MOLDED PAPERBOARD PACKAGING AND METHODS OF MAKING THE SAME

Abstract

Paperboard packaging is provided that includes a paperboard tray and a tray cover. The paperboard tray includes a base configured to receive and hold one or more products therein and a planar lip that extends from and around the base to define a boundary of the paperboard tray. The tray cover is coupled to the planar lip of the paperboard tray over the products to trap the products therebetween.

Claims

1. A paperboard package comprising: a formed paperboard tray comprising a one or a plurality of formed pockets or depressions having varying depths from a base surface depth level.

2. The paperboard package of claim 1, wherein at least one formed pocket or depression included in the plurality of formed pockets or depressions is wholly contained within another formed pocket or depression.

3. The paperboard package of claim 1, further comprising at least one cut-out opening or window disposed in one or a plurality of the formed pockets or depressions.

4. The paperboard package of claim 1, comprising a first pocket of a first depth and a second pocket of a second depth, wherein the second pocket is within the first pocket.

5. The paperboard package of claim 1, wherein deeper pockets or depressions included in the plurality of formed pockets or depressions are disposed within shallower pockets.

6. The paperboard package of claim 1, further comprising a panel adapted to fit on or be adhered to a top portion of the formed paperboard tray thereby forming packaging in which products may be contained and stored within the plurality of formed pockets or depressions.

7. The paperboard package of claim 1, wherein the formed paperboard tray is formed from a paperboard blank having one or more creases configured to aid in forming the paperboard blank into the formed paperboard tray when pressed in a press.

8. A formed paperboard tray product comprising: a paperboard tray including a paperboard base that defines a first pocket having a first depth measured from a surface of an unformed part of the paperboard base to a bottom surface of the first pocket, and a second pocket having a second depth measured from the surface of the unformed part of the paperboard base to a bottom surface of the second pocket, wherein the first and second depths are different.

9. The formed paperboard tray product of claim 8, further comprising at least one window disposed within at least one of the first or second pockets.

10. The formed paperboard tray product of claim 8, wherein the second pocket is partially disposed within the first pocket.

11. The formed paperboard tray of claim 10, wherein the paperboard base defines a third pocket having a third depth measured from the surface of the unformed part of the paperboard base to a bottom surface of the third pocket, and wherein the first and second depths are different from the third depth.

12. The formed paperboard tray product of claim 11, wherein the third pocket is partially or completely disposed within the second pocket.

13. The formed paperboard tray product of claim 8, further comprising a panel adapted to fit on or be adhered to the unformed part of the paperboard base of the paperboard tray thereby forming packaging in which products may be contained and stored within the pockets or depressions.

14. The formed paperboard tray product of claim 13, wherein the panel comprises paperboard.

15. The formed paperboard tray product of claim 14, wherein the panel comprises a plurality of pockets of varying depths.

16. The formed paperboard tray product of claim 8, wherein the paperboard tray is formed from a paperboard blank having one or more creases configured to aid in forming the paperboard blank into the paperboard tray when pressed in a press.

17. A method of assembling a package with one or more products therein, the method comprising: providing a paperboard blank with predetermined dimensions based on the one or more products to be packaged, applying one or more creases to the paperboard blank at predetermined locations to aid in forming a formed paperboard tray from the paperboard blank, arranging the paperboard blank with the one or more creases applied thereto in a press, pressing the paperboard blank in the press at least once while applying heat to the paperboard blank to provide the formed paperboard tray including a base that defines a plurality of pockets or depressions and a planar lip that extends from and around the base to define a boundary of the formed paperboard tray, arranging the one or more products in the plurality of pockets or depressions of the formed paperboard tray, providing a tray cover with predetermined dimensions based on the formed paperboard tray, and coupling the tray cover to the tray lip of the formed paperboard tray after arranging the one or more products in the plurality of pockets or depressions to trap the one or more products therebetween.

18. The method of claim 17, wherein pressing the paperboard blank in the press includes multiple pressing steps while applying heat to the paperboard blank to provide the formed paperboard tray.

19. The method of claim 17, further comprising applying a printed label to the paperboard blank.

20. The method of claim 17, further comprising cutting out one or more windows from the paperboard blank.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0022] FIG. 1A is a top view of a formed paperboard tray according to an embodiment of the present disclosure showing the paperboard tray includes a plurality of pockets or depressions of varying depths therein;

[0023] FIG. 1B is a bottom view of the formed paperboard tray of FIG. 1A;

[0024] FIG. 2A is a top view of a formed paperboard tray according to another embodiment of the present disclosure showing the paperboard tray includes a plurality of pockets or depressions of varying depths therein and a cut-out opening or window within one or both of the pockets or depressions;

[0025] FIG. 2B is a bottom view of the formed paperboard tray of FIG. 2A;

[0026] FIG. 3 is an exploded view of a package including the formed paperboard tray of FIGS. 1A and 1B and a tray cover configured to be coupled to the tray to trap the products therebetween;

[0027] FIG. 4A is a cross-section view of the formed paperboard tray of FIG. 1A taken along line A-A showing the plurality of pockets or depressions have varying depths;

[0028] FIG. 4B is a cross-section view of the formed paperboard tray of FIG. 1A taken along line B-B showing a first pocket of the paperboard tray has a first depth, a second pocket of the paperboard tray has a second depth that is different from the first depth, and a third pocket of the paperboard tray has a third depth that is different from the first and second depths;

[0029] FIG. 5 is a diagrammatic view of a method of forming the formed paperboard tray of FIGS. 1A-B or FIGS. 2A-B for a formed paperboard package showing the method includes providing a paperboard blank or sheet with predetermined dimensions based on the type of product to be packaged and a paperboard tray cover with predetermined dimensions based on the paperboard tray to be formed, processing the paperboard blank based on the type of product to be packaged by (i) applying graphics, logos, or colors, (i) cutting out windows, (iii) and/or (iii) scoring the paperboard blank in predetermined locations to help with forming the tray, pressing or forming the paperboard blank into the formed paperboard tray via a press, packaging the product in the packaging by assembling the tray and the tray cover;

[0030] FIG. 6A is a front view of the paperboard blank to be formed into the formed paperboard tray as shown in FIG. 6B;

[0031] FIG. 6B is a front view of the formed paperboard tray after the pressing stage of the method of FIG. 5;

[0032] FIG. 7 is diagrammatic view of the pressing or forming stage of the method of FIG. 5 showing the pressing or forming stage includes arranging the paperboard blank on the mold tool of the press, pressing the paperboard blank in the press while applying heat to the paperboard blank to provide the formed paperboard tray, and removing the mold tool after a predetermined press period; and

[0033] FIG. 8 is diagrammatic view of the packaging stage of the method of FIG. 5 showing the packaging stage includes arranging the product in the formed paperboard tray and coupling or adhering the tray cover to the paperboard tray with the product in the pocket to trap the product therebetween.

[0034] FIG. 9A is a perspective view of the package of FIG. 3 showing the tray cover may include a perforated portion attached thereto with perforations to enable the perforated section to be removed as shown in FIG. 9B; and

[0035] FIG. 9B is a perspective view of the package of FIG. 9A showing a user removing the perforated portion from the rest of the tray cover to expose the products within the package so that the products may be removed from the package.

DETAILED DESCRIPTION

[0036] A package 10 according to an embodiment of the present disclosure is shown in FIGS. 1A-B and 3-4B. The package 10 includes a tray 12 and a tray cover 14 as shown in FIGS. 1A-B and 3-4B. The formed paperboard tray 12 is formed to define a plurality of formed pockets or depressions 16, 18, 20 configured to receive and hold one or more products 13 therein. The tray cover 14, also sometimes referred to as a panel 14, is coupled to the tray 12 to close an opening to the pockets or depressions 16, 18, 20 of the tray 12 and block removal of the product 13 from the tray 12 thereby sealing the product(s) 13 therein.

[0037] The tray 12 of the package 10 is a formed paperboard tray 12 formed from a flat paperboard blank or sheet 12 via a press 50 as shown in FIGS. 5-8. The flat paperboard blank 12 has predetermined dimensions (e.g., size and shape) based on a product type or product 13 to be held or stored within the package 10 (e.g., health/beauty products (razors, toothbrush, toothpaste, lip balm, vitamins, cosmetics, sunscreen), electronics (phone, tablet), cleaning products, drink products (coffee grounds, powdered drink mix), medication (pills, tablets, or other like pharmaceuticals), laundry detergent, batteries, medical devices, food items, eyeglasses, and food products). The flat paperboard blank 12 is pressed between mold tools 52, 54 of the press 50 while applying heat to the paperboard blank 12 to provide the formed paperboard tray 12.

[0038] The resulting formed paperboard tray 12 includes a base 22 and a planar lip 24 that extends from and around an edge of the base 22 as shown in FIGS. 1A-B and 3-4B. The base 22 defines pockets or depressions 16, 18, 20 configured to receive one or more products 13 therein. The pockets or depressions 16, 18, 20, and thus the base 22, are formed by pressing the flat paperboard blank 12 in the press 50. The flat paperboard blank 12 has one or more creases 15 configured to aid in forming the paperboard blank 12 into the formed paperboard tray 12 without tearing or destroying the paperboard blank when pressed in a press 50.

[0039] As shown in FIGS. 1A-B and 3-4B, the base 22 of the paperboard tray 12 includes a first pocket or depression 16, a second pocket or depression 18, and a third pocket or depression 20. The number of pockets or depressions may vary based on the product(s) 13 to be packaged. For example, the paperboard tray 12 may be formed to define more than three pockets or depressions. In some embodiments, the paperboard tray 12 may be formed to define less than three pockets or depressions.

[0040] The plurality of pockets or depressions 16, 18, 20 have varying depths as shown in FIGS. 1A-B and 3-4B. The pockets or depressions 16, 18, 20 have varying depths such that each pocket or depression 16, 18, 20 has a different depth. The first pocket 16 has a first depth d, the second pocket 18 has a second depth d, and the third pocket 20 has a third depth d as shown in FIGS. 1A-B and 4A-B. The deeper pockets are partially or wholly disposed within shallower pockets. Therefore, the second pocket 18 is partially or wholly disposed within the first pocket 16 and the third pocket 20 is partially or wholly disposed within the first pocket 16 and the second pocket 18.

[0041] The vast majority of product packaging is made using one-time use plastic due to abundance, relatively inexpensive cost, ease of use, resilience, printability, and versatility. Indeed, for example, one-time use plastics may easily be made to be opaque, transparent and/or translucent, which may be useful for displaying products within product packaging made therefrom. However, plastic is difficult to decompose and therefore much of it ends up in landfills, waterways, and, generally, as a pollutant in the environment. While recycling of one-time use plastics may be done, it is estimated that a very small percentage of plastic packaging is, actually, recycled. Moreover, recycling plastic requires energy and chemical usage which itself may be harmful to the environment. Moreover, most food products are not recycled because they tend to be mixed with residual food products.

[0042] Unlike plastic packaging, paperboard packaging decomposes more quickly and is easier to recycle that one-time use plastics. Moreover, paperboard packaging may be easily printed and cut into particular flat shapes. Even still, the paperboard material may not be as easy to formed into desired shapes. Thus, the paperboard tray 12 has creases 15 that aid in the formation of the tray 12. The creases 15 in the paperboard blank 12 aid in forming the paperboard blank 12 into a three-dimensional tray 12 with the pocket 16 without tearing or destroying the paperboard blank 12, or otherwise forming uncontrolled creases in the tray 12 that may be unsightly and induce locations of weakness in the paperboard that may lead to tearing of the same when in use.

[0043] Additionally, the multiple pockets or depressions 16, 18, 20 and the unique arrangement of pockets or depressions 16, 18, 20 may minimize the number of creases 15 used to aid in forming the paperboard tray 12 since the arrangement of the pockets or depressions 16, 18, 20 provide a place for the paperboard to go as it is formed. Also, due to the unique arrangement of pockets or depressions 16, 18, 20, each having a depth that is different, products 13 contained therein may be uniquely arranged and held therein.

[0044] With the package 10 of the present disclosure initially described above, the package 10 and a method 100 of forming the package 10 is now described in more detail. The package 10 includes a tray 12 and a tray cover 14 as shown in FIGS. 1A-4B. The tray 12 is a formed/pressed paperboard tray 12 made from paperboard material. Similarly, the tray cover 14 is a paperboard panel from paperboard material. Preferably, the paperboard material is a dry paperboard. The dry paperboard material may have a moisture content between about 5% to 10%. In some embodiments, the paperboard material may have a moisture content between about 8% to 10%.

[0045] The formed/pressed paperboard tray 12 includes a base 22 and a planar lip 24 as shown in FIGS. 1A-4B. The base 22 may also be referred to as a body 22 of the tray 12. The planar lip 24, also referred to as an outer rim 24, extends from and around a perimeter edge of the base 22 to define a boundary of the tray 12. The base 22 defines a plurality of pockets or depressions 16, 18, 20 as shown in FIGS. 1A-4B. The pockets or depressions 16, 18, 20 are configured to receive one or more products 13 therein. An opening to the pockets or depressions 16, 18, 20 is defined by the planar lip 24 as shown in FIGS. 1A-4B. The pockets or depressions 16, 18, 20 extend from the opening in the planar lip 24.

[0046] The plurality of pockets or depressions 16, 18, 20 have varying depths as shown in FIGS. 1A-B and 3-4B. The pockets or depressions 16, 18, 20 have varying depths such that each pocket or depression 16, 18, 20 has a different depth. The first pocket 16 has a first depth d, the second pocket 18 has a second depth d, and the third pocket 20 has a third depth d as shown in FIGS. 1A-B and 4A-B. The deeper pockets are partially or wholly disposed within shallower pockets. Therefore, the second pocket 18 is partially or wholly disposed within the first pocket 16 and the third pocket 20 is partially or wholly disposed within the first pocket 16 and the second pocket 18.

[0047] The first pocket or depression 16 includes a bottom surface 26 and at least one side wall 28 disposed partially or completely therearound as shown in FIGS. 1A-B and 3-4B. The bottom surface 26 is spaced apart from the planar lip 24. The wall 28 extends between the planar lip 24 and the bottom surface 26 such that the first pocket or depression 16 has a first depth d. The first depth d is defined between the bottom surface 26 of the depression 16 and a surface 30 of an unformed part of the paperboard tray 12, i.e., the planar lip 24.

[0048] The second pocket or depression 18 includes a bottom surface 32 and a first side wall 34 disposed partially or completely therearound as shown in FIGS. 1A-B and 3-4B. The first side wall 34 partially circumscribes the second pocket or depression 18 since the second pocket or depression 18 is disposed within the first pocket or depression 16. The first side wall 34 partially circumscribes the second pocket or depression 18 at a distance d from the bottom surface 32 of the second pocket or depression 18 to the bottom surface 26 of the first pocket or depression 16.

[0049] The second pocket or depression 18 further includes a second side wall 36 disposed partially around the bottom surface 32 as shown in FIGS. 1A-B and 3-4B. The second side wall 36 partially circumscribes the second pocket or depression 18 at a distance d from the bottom surface 32 of the second pocket or depression 18 to the surface 30 of the unformed part of the paperboard tray 12, i.e. the planar lip 24. The distance d is the sum of the distance d and the distance d. Thus, the second pocket or depression 18 has a second depth d.

[0050] The third pocket or depression 20 includes a bottom surface 42 and a first side wall 44 disposed partially or, as illustrated in FIGS. 1A-B and 3-4B, completely therearound. The first side wall 44 of the third pocket or depression 20 may circumscribe the third pocket or depression 20 at a distance d from the bottom surface 42 of the third pocket or depression 20 to the bottom surface 32 of the second pocket or depression 18. The third pocket or depression 20 has a third depth d defined between the bottom surface 42 of the third pocket or depression 20 and the surface 30 of the unformed part of the paperboard tray 12. Thus, the third depth d is the sum of the distance d from the bottom surface 42 of the third pocket or depression 20 to the bottom surface 32 of the second pocket or depression 18, the distance d from the bottom surface 32 of the second pocket or depression 18 to the bottom surface 26 of the first pocket or depression 16, and the distance d from the bottom surface 26 of the first pocket or depression 16 to the surface 30 of the unformed part of the paperboard tray 12.

[0051] The tray cover 14 is coupled to or adhered to the planar lip 24 as shown in FIGS. ##. The tray cover 14 may be heat sealed to the planar lip 24 to couple the tray cover 14 to the tray 12 as suggested in FIG. 29. The heat seal between the planar lip 24 and the tray cover 14 creates a perimeter seal around the planar lip 24 at adheres the tray cover 14 to the tray 12. The shape of the tray 12 makes heat sealing the tray cover 14 to the tray 12 easier because the same mold tool 52, 54 may be used. In other words, the mold tool 52, 54 need not be changed out for heat sealing equipment. In other embodiments, the tray cover 14 may be coupled to the planar lip 24 using another suitable method.

[0052] In some embodiments, the tray cover 14 may be a formed/pressed paperboard tray cover instead of a paperboard sheet. The tray cover 14 may be a formed paperboard tray cover formed from another paperboard blank 12 having one or more creases 15 configured to aid in forming the paperboard blank 12 into the formed paperboard tray cover 14 without tearing or destroying the paperboard blank 12 when pressed in the press 50 like the tray cover 14. The tray cover 14 may include a plurality of pockets or depressions that mirror the pocket or depressions 16, 18, 20 in the tray 12. The pockets/depressions in the tray 12 and the tray cover 14 would cooperate to receive the products 13 when coupled together.

[0053] The tray 12 and/or tray cover 14 may also include a printed label, graphic, and/or logo 17 attributed to the product 13 in the pockets or depressions 16, 18, 20. The paperboard material make it possible to directly print the label, graphic, and/or logo 17 onto the tray 12 and/or tray cover 14. Other paperboard packaging, like molded paperboard pulp material, the label, graphic, or logo has to be separate and attached thereto using a suitable method.

[0054] In some embodiments, the tray 12 or the tray cover 14 may have a perforated section 60 that is removable to expose the products 13 within the package 10 so that the products 13 may be removed from the package 10. The perforated section 60 is attached with perforations to enable the perforated section 60 to be removed. As shown in FIGS. 9A and 9B, the tray cover 14 is formed to include a perforated section 60. In other embodiments, the perforated section 60 may be included in the formed paperboard tray 12.

[0055] Another embodiment of a package 210 in accordance with the present disclosure is shown in FIGS. 2A and 2B. The package 210 is substantially similar to the package 10 shown in FIGS. 1A-B and 3-4B. and described herein. Accordingly, similar reference numbers in the 200 series indicate features that are common between the package 10 and the package 210. The description of the package 10 is incorporated by reference to apply to the package 210, except in instances when it conflicts with the specific description and the drawings of the package 10.

[0056] The package 210 includes a tray 212 and a tray cover as shown in FIGS. 2A and 2B. Like the tray 12, the tray 212 is a formed/pressed paperboard tray 12 made from paperboard material. As shown in FIGS. 2A and 2B, the tray 212 further includes at least one window 246 disposed therein for viewing product 13 in the package 210.

[0057] The formed/pressed paperboard tray 212 includes a base 222 and a planar lip 224 as shown in FIGS. 2A and 2B. The planar lip 224 extends from and around a perimeter edge of the base 222 to define a boundary of the tray 212. The base 222 defines a plurality of pockets or depressions 216, 218, 220 as shown in FIGS. 2A and 2B. The pockets or depressions 216, 218, 220 are configured to receive one or more products 13 therein.

[0058] The plurality of pockets or depressions 216, 218, 220 are similar, if not the same as the pockets or depressions 16, 18, 20 in FIGS. 1A-B and 3-4B. The plurality of pockets or depressions 216, 218, 220 have varying depths such that each pocket or depression 216, 218, 220 has a different depth as shown in FIGS. 2A and 2B. The first pocket 216 has a first depth d, the second pocket 218 has a second depth d, and the third pocket 20 has a third depth d. The deeper pockets are partially or wholly disposed within shallower pockets. Therefore, the second pocket 218 is partially or wholly disposed within the first pocket 216 and the third pocket 220 is partially or wholly disposed within the first pocket 216 and the second pocket 218.

[0059] The first pocket or depression 216 includes a bottom surface 226 and at least one side wall 228 disposed partially or completely therearound as shown in FIGS. 2A and 2B. The second pocket or depression 218 includes a bottom surface 232, a first side wall 234 disposed partially or completely therearound, and a second side wall 236 disposed partially around the bottom surface 232 as shown in FIGS. FIGS. 2A and 2B. The third pocket or depression 220 includes a bottom surface 242 and a first side wall 244 disposed completely therearound as illustrated in FIGS. 2A and 2B.

[0060] The window 246 is formed in the bottom surface 232 of the second pocket or depression 218 as shown in FIGS. 2A and 2B. In some embodiments, the window or windows 246 may be formed in the bottom surface 226 of the first pocket or depression 216, the bottom surface 232 of the second pocket or depression 218, and/or the bottom surface 242 of the third pocket or depression 220. In some embodiments, the window or windows 246 may extend across the pockets or depressions 216, 218, 220.

[0061] In the illustrative embodiment, the window 246 is open and no material is disposed thereover as shown in FIGS. 2A and 2B. In some embodiments, the window 246 may be covered or material is disposed thereover. For example, a transparent thermoplastic film thereon may cover the windows 246. The transparent thermoplastic film may be any apparent to those skilled in the art; however, a preferable thermoplastic film may be made from polylactic acid (PLA), which may degrade in the presence of time and moisture, and therefore may be considered environmentally friendly.

[0062] In some embodiments, the window 246 may be covered by a paper-based film that may be transparent or translucent. The translucent paper material, when present in the embodiments provided herein, may be made from glassine, which is a translucent paper-based material, so that the entirety of the paperboard packaging may be recyclable and/or compostable without separation of elements therefrom, such as, for example, plastic films or the like. Of course, other paper-based materials that may have transparent and/or translucent properties may also be used to cover the window 246, and the present disclosure should not be limited as described herein.

[0063] In some embodiments, the window 246 may be covered by a scrim material, preferably made from a plurality of filaments interweaved together, thereby forming a barrier through which large products are prevented from passing through, but allowing viewability of the products contained therein, and for the passage of air. The scrim material may be made from any kind of filaments, such as, for example, CLAF, which is a cross laminated polyolefin open mesh nonwoven material. Preferably, the scrim material may be made from natural fibers or filaments, such as made from paper materials or cotton, or other plant-based materials, that are easily recyclable and/or compostable with the paperboard material, so that when recycled or composted, the scrim material need not be removed from the paperboard material. Moreover, the scrim material may be adhered as a layer on the flat blank or applied in individual locations discretely over the windows 246 and adhered to the paperboard material.

[0064] A method 100 of forming and assembling the package 10 with the product 13 arranged therein includes a pre-processing stage 120, a pressing or forming stage 130, and a packaging stage 140 as shown in FIG. 5. In the pre-processing stage 110, the paperboard blank or sheet 12 is processed prior to the pressing/forming stage 130 based on the type of product 13 to be packaged. In the pressing or forming stage 130, the paperboard blank 12 is fed through the press 50 to be formed into the formed paperboard tray 12. In the packaging stage 140, the product(s) 13 is arranged in the tray 12 and the package 10, i.e., the tray 12 and the tray cover 14 are assembled.

[0065] The method 100 includes providing a paperboard blank 12 with predetermined dimensions based on the type of product 13 to be packaged as suggested by block 110. The paperboard blank 12 has predetermined dimensions (e.g., size and shape) based on the product 13 to be held or stored within the package 10. For example, the paperboard blank 12 for a larger product 13 may be larger than the paperboard blank 12 for a smaller product 13.

[0066] The method 100 also includes providing a tray cover 14 that has predetermined dimensions based on the formed paperboard tray 12 as suggested by block 112. The paperboard blank 12 and the tray cover 14 may also have predetermined properties (e.g., type of paperboard material, moisture content, etc.). In the illustrative embodiment, the paperboard blank 12 and the tray cover are a dry paperboard. The tray 12 and the tray cover 14 are not made from a molded paperboard pulp material.

[0067] Once the paperboard blank 12 is provided, the paperboard blank 12 is pre-processed in the pre-processing stage 120. The pre-processing stage 120 of the method 100 may include: (i) applying graphics, logos, and/or colors to the paperboard blank 12 as suggested by block 122, (ii) cutting out the window(s) 46 from the paperboard blank 12 as suggested by block 124, (iii) scoring the paperboard blank 12 to apply creases or score lines 15 in strategic locations as suggested by block 126, and/or (iv) applying perforations 62 to the paperboard blank 12 in predetermined locations as suggested by block 128 as shown in FIG. 5.

[0068] The creases 15 are configured to aid in the forming the formed paperboard tray 12 via a press 50 in the pressing/forming stage 130. After the paperboard blank 12 is pressed into the formed paperboard tray 12, the creases or score lines 15 are creases 15 in the tray 12 as shown in FIGS. 6A and 6B. The creases 15 are applied in predetermined areas on the paperboard blank 12 based on the pockets or depressions 16, 18, 20 to be formed. Additionally, partially circumscribing the pockets or depressions 16, 18, 20 allows the paperboard to fold onto itself with reduces the number of creases 15 used because the

[0069] In some embodiments, the graphics, logos, and/or colors 17 may be applied after the pressing stage 130. Additionally, or alternatively, the graphics, logos, and/or colors 117 may be applied may be applied to the tray cover 14. In some embodiments, the window(s) may be cut out after the pressing stage 130, window(s) may be cut out of the tray cover 14 instead, or omitted entirely. In some embodiments, the perforations 62 may be applied to the tray 12 so that the tray 12 has a perforated section 60 as shown in FIGS. 9A and 9B.

[0070] The processed paperboard blank 12 then moves to the pressing or forming stage 130 as shown in FIG. 5. To form the formed/pressed paperboard tray 12, the paperboard blank 12 is pressed between two mold tools 52, 54 of the press 50. The mold tools 52, 54 used are based on the paperboard tray 12 to be formed. The mold tools 52, 54 are female and male tools that cooperate to form a mold cavity 56. In the illustrative embodiment, the mold cavity 56 has the desired shape of the formed paperboard tray 12 as shown in FIGS. 7 and 8. In some embodiments, the mold cavity 56 may have only a portion of the paperboard tray 12 to be formed. In such embodiments, multiple mold tools 52, 54 with different sections of the paperboard tray 12 to be formed may be used to press the paperboard blank 12 in steps.

[0071] The pressing or forming stage 130 includes (i) arranging the paperboard blank 12 on one of the mold tools 52, 54 of the press 50 as suggested by block 134, (ii) pressing the paperboard blank 12 in the press 50 while applying heat at a predetermined temperature to the paperboard blank 12 to provide the formed paperboard tray 12 as suggested by block 136, and (iii) removing one of the mold tools 52, 54 after a predetermined press period to be able to remove the paperboard tray 12 from the press 50 as suggested by block 138 as shown in FIGS. 5 and 7. The mold tools 52, 54 may be heated so as to apply heat to the paperboard blank 12 during the pressing stage 130.

[0072] In some embodiments, the predetermined temperature may be greater than 300 degrees Fahrenheit. In some embodiments, the predetermined temperature may be greater than 350 degrees Fahrenheit. In some embodiments, the predetermined temperature may be greater than 400 degrees Fahrenheit. In some embodiments, the predetermined temperature may be between about 300 and about 450 degrees Fahrenheit. In some embodiments, another suitable predetermined temperature may be used.

[0073] The step of pressing the paperboard blank 12 to form the paperboard tray 12 may be done in a single step or several steps. In a single pressing step 136, the mold cavity 56 has the desired shape of the formed paperboard tray 12 such that the plurality of pockets or depressions 16, 18, 20 are formed at the same time. If the pressing step 136 is done incrementally, the multiple mold tools 52, 54 may be used with mold cavities 56 that form a different pocket or depression 16, 18, 20. Each press sequentially imparts each pocket or depression 16, 18, 20 at varying depths. For example, the first pocket or depression 16 may be pressed/formed first, then the second pocket or depression 18, and then the third pocket or depression 20.

[0074] For some packages 10, the pressing stage 130 may also include applying a coating to one of or both of the mold tools 52, 54 as suggested by block 132 as shown in FIG. 5. The coating may be applied before the paperboard blank 12 is fed into the press 50. The coating is configured to improve the mold release of the formed paperboard tray 12 and prevent the mold 52, 54 from pulling off the graphics, logos, and/or colors from the tray 12.

[0075] Once the paperboard tray 12 is formed, the product 13 may be packaged therein in the packaging stage 140 as shown in FIG. 5. The packaging stage 140 includes: (i) arranging the product 13 in the pocket 16 in the formed paperboard tray 12 as suggested by block 142 and (ii) coupling or adhering the tray cover 14 to the paperboard tray 12 with the product 13 in the pocket 16 to trap the product 13 therebetween as suggested by block 144 as shown in FIGS. 5 and 8.

[0076] The tray cover 14 is coupled to the tray 12 by heat sealing the tray cover 14 to the planar lip 24 of the tray 12 as suggested in FIG. 8. The shape of the tray 12 makes heat sealing the tray cover 14 to the tray 12 easier because the same mold tool 52, 54 may be used. In other words, the mold tool 52, 54 need not be changed out for heat sealing equipment. In other embodiments, the tray cover 14 may be coupled to the planar lip 24 using another suitable method.

[0077] The method 100 of forming and assembling the package 10 with the product 13 arranged therein may also include additional steps to form the formed paperboard tray cover 14. The tray cover 14 is formed using a similar process as forming the tray 12. The tray cover 14 is then arranged over the tray 12 with the products 13 in the pockets or depressions 16, 18, 20 so that a portion of the products 13 extend into the pockets or depressions in the tray cover 14. The tray cover 14 is then coupled to the tray 12 to trap the products 13 therebetween.

[0078] The present disclosure relates to paperboard packaging. Specifically, the present disclosure includes formed paperboard packaging 10, 210 having a plurality of formed pockets or depressions 18, 16, 20, 216, 218, 220 having varying depths from a base surface depth level. Moreover, the formed paperboard packaging 10, 210 may include a plurality of formed pockets or depressions 18, 16, 20, 216, 218, 220 having varying depths form a base surface depth level, wherein at least one formed pocket or depression is wholly contained within another formed pocket or depression. In addition, the formed paperboard packaging 210 may include a plurality of formed pockets or depressions 216, 218, 220 having varying depths from a base surface depth level and further having a cut-out opening or window 246 disposed one or a plurality of the formed pockets or depressions 216, 218, 220.

[0079] According to one embodiment, paperboard packaging 10, 210 is provided that includes pockets 16, 18, 20, 216, 218, 220 of varying depths, respectively. According to one embodiment, the paperboard packaging 10, 210 may include a first pocket 16, 216 of a first depth and a second pocket 18, 218 of a second depth, wherein the second pocket 18, 218 is within the first pocket 16, 216. According to one embodiment, the paperboard packaging 10, 210 may include a plurality of pockets 16, 18, 20, 216, 218, 220 of varying depths wherein deeper pockets are disposed within shallower pockets.

[0080] According to one embodiment, a formed paperboard tray product 10, 210 is provided. The formed paperboard tray 12, 212 may include a paperboard base 22, 222 including a first pocket 16, 216 having a first depth measured from a surface 30 of an unformed part 24 of the paperboard tray 12, 212 to a bottom surface 26, 226 of the first pocket 16, 216, and a second pocket 18, 218 having a second depth measured from the surface 30 of the unformed part 24 of the paperboard tray 12, 212 to a bottom surface 42, 242 of the second pocket 18, 218, wherein the first and second depths are different. The formed paperboard tray product 10, 210 further including a window 46, 246 disposed within at least one of the first or second pockets 16, 18, 216, 218.

[0081] It is, therefore, an advantage and objective of the present disclosure to provide improved paperboard packaging. According to one embodiment, paperboard packaging 10, 210 is provided that may easily be formed into desired shapes to hold products 13 therein. According to one embodiment, paperboard packaging 10, 210 is provided that may be made from various types of paperboard dependent upon desired characteristics. According to one embodiment, paperboard packaging 10, 210 is provided that provides pockets 16, 18, 20, 216, 218, 220 of varying depths, respectively. According to one embodiment, paperboard packaging 10, 210 is provided that includes a first pocket 16, 216 of a first depth and a second pocket 18, 218 of a second depth, wherein the second pocket 18, 218 is within the first pocket 16, 216. According to one embodiment, paperboard packaging 10, 210 is provided that includes a plurality of pockets 16, 18, 20, 216, 218, 220 of varying depths wherein deeper pockets are disposed within shallower pockets.

[0082] Referring now to the drawings, FIG. 1 illustrates a perspective view of a formed paperboard tray 12 in an embodiment of the present disclosure. The formed paperboard tray 12 includes a base material or paperboard blank 12 that may be formed utilizing paperboard forming methods as described herein. The formed paperboard tray 12 may be utilized for holding products 13 therein and may have another panel or tray cover 14 disposed thereon and adhered or otherwise attached thereto for sealing a product 13 therein.

[0083] The formed paperboard tray 12 may be generally formed by taking a flat paperboard blank 12, applying graphics and/or colors 17 thereto, applying creases 15 thereto in strategic locations to aid in the forming of the formed paperboard tray 12 via a press 50. The creases 15 may be near corners of pockets or depressions 16, 18, 20 that are formed therein via a press 50, as illustrated in FIGS. 1A-B and 6A-B. The creases 15 may aid in forming the paperboard blank 12 into a three-dimensional tray 12 having a plurality of pockets or depressions 16, 18, 20 without tearing or destroying the paperboard blank 12, or otherwise forming uncontrolled creases that may be unsightly and induce locations of weakness in the paperboard that may lead to tearing of the same when in use.

[0084] According to one embodiment, the paperboard tray 10 may have a plurality of pockets or depressions 16, 18, 20 formed therein, formed by pressing the paperboard tray blank 12 having the creases 15 therein to form the plurality of pockets or depressions 16, 18, 20 in the formed paperboard tray 12. As illustrated in FIG. 1A, the paperboard tray 12 may include a first pocket or depression 16, a second pocket or depression 18, and a third pocket or depression 20. The creases 15 may generally be disposed within a blank paperboard panel 12, namely one that is unformed. The creases 15 may aid in the forming of the pockets or depressions 16, 18, 20, as described herein. The resulting creases 15 may be contained around the pockets or depressions 16, 18, 20 formed therein or within the pockets or depressions 16, 18, 20, as illustrated in FIGS. 1A and 1B and described herein.

[0085] The first pocket or depression 16 may have a bottom surface 26 and at least one side wall 28 disposed partially or completely therearound. Thus, the first pocket or depression 16 may form a well, wherein the bottom surface 26 has a first depth d from a surface 30 of an unformed part of the paperboard tray 12, i.e., the planar lip 24.

[0086] The second pocket or depression 18 may have a bottom surface 32 and a first side wall 34 disposed partially or completely therearound. The first side wall 34, as illustrated in FIGS. 1A-1B, may partially circumscribe the second pocket or depression 18 a distance d from the bottom surface 32 to the bottom surface 26 of the first pocket or depression 16 since the second pocket or depression 18 is disposed within the pocket or depression 18. The second pocket or depression 18 may further have a second side wall 36 that partially circumscribes the second pocket or depression 18 at a distance d from the bottom surface 32 to the surface 26 of the unformed part of the paperboard tray 10. The distance d may therefore be the sum of the distance d and the distance d.

[0087] The third pocket or depression 20 may have a bottom surface 42 and a first side wall 44 disposed partially or, as illustrated in FIGS. 1A-1B, completely therearound. The first side wall 44 of the third pocket or depression 20 may circumscribe the third pocket or depression 20 a distance d from the bottom surface 42 to the bottom surface 32 of the second pocket or depression 18. Thus, the depth d of the bottom surface 42 from the surface 26 of the unformed part of the paperboard tray 10 may be the sum of the distances from the bottom surface 42 of the third pocket or depression 20 to the bottom surface 32 of the second pocket or depression 18 (d), the distance from the bottom surface 32 of the second pocket or depression 18 to the bottom surface 26 of the first pocket or depression 16 (d), and the distance from the bottom surface 26 of the first pocket or depression 16 to the surface 30 of the unformed part of the paperboard tray 10 (d).

[0088] FIG. 1B illustrates a bottom view of the paperboard tray 12 showing how the pockets or depressions 16, 18, 20 appear from the opposite side thereof. Due to the unique arrangement of pockets or depressions 16, 18, 20, each having a depth that is different, products 13 contained therein may be uniquely arranged and held therein. In use, the package 10 may preferably have a panel 14, such as a flat paperboard panel 14 that is adhered to or otherwise held or attached to the paperboard tray 12. For example, an adhesive may be placed on the surface 30 of the unformed part of the paperboard tray 12, i.e., the planar lip 24, and a flat paperboard panel 14 may be placed thereon and held in place, thereby forming the packaging 10 with interior spaces that correspond to the pockets or depressions 16, 18, 20 as described herein. Alternatively, the panel 14 formed as a paperboard tray, in the same manner described herein with pockets or depressions of varying depths or via conventional ways, may be adhered to the paperboard tray 12 to form packaging 10 for items therein.

[0089] According to one embodiment, the plurality of pockets or depressions 16, 18, 20, as described herein, may be formed at the same time using a single press that may press a paperboard blank 12, having strategically placed creases 15, into the shape as illustrated, namely with the plurality of pockets or depressions 16, 18, 20 having different depths therein. Alternatively, a plurality of presses may be utilized sequentially to impart each pocket or depression 16, 18, 20 at varying depths.

[0090] FIGS. 2A-2B illustrate an alternate embodiment of the present disclosure of a formed paperboard tray 212 having a plurality of pockets or depressions 216, 218, 220 that may be generally the same or similar to the pockets or depressions 16, 18, 20 as described above with reference to FIGS. 1A-1B, namely having different depths from one another relative to an unformed part of the paperboard tray 212. One or more of the pockets or depressions 216, 218, 220 may further have an opening or window disposed therein. As illustrated in FIGS. 2A-2B, pocket or depression 218 may have an opening or window 246 disposed therein through the bottom surface 232 thereof. The opening or window 246 may be formed via die-cut, laser cut, blade cut, or any other methodology and may be done prior to pressing the pockets or depressions 216, 218, 220 therein or after pressing the pockets or depressions 216, 218, 220 therein.

[0091] As with the paperboard tray 212, described above, a panel may be adapted to attach to or be adhered to the paperboard tray 212 such as a top portion of the paperboard tray 212, thereby forming packaging 210 in which products may be contained and stored within the pockets or depressions 216, 218, 220. The panel adhered thereto may also be a formed paperboard panel as described above, having a plurality of pockets or depressions of varying depths, or may be formed in conventional ways.

[0092] The paperboard packaging 10, 210 as provided herein may be utilized to hold or store various products or items such as consumer products. Such consumer products include health/beauty products (razors, toothbrush, toothpaste, lip balm, vitamins, cosmetics, sunscreen), electronics (phone, tablet), cleaning products, drink products (coffee grounds, powdered drink mix), medication (pills, tablets, or other like pharmaceuticals), laundry detergent, batteries, medical devices, food items, eyeglasses, and food products. The paperboard packaging 10, 210, including a tray 12, 212 and panel 14 as provided herein, may be adapted to be hung up on a retail store or be placed on a retail store shelf.

[0093] As used herein, the term about refers to the cited value being within the errors arising from the standard deviation found in their respective testing measurements, and if those errors cannot be determined, then about may refer to, for example, within 5%, 4%, 3%, 2%, or 1% of the cited value.

[0094] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present disclosure and without diminishing its attendant advantages. Further, references throughout the specification to the disclosure are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the disclosure as a whole. Moreover, the disclosure illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.