of components are used for convenience and describe one of many possible configurations.

[0021] Referring to FIG. 1, an exploded view of an example embodiment of a packaging system 100 is illustrated. The packaging system 100 includes a base box 102, a tray 104, and a lid 106. In some embodiments, the lid 106 may be optional.

[0022] The base box 102 includes a bottom panel 108 and a plurality of wall panels 110 that extend from or are connected to the bottom panel 108. Each of the bottom panel 108 and the plurality of wall panels 110 has an interior surface that cooperate to form an interior space 112 of the base box 102. Similarly, each of the bottom panel 108 and the plurality of wall panels 110 has an exterior surface that cooperate to form an exterior of the base box 102.

[0023] The tray 104 includes a primary panel 114 and a plurality of flaps 116 that extend from the primary panel 114. In the illustrated embodiment, the plurality of flaps 116 are integrally formed with the primary panel 114. As also shown in the illustrated embodiment, the primary panel 114 includes a recess 118 that is configured to have a product positioned therein. The recess 118 may be shaped so as to be able to receive the product therein and hold the product in place within the packaging system 100. In some embodiments, the primary panel 114 may include multiple recesses configured to hold multiple products or different parts or components of one or more products.

[0024] The tray 104 may be formed of a moldable material or substrate. For instance, the tray 104 may be formed of a pulp, plastic, paper foam, or other moldable material. One or more molds and/or presses may be used to mold the moldable material into the general shape of the tray 104. For instance, one or more molds and/or presses may be used to form the primary panel 114 with the recess 118 therein and the plurality of flaps 116. One or more cutting tools (e.g., die cutter, knives, etc.) may be used to cut or trim the tray 104 to its final dimensions. Cutting or trimming the tray 104 to its final dimensions may form the outer edges of the plurality of flaps 116.

[0025] The lid 106 includes a top panel 120 and a plurality of wall panels 122 that extend from or are connected to the top panel 120. Each of the top panel 120 and the plurality of wall panels 122 has an interior surface that cooperate to form an interior space of the lid 106. Similarly, each of the top panel 120 and the plurality of wall panels 122 has an exterior surface that cooperate to form an exterior of the lid 106.

[0026] Attention is now directed to FIGS. 2 and 3. FIG. 2 illustrates an underside of the tray 104 and FIG. 3 illustrates a closeup view of a portion of the underside of the tray 104. As can be seen, the recess 118 in the top or front surface of the primary panel 114 forms a corresponding protruding portion 124 on the bottom or back surface of the primary panel 114.

[0027] Additionally, the bottom or back surface of the tray 104 also has grooves 126 formed therein. In the illustrated embodiment, the grooves 126 are located where the primary panel 114 and the plurality of flaps 116 meet. As can be best seen in FIG. 3, the grooves 126 may have walls 128 that are angled relative to one another. For instance, the walls 128 in the illustrated embodiment are angled at about 900 relative to one another. In other embodiments, the walls 128 may be angled more or less than 90, such as 30, 45, 60, 75, 115, 130, 145, 160, or any other desired angle.

[0028] The angles walls 128 of the grooves 126 may facilitate folding of the plurality of flaps 116 relative to the primary panel 114. For instance, the grooves 126 may allow the plurality of flaps 116 to fold relative to the primary panel 114 to a predetermined angle. By way of example, when the grooves 126 have walls 128 that are angled at about 900 relative to one another, the plurality of flaps 116 can be folded relative to the primary panel 114 so that the primary panel 114 and each of the plurality of flaps 116 forms an angle of about 90. The grooves 126 may also allow the folds between the primary panel 114 and the plurality of flaps 116 to have a desired aesthetic, such as a relatively sharp outer contour.

[0029] In addition to the grooves 126, opposing edges of each flap 116 may also include a bevel or chamfer 130. The chamfers 130 may be oriented in the same direction and to the same angle as the grooves 126 that run colinear or parallel to the chamfer 130. In some embodiments, the grooves 126 and chamfers 130 are formed at the same time and with the same tool(s). For instance, the grooves 126 and chamfers 130 may be cut into the tray 104 with any suitable tool (e.g., knives, CNC, etc.).

[0030] The chamfers 130 may facilitate folding of the plurality of flaps 116. For instance, the chamfers 130 may allow the plurality of flaps 116 to fold in a desired manner. By way of example, when the plurality of flaps 116 are folded relative to the primary panel 114, the chamfers 130 on adjacent flaps 116 abut one another and allow for the adjacent flaps 116 to form a joint having a desired aesthetic, such as a relatively sharp outer contour (e.g. a substantially 90 degree edge).

[0031] In some embodiments, the protruding portion 124 and the plurality of flaps 116 may have one or more dimensions that are similar or the same. For instance, each flap 116 may have a dimension 132 that extends from an edge of the groove 126 to an outer edge of the flap 116 (an edge opposite to the groove 126/primary panel 114). The dimension 132 may be referred to as a height of the flap 116. Similarly, the protruding portion 124 may have a dimension 134 that extends from the underside of a planar portion of the primary panel 124 to an apex or plateau of the protruding portion 124. In some embodiments, the dimensions 132, 134 are substantially equal to one another. Additionally, the dimensions 132, 134 may be substantially equal to a height of the wall panels 110 of the base box 102.

[0032] Attention is now directed to FIGS. 4-7, which illustrate an example process of assembling the base box 102 and the tray 104 into a base box assembly 136. The tray 104 can be attached to the base box 102 to form the base box assembly 136. The attachment can be accomplished with the use of an adhesive. For instance, an adhesive 138 can be applied to the tray 104 and/or the base box 102. In the illustrated embodiment, the adhesive 138 is applied to the underside of the tray 104. Specifically, the adhesive 138 is applied to the plurality of flaps 116. The adhesive 138 can be applied to substantially the entire lengths of the plurality of flaps 116, or at discrete locations on the plurality of flaps 116. The adhesive 138 may optionally also be applied to the protruding portion 124. In other embodiments, the adhesive 138 can be applied to the base box 102, including the exterior surfaces of the wall panels 110 and optionally the interior surface of the bottom panel 108.

[0033] The tray 104 can then be associated with the base box 102. For instance, as shown in FIG. 5, with the underside of the tray 104 facing up, the base box 102 can be positioned on the tray 104. More specifically, the base box 102 can be positioned on the tray 104 so that the protruding portion 124 extends into the interior space 112 of the base box 102. Additionally, the top edges of the wall panels 110 (the edge opposite to the bottom panel 108) can be positioned adjacent to the grooves 126. The grooves 126 may be spaced apart from one another distances that are substantially equal to or only slightly larger than (e.g., 0.05 inches, 0.1 inches, 0.15 inches, 0.20 inches, 0.025 inches, etc.) the distances between the wall panels 110. For instance, the distance between the wall panels 110 may be substantially the same as the distance between the inner edges of the grooves 126. As such, the top edges of the wall panels 110 may engage the grooves 126 or may be positioned towards an inside edge of the grooves 126. This allows the flaps 116, when folded along the grooves 126, to engage with the wall panels 110 without material obstruction as shown in FIGS. 7, 9, and 10.

[0034] In other embodiments, the base box 102 can be positioned with the interior space 112 opening upwards or in another direction and the tray 104 can be positioned thereon, with the protruding portion 124 extending partially into the interior space 112.

[0035] When the base box 102 and the tray 104 are so associated, as shown in FIG. 6, the protruding portion 124 of the tray 104 can extend into the interior space 112 of the base box 102. In embodiments where the height of the convex portion 124 is substantially equal to the height of the interior surface of the wall panels 110, the protruding portion 124 may extend into the interior space 112 and contact the bottom panel 108, as shown in FIG. 10. When adhesive 134 is applied to the convex portion 124 and/or the bottom panel 108, the adhesive 134 can secure the protruding portion 124 to the bottom panel 108.

[0036] Notably, the plurality of flaps 116 are not inserted into the interior space 112 of the base box 102 when the base box 102 and the tray 104 are associated with one another. As shown in FIG. 6, the plurality of flaps 116 extend out beyond the wall panels 110 of the base box 102. The plurality of flaps 116 can then be folded along the grooves 126 so as to bring the plurality of flaps 116 into contact with the exterior surfaces of the wall panels 110 of the base box 102, as shown in FIGS. 6, 7, and 10. Specifically, the underside surfaces of the plurality of flaps 116 are brought into contact with the exterior surfaces of the wall panels 110. The adhesive 134 on the plurality of flaps 116 and/or the exterior surfaces of the wall panels 110 can secure the plurality of flaps 116 to the exterior surfaces of the wall panels 110, as shown in FIG. 7.

[0037] Forming the base box assembly 136 with the plurality of flaps 116 attached to the outside of the base box 102 can provide the base box assembly 136 with a unique aesthetic. For instance, as shown in FIG. 8, top and side views of the base box assembly 136 have a continuous, monolithic appearance. That is, the molded and folded tray 104 provides the top and sides of the of the base box assembly 136 with a unitary appearance without any seams between the recess 118, the planar portion of the primary panel 114, and the plurality of flaps 116. Furthermore, the chamfers 130 on the plurality of flaps 116 allow for the plurality of flaps 116 to form seams 140 that substantially disappear and, rather, appear as a continuous surface across the corners of the base box assembly 136.

[0038] Additionally, the noted construction of the base box assembly 136 also provides for a unique appearance to the underside of the base box assembly 136. The underside of a typical box will include a bottom surface and edge folds that extend into sidewalls of the box. In contrast, and as shown in FIGS. 9 and 10, the underside of the base box assembly 136 includes the bottom panel 108 of the base box 102 and the edges of the plurality of flap 116, with a joint or seam 142.

[0039] FIG. 11 illustrates a diagram showing a method 150 for forming a packaging system according to an example embodiment. The method 150 can include a step 152 of providing a base box, such as base box 102. As noted above, the base box can have a bottom panel and a plurality of walls that define an interior space. The plurality of wall can have exterior surfaces.

[0040] The method 150 can also include a step 154 of providing a tray, such as tray 104. The tray may have a primary panel and a plurality of flaps extending from the primary panel. The primary panel may also have a recess that may be sized and configured to hold one or more products therein. The tray may be formed with a moldable material via a met molding or other process. In some embodiments, the method 150 also includes forming grooves in the tray 104 between the primary panel and the plurality of flaps to facilitate folding of the flaps relative to the primary panel. Furthermore, the method 150 may also include forming chamfers on edges of the flaps so that adjacent edges of the flaps form a desired angle (e.g., 90 degrees) when the flaps are folded.

[0041] The method 150 also includes a step 156 of attaching the tray to the base box. In some embodiments, the step 156 includes inserting the protruding portion of the tray into the interior space of the base box. Additionally, the step 156 may also include folding and attaching the plurality of flaps of the tray onto the exterior surfaces of the plurality of walls of the base box.

[0042] According to one embodiment, a packaging system includes a base box having a plurality of walls defining an interior space, the plurality of walls having exterior surfaces. The packaging system also includes a tray attached to the base box. The tray includes a primary panel with a recess that extends at least partially into the interior space of the base box, and a plurality of flaps extending from the primary panel and attached to the exterior surfaces of the plurality of walls.

[0043] In some embodiments, the tray comprises an underside having a groove formed therein between the primary panel and each of the plurality of flaps.

[0044] In some embodiments, each groove comprises opposing walls that are angled relative to one another.

[0045] In some embodiments, the opposing walls are angled relative to one another at an angle that enables the plurality of flaps to be folded to a predetermined angle relative to the primary panel.

[0046] In some embodiments, opposing ends of each of the plurality of flaps comprises a chamfer.

[0047] In some embodiments, the chamfers are angled to enable the ends of adjacent flaps to form a seam such that the adjacent flaps are oriented at a predetermined angle relative to one another.

[0048] In some embodiments, the tray is a monolithic component.

[0049] In some embodiments, the tray is formed of a moldable material.

[0050] In some embodiments, the each of the plurality of flaps has a dimension that is substantially equal to a dimension of the plurality of walls.

[0051] In some embodiments, the dimension of the flaps is a distance between a groove formed in the tray and an outer edge of the flap and the dimension of the wall is a height of the exterior surface of the wall.

[0052] In some embodiments, the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels.

[0053] In one embodiment, a packaging system includes a base box assembly and a lid.

[0054] The base box assembly includes a base box and a monolithic molded tray. The base box has a plurality of walls defining an interior space, with each of the plurality of walls having an exterior surface and an upper edge. The tray includes a primary panel and a plurality of flaps. The primary panel includes a planar portion that rests on the upper edges of the plurality of walls of the base box, and a recess that extends at least partially into the interior space of the base box. The plurality of flaps extend from the primary panel and are attached to the exterior surfaces of the plurality of walls. A plurality of folds are formed between the primary panel and the plurality of flaps. The lid has a top panel and a plurality of wall panels that cooperate to form and interior space that is configured to receive the base box assembly at least partially therein.

[0055] In some embodiments, the tray comprises a groove formed therein between the primary panel and each of the plurality of flaps.

[0056] In some embodiments, the grooves facilitate forming the plurality of folds.

[0057] In some embodiments, the recess is configured to receive a product therein for packaging within the packaging system.

[0058] In some embodiments, the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels.

[0059] In one embodiment, a method for forming a packaging system includes: providing a base box having a plurality of walls that define an interior space and have exterior surfaces; providing a tray having a primary panel and a plurality of flaps extending from the primary panel, the primary panel having a recess; and attaching the tray to the base box so that the recess extends at least partially into the interior space and the plurality of flaps are attached to the exterior surfaces.

[0060] In some embodiments, the method includes forming a plurality of grooves in the tray between the primary panel and the plurality of flaps.

[0061] In some embodiments, the method includes forming chamfers on opposing ends of each of the plurality of flaps.

[0062] In some embodiments, providing the tray comprising forming the tray with a moldable material and a molding process.

CONCLUSION

[0063] While certain embodiments of the present disclosure have been described in detail, with reference to specific configurations, parameters, components, elements, etcetera, the descriptions are illustrative and are not to be construed as limiting the scope of the claimed invention.

[0064] Furthermore, it should be understood that for any given element of component of a described embodiment, any of the possible alternatives listed for that element or component may generally be used individually or in combination with one another, unless implicitly or explicitly stated otherwise.

[0065] In addition, unless otherwise indicated, numbers expressing quantities, constituents, distances, or other measurements used in the specification and claims are to be understood as optionally being modified by the term about or its synonyms. When the terms about, approximately, substantially, or the like are used in conjunction with a stated amount, value, or condition, it may be taken to mean an amount, value or condition that deviates by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01% of the stated amount, value, or condition. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0066] Any headings and subheadings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims.

[0067] It will also be noted that, as used in this specification and the appended claims, the singular forms a, an and the do not exclude plural referents unless the context clearly dictates otherwise. Thus, for example, an embodiment referencing a singular referent (e.g., widget) may also include two or more such referents.