Abstract
A packaging comprises a tray and a tray cover. The tray is formed to define a pocket configured to receive one or more products therein. The tray cover is coupled to the tray over the one or more products in the pocket to close an opening to the pocket. Methods of making the same are further provided.
Claims
1. A paperboard package comprising: a formed paperboard tray formed from a paperboard blank having one or more creases configured to aid in forming the paperboard blank into the formed paperboard tray without tearing or destroying the paperboard blank when the paperboard blank is pressed in a press, the formed paperboard tray including a tray base that defines a tray pocket configured to receive one or more products and a planar tray lip that extends from and around the tray base to define a boundary of the formed paperboard tray, and a paperboard tray cover that couples to the tray lip of the tray over at least a portion of the one or more products in the tray pocket to close an opening to the tray pocket.
2. The paperboard package of claim 1, wherein the paperboard tray cover is heat sealed directly to the tray lip of the formed paperboard tray to couple the tray cover to the formed paperboard tray.
3. The paperboard package of claim 1, wherein the tray cover is a formed paperboard tray cover formed from another paperboard blank having one or more creases configured to aid in forming the paperboard blank into the formed paperboard tray cover without tearing or destroying the paperboard blank when pressed in the press.
4. The paperboard package of claim 3, wherein the paperboard tray cover includes a cover base that defines a cover pocket configured to receive the one or more products and a planar cover lip that extends from and around the cover base to define a boundary of the formed paperboard tray cover, and wherein the tray lip is coupled to the cover lip so that the tray pocket and the cover pocket to trap the one or more products therebetweeen.
5. The paperboard package of claim 4, wherein at least one of the tray base and the cover base is formed to include one or more windows for viewing one or more products contained therein.
6. The paperboard package of claim 1, wherein the tray cover is formed to include at least one window for viewing one or more products contained therein.
7. The paperboard package of claim 6, wherein a portion of the one or more products extend out through the at least one window such that the portion of the one or more products extends past the tray lip of the formed paperboard tray.
8. The paperboard package of claim 1, wherein at least one of the formed paperboard tray and the tray cover includes a printed label attributed to the one or more products in the tray pocket of the formed paperboard tray.
9. A paperboard package comprising: a formed paperboard tray formed from a paperboard blank having one or more creases configured to form the tray when the paperboard blank is pressed in a press, the formed paperboard tray including at least one tray base that defines a first tray pocket configured to receive one or more products and a tray lip that extends from and around the at least one tray base to define a boundary of the formed paperboard tray, and a paperboard tray cover that couples to the tray lip of the tray over at least a portion of the one or more products in the first tray pocket to close an opening to the first tray pocket.
10. The paperboard package of claim 9, wherein the paperboard tray cover is heat sealed directly to the tray lip of the formed paperboard tray to couple the tray cover to the formed paperboard tray.
11. The paperboard package of claim 9, wherein the tray cover is a formed paperboard tray cover formed from another paperboard blank having one or more creases configured to aid in forming the paperboard blank into the formed paperboard tray cover without tearing or destroying the paperboard blank when pressed in the press, wherein the paperboard tray cover includes at least one cover base that defines a first cover pocket configured to receive the one or more products and a cover lip that extends from and around the at least one cover base to define a boundary of the formed paperboard tray cover, and wherein the tray lip is coupled to the cover lip so that the first tray pocket and the first cover pocket to trap the one or more products therebetweeen.
12. The paperboard package of claim 11, wherein the at least one tray base and/or the at least one cover base is formed to include one or more windows for viewing one or more products contained therein.
13. The paperboard package of claim 9, wherein the tray cover is formed to include at least one window for viewing one or more products contained therein.
14. The paperboard package of claim 13, wherein a portion of the one or more products extend out through the at least one window such that the portion of the one or more products extends past the tray lip of the formed paperboard tray.
15. The paperboard package of claim 9, wherein at least one of the formed paperboard tray and the tray cover includes a printed label attributed to the one or more products in the first tray pocket of the formed paperboard tray.
16. The paperboard package of claim 9, wherein the formed paperboard tray includes a first tray base and a second tray base spaced apart from the first tray base, the first tray base forming the first tray pocket and the second tray base forming a second tray pocket, and wherein the tray lip extends between and interconnects the first tray base and the second tray base.
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 while applying heat to the paperboard blank to provide the formed paperboard tray including a tray base that defines a tray pocket and a tray lip that extends from and around the tray base to define a boundary of the formed paperboard tray, arranging the one or more products in the tray pocket 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 tray pocket to trap the one or more products therebetween.
18. The method of claim 17, further comprising applying a printed label to the paperboard blank.
19. The method of claim 17, further comprising cutting out one or more windows from the paperboard blank.
20. The method of claim 17, wherein coupling the tray cover to the tray lip of the formed paperboard tray includes heat sealing the tray cover to the tray lip of the formed paperboard tray.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] 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.
[0040] FIG. 1 is a perspective view of a package according to an embodiment of the present disclosure;
[0041] FIG. 2 is a side view of the package of FIG. 1 showing the package includes support means for supporting the package on a planar surface in an upright orientation as shown in FIGS. 3-5 so that the package is free-standing in the upright orientation without any external supports;
[0042] FIG. 3 is an exploded view of the package of FIG. 1 showing the package includes a formed paperboard tray that defines a pocket configured to receive a product and a tray cover that couples to the tray over at least a portion of the product in the pocket to close an opening to the pocket;
[0043] FIG. 4 is a cross-section view of the package of FIG. 1 showing the tray includes a base that defines the pocket and a planar lip that extends from and around an edge of the base, and further showing the base and the planar lip cooperate to provide the support means for supporting the package in the upright orientation in which the tray cover extends substantially perpendicular to the planar surface so that the package is free-standing in the upright orientation;
[0044] FIG. 5 is a rear view of the package of FIG. 1;
[0045] FIG. 6 is a bottom view of the package of FIG. 1;
[0046] FIG. 7A is a rear view of a package according to another embodiment of the present disclosure;
[0047] FIG. 7B is a front view of the package of FIG. 7A;
[0048] FIG. 7C is a bottom perspective view of the package of FIG. 7A;
[0049] FIG. 8A is a rear view of a package according to an embodiment of the present disclosure;
[0050] FIG. 8B is a front view of the package of FIG. 8A;
[0051] FIG. 8C is a bottom perspective view of the package of FIG. 8A
[0052] FIG. 9 is a rear view of a package according to another embodiment of the present disclosure;
[0053] FIG. 10 is a rear perspective view of the package of FIG. 9 showing the package includes support means for supporting the package on a planar surface in the upright orientation so that the package is free-standing in the upright orientation without any external supports;
[0054] FIG. 11 is an exploded view of the package of FIG. 1 showing the package includes a formed paperboard tray that defines a pocket configured to receive multiple products and a tray cover that couples to the tray over at least a portion of the product in the pocket to close an opening to the pocket;
[0055] FIG. 12 is a rear view of the formed paperboard tray of the package of FIG. 11 showing the tray includes a base that defines the pocket and a planar lip that extends from and around an edge of the base, and further showing the base is formed to include one or more windows for viewing one or more products contained therein;
[0056] FIG. 13 is a front view of the formed paperboard tray of the package of FIG. 11;
[0057] FIG. 14 is a front view of a package according to another embodiment of the present disclosure;
[0058] FIG. 15 is a side perspective view of the package of FIG. 14 showing the package includes support means for supporting the package on a planar surface in an upright orientation as shown in FIGS. 15 and 17 so that the package is free-standing in the upright orientation without any external supports;
[0059] FIG. 16 is an exploded view of the package of FIG. 14 showing the package includes a formed paperboard tray has a first base and a second base that define two separate pockets configured to receive a product and a tray cover that couples to the tray over at least a portion of the product in the pocket to close an opening to the pocket;
[0060] FIG. 17 is a cross-section view of the package of FIG. 14 showing the tray includes first and second bases and a planar lip that extends from the first and second bases, and further showing the first and second bases and the planar lip cooperate to provide the support means for supporting the package in the upright orientation in which the tray cover extends substantially perpendicular to the planar surface so that the package is free-standing in the upright orientation;
[0061] FIG. 18 is a rear view of the package of FIG. 14 showing the planar lip includes a bottom section that extends from bottom walls of the first and second bases, a top section that extends from the top walls of the first and second bases, side sections that extend between and interconnect the bottom and top sections, and an interconnecting section that extends between a side wall of the first base and a side wall of the second base;
[0062] FIG. 19 is a top view of the package of FIG. 14;
[0063] FIG. 20 is a front view of a package according to another embodiment of the present disclosure;
[0064] FIG. 21 is a side view of the package of FIG. 20 showing the product(s) is substantially centered between the top and bottom of the package;
[0065] FIG. 22 is an exploded view of the package of FIG. 20 showing the package includes a formed paperboard tray that defines a pocket configured to receive one or more products and a tray cover that couples to the tray over at least a portion of the one or more products in the pocket to close an opening to the pocket;
[0066] FIG. 23 is a cross-section view of the package of FIG. 20 showing the formed paperboard tray includes a base that defines the pocket and a planar lip that extends from the base, and further showing the tray cover is a paperboard panel coupled to the planar lip of the base;
[0067] FIG. 24 is a front view of the formed paperboard tray included in the package of FIG. 20;
[0068] FIG. 25 is a top view of the formed paperboard tray of FIG. 24;
[0069] FIG. 26 is a front view of a package according to another embodiment of the present disclosure;
[0070] FIG. 27 is a side view of the package of FIG. 26 showing the package includes a formed paperboard tray and a formed paperboard tray cover;
[0071] FIG. 28 is an exploded view of the package of FIG. 26 showing the formed paperboard tray defines a tray pocket and the formed paperboard tray cover defines a cover pocket that cooperate to receive one or more products when coupled together;
[0072] FIG. 29 is a cross-section view of the package of FIG. 26 showing the tray and tray cover each include a base defining a pocket therein and a planar lip that extends from the respective base and couples to the planar lip of the other;
[0073] FIG. 30 is a diagrammatic view of a method of forming a paperboard tray for a formed paperboard package like in FIGS. 1-29 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, (ii) cutting out windows, 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;
[0074] FIG. 31A is a front view of the paperboard blank to be formed into the formed paperboard tray as shown in FIG. 31B;
[0075] FIG. 31B is a front view of the formed paperboard tray after the pressing stage of the method of FIG. 30;
[0076] FIG. 32 is diagrammatic view of the pressing or forming stage of the method of FIG. 30 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;
[0077] FIG. 33 is diagrammatic view of the packaging stage of the method of FIG. 30 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;
[0078] FIG. 34A is a front view of the paperboard blank to be formed into the formed paperboard tray as shown in FIG. 34B;
[0079] FIG. 34B is a front view of the formed paperboard tray after the pressing stage of the method of FIG. 30;
[0080] FIG. 35 is diagrammatic view of the pressing or forming stage of the method of FIG. 30 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;
[0081] FIG. 36 is diagrammatic view of the packaging stage of the method of FIG. 30 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.
DETAILED DESCRIPTION
[0082] A package 10 according to an embodiment of the present disclosure is shown in FIGS. 1-6. The package 10 includes a tray 12 and a tray cover 14 as shown in FIGS. 1-6. The tray 12 is formed to define at least one pocket 16 configured to receive one or more products 13. The tray cover 14 couples to the tray 12 over at least a portion of the product 13 arranged in the pocket 16 to close an opening to the pocket 16 and block removal of the product 13 from the tray 12. The tray cover 14 may include at least one window 18 disposed therein for viewing product 13 in the package 10, as illustrated in FIG. 1.
[0083] 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. 31A-33. 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.
[0084] 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. 2-6. The base 22 defines the pocket 16 configured to receive one or more products 13 therein. The pocket 16, and thus the base 22, is 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 the press 50.
[0085] Additionally, the base 22 and the planar lip 24 of the formed paperboard tray 12 cooperate to provide support means for supporting the package 10 on a planar surface 11 in an upright orientation so that the package 10 is free-standing in the upright orientation. The support means or product self-support structure 20 holds the package 10 in the upright orientation without any external supports so that the package 10 is free-standing or self-supported.
[0086] 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.
[0087] 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.
[0088] Additionally, paperboard packaging may make it difficult for consumers to view the products therein because the paperboard is not transparent or translucent like plastic materials. The paperboard package 10 of the present disclosure includes the support means or product self-support structure 20 that holds the package 10 in the upright orientation without any external supports so that the package 10 is free-standing or self-supported in the upright orientation. The paperboard tray 12 is formed with the base 22 and the planar lip 24. The tray cover 14 may be directly coupled to the planar lip 24 to trap the product 13 between the tray 12 and the tray cover 14 for easy assembly with minimal material used. The base 22 and the planar lip 24 then cooperate to provide the product self-support structure 20 to hold the package 10 in the upright orientation.
[0089] The tray cover 14 also includes at least one window 18 for the product 13 arranged in the pocket 16 of the package 10 to be visible to the consumer as shown in FIGS. 1, 3, 4, and 6. The window 18 is sized to allow a portion of the product 13 to extend therethrough, while blocking assess to the product 13 located in the pocket 16 such that the product 13 may not be removed from the package 10. As a result, the product 13 extends past or over the lip 24 as shown in FIGS. 2, 4, and 6. The shape and orientation of the base 22 maintains the product's center of mass at the equilibrium, making the package 10 more stable in the upright orientation and more difficult to knock over.
[0090] In the upright orientation, the graphics or logo on the package 10 and/or the product 13 may be more visible to the consumer when the package 10 is arranged on the planar surface 11, such as a shelf or display. The product self-support structure 20 enables the graphics or logo on the package 10 and/or the product 13 to face out towards the consumer when arranged on the shelf or display. Additionally, the product self-support structure 20 holds the package 10 in the upright orientation without the need for additional supports, which minimizes the amount of packaging material and thus costs.
[0091] 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, a tray cover 14, and support means for supporting the package 10 on a planar surface 11 in an upright orientation so that the package 10 is free-standing in the upright orientation as shown in FIGS. 2-5. 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%.
[0092] The formed/pressed paperboard tray 12 includes a base 22 and a planar lip 24 as shown in FIGS. 2-6. 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 the pocket 16, also referred to as a cavity 16, configured to receive one or more products 13. An opening to the pocket 16 is defined by the planar lip 24 as shown in FIGS. 2-6. The pocket 16, or cavity 16, extends from the opening in the planar lip 24.
[0093] The base 22 and the planar lip 24 of the formed paperboard tray 12 cooperate to provide the support means 20 or self-support structure 20 for supporting the package 10 on the planar surface 11 in the upright orientation. In the upright orientation, the tray cover 14 extends at an angle relative to the planar surface 11 as shown in FIGS. 1-5. In the upright orientation, the tray cover 14 extends substantially perpendicular to the planar surface 11 as shown in FIGS. 1-5. Substantially perpendicular may mean extending at an angle A of about 90 degrees relative to the planar surface 11.
[0094] In some embodiments, substantially perpendicular may mean extending at an angle A of about 95 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A of about 100 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A of about 105 degrees relative to the planar surface 11.
[0095] In some embodiments, substantially perpendicular may mean extending at an angle A between about 90 degrees and about 110 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 90 degrees and about 105 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 90 degrees and about 100 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 90 degrees and about 95 degrees relative to the planar surface 11.
[0096] In some embodiments, substantially perpendicular may mean extending at an angle A between about 95 degrees and about 110 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 95 degrees and about 105 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 95 degrees and about 100 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 100 degrees and about 110 degrees relative to the planar surface 11. In some embodiments, substantially perpendicular may mean extending at an angle A between about 105 degrees and about 110 degrees relative to the planar surface 11.
[0097] The base 22 of the tray 12 includes a bottom wall 26, a top wall 28, and
[0098] interconnecting side walls 32, 34, 38 as shown in FIGS. 2-6. The top wall 28 is spaced apart from the bottom wall 26. The interconnecting side walls 30, 32, 34 extend between and interconnect the bottom wall 26 and the top wall 28. The bottom wall 26, the top wall 28, and interconnecting side walls 30, 32, 34 cooperate to define the pocket 16 as shown in FIGS. 2-6.
[0099] The interconnecting side walls 30, 32, 34 include a first side wall 30, a second side wall 32, and a back side wall 34 as shown in FIGS. 2-6. The back side wall 34 extends between and interconnects the two side walls 30, 32. In the illustrative embodiment, the back side wall 34 is curved. The curvature of the back side wall 34 may match the curvature of the one or more products 13 located in the pocket 16. In other embodiments, the back side wall 34 may be substantially planar or may have another suitable shape to match the shape of the product 13 located therein.
[0100] The bottom wall 26 of the base 22 extends at an angle 36 relative to the planar surface 11 as shown in FIG. 4. The angle 36 of the bottom wall 26 causes the weight of the product 13 located in the pocket 16 of the tray 12 to shift towards the back side wall 34 of the tray 12 to balance the overall weight of the package 10 and the product 13 when the package 10 is moved to the upright orientation so that the package 10 is free-standing in the upright orientation. The package 10 distributes the weight of the product 13 located in the pocket 16 of the tray 12 to balance the weight of the package 10 and product 13 so that the package 10 is self-supported in the upright orientation. In other words, the package 10 maintains the product's center of mass at an equilibrium point to prevent the package 10 and the product 13 from falling or tipping over when placed in the upright orientation.
[0101] The lip 24 has a bottom section 38, a top section 40, and side sections 42, 44 as shown in FIGS. 2-6. The bottom section 38 of the lip 24 extends from the bottom wall 26 of the base 22 and rests on the planar surface 11 when in the package 10 is in the upright position. The top section 40 of the lip 24 extends from the top wall 28 such that the top section 40 is spaced apart from the planar surface 11 on which the package 10 is supported. The side sections 42, 44 extend between and interconnect the bottom and top sections 38, 40 of the lip 24.
[0102] The bottom wall 26 of the base 22 and the bottom section 38 of the lip 24 cooperate to provide the support means 20 or self-support structure 20. In the illustrative embodiment, at least one point 26P on the bottom wall 26 of the base 22 and the bottom section 34 of the lip 24 cooperate to provide the self-support structure 20. In other words, a larger area of the planar surface 11 is contacted by the bottom section 38 of the lip 24 than the bottom wall 26 of the base 22.
[0103] The tray cover 14 is coupled to or adhered to the planar lip 24 as shown in FIGS. 1-6. 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.
[0104] The tray cover 14 is formed to include at least one window 18 to view the product 13 arranged in the pocket 16 of the package 10 as shown in FIGS. 1, 3, 4, and 6. The window 18 is sized to allow a portion of the product 13 to extend therethrough, while blocking assess to the product 13 located in the pocket 16 such that the product 13 may not be removed from the tray 12. In other words, the window 18 is smaller than the product 13.
[0105] In the illustrative embodiment, the window 18 is open and a portion of the product 13 extends out through the window 18 as shown in FIGS. 1-6. The portion of the product 13 extends past or over the lip 24 as shown in FIGS. 2, 4, and 6. The pocket 16 is sized to only receive a portion of the product 13 so that the product 13 extends out past the tray 12. The tray cover 14 couples to the tray 12 over at least a portion of the product 13 with the window 18 aligned with the product 13 to block the product 13 from being removed from the tray 12.
[0106] As shown in FIGS. 1-6, the window 18 is open and no material is disposed thereover. In some embodiments, the window 18 may be covered or material is disposed thereover. The product 13 may still partially extend out through the window 18 with the covering or material extending over the portion of the product 13 that extends out through the window 18. For example, a transparent thermoplastic film thereon may cover the windows 18. 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.
[0107] In some embodiments, the window 18 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 18, and the present disclosure should not be limited as described herein.
[0108] In some embodiments, the window 18 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 18 and adhered to the paperboard material.
[0109] In some embodiments, the tray cover 14 also includes a printed label, graphic, and/or logo attributed to the product 13 in the pocket 16. In some embodiments, the base 22 may includes a printed label, graphic, and/or logo attributed to the product 13 in the pocket 16. The paperboard material make it possible to directly print the label, graphic, and/or logo 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.
[0110] 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. 30. In the pre-processing stage 120, 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.
[0111] 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.
[0112] 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.
[0113] 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) from the paperboard blank 12 as suggested by block 124, and/or (iii) scoring the paperboard blank 12 to apply creases or score lines 15 in strategic locations as suggested by block 126 as suggested in FIG. 30. 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. 31A and 31B.
[0114] 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) 18 may be cut out after the pressing stage 130 or omitted entirely.
[0115] The processed paperboard blank 12 then moves to the pressing or forming stage 130 as shown in FIG. 30. 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 cooperate to form a mold cavity 56 that has the desired shape of the formed paperboard tray 12. The mold tools 52, 54 used are based on the paperboard tray 12 to be formed. The mold tools 52, 54 are the female and male tools 52, 54 of the tray 12.
[0116] 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 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. 30 and 32. The mold tools 52, 54 are configured to press at an angle as suggested in FIG. 30 to enable the bottom wall 26 to be formed at an angle 36. The mold tools 52, 54 may be heated so as to apply heat to the paperboard blank 12 during the pressing stage 130.
[0117] 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.
[0118] 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. 30. 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.
[0119] Once the paperboard tray 12 is formed, the product 13 may be packaged therein in the packaging stage 140 as shown in FIG. 30. 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. 30 and 33.
[0120] 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. 33. 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.
[0121] Another embodiment of a package 210 in accordance with the present disclosure is shown in FIGS. 7A-C. The package 210 is substantially similar to the package 10 shown in FIGS. 1-6 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.
[0122] The package 210 includes a tray 212 and a tray cover. The tray 212 is formed to define a pocket 216 configured to receive one or more products 13 as shown in FIGS. 7A-C. The tray 212 includes a base 222 and a planar lip 224 that extends from and around an edge of the base 222 as shown in FIGS. 7A-C. The base 222 defines the pocket 216 configured to receive one or more products 213 therein.
[0123] The base 222 and the lip 224 of the tray 212 cooperate to provide the support means for supporting the package 210 on the planar surface 11 in the upright orientation. In this way, the package 210 is free-standing in the upright orientation. In the illustrative embodiment, the pocket 216 is shallower than the embodiment of FIGS. 1-6. In other words, more of the product 213 extends out of the pocket 216 compared to the product 13 in FIGS. 1-6. Even still, the self-support structure 220 shifts or distributes the weight of the product 213 to balance the overall weight of the package 210 and the product 213 when the package 210 is moved to the upright orientation so that the package 210 is free-standing in the upright orientation.
[0124] The base 222 of the tray 212 includes a bottom wall 226, a top wall 228 spaced apart from the bottom wall 226, and interconnecting side walls 230, 232, 234 that extend between and interconnect the bottom wall 226 and the top wall 228 as shown in FIGS. 7A-C. The bottom wall 226, the top wall 228, and interconnecting side walls 230, 232, 234 cooperate to define the pocket 216.
[0125] The bottom wall 226 of the base 222 extends at an angle relative to the planar surface 11 as shown in FIGS. 7A-C. The angle of the bottom wall 226 causes the weight of the product 213 located in the pocket 216 of the tray 212 to shift towards the back side wall 234 of the tray 212 to balance the overall weight of the package 210 and the product 213 when the package 210 is moved to the upright orientation so that the package 210 is free-standing in the upright orientation. The package 210 distributes the weight of the product 213 located in the pocket 216 of the tray 212 to balance the weight of the package 210 and product 213 so that the package 210 is self-supported in the upright orientation.
[0126] The lip 224 has a bottom section 238, a top section 240, and side sections 242, 244 as shown in FIGS. 7A-C. The bottom section 238 of the lip 224 extends from the bottom wall 226 of the base 222 and rests on the planar surface 11 when in the package 210 is in the upright position. The top section 240 of the lip 224 extends from the top wall 228 such that the top section 240 is spaced apart from the planar surface 11 on which the package 10 is supported. The side sections 242, 244 extend between and interconnect the bottom and top sections 238, 240.
[0127] Another embodiment of a package 310 in accordance with the present disclosure is shown in FIGS. 8A-C. The package 310 is substantially similar to the package 10 shown in FIGS. 1-6 and described herein. Accordingly, similar reference numbers in the 300 series indicate features that are common between the package 10 and the package 310. The description of the package 10 is incorporated by reference to apply to the package 310, except in instances when it conflicts with the specific description and the drawings of the package 10.
[0128] The package 310 includes a tray 312 and a tray cover. The tray 312 is formed to define a pocket 316 configured to receive one or more products 13 as shown in FIGS. 7A-C. The tray 312 includes a base 322 and a planar lip 324 that extends from and around an edge of the base 322 as shown in FIGS. 8A-C. The base 322 defines the pocket 316 configured to receive one or more products 313 therein.
[0129] The base 322 and the lip 324 of the tray 312 cooperate to provide the support means or self-support structure 320 for supporting the package 310 on the planar surface 11 in the upright orientation. In this way, the package 310 is free-standing in the upright orientation. In the illustrative embodiment, the pocket 316 is shallower than the embodiment of FIGS. 1-6. In other words, more of the product 313 extends out of the pocket 316 compared to the product 13 in FIGS. 1-6. Even still, the self-support structure 320 shifts or distributes the weight of the product 313 to balance the overall weight of the package 310 and the product 313 when the package 310 is moved to the upright orientation so that the package 310 is free-standing in the upright orientation. The tray 312 of the embodiment of FIGS. 8A-C has a different shaped pocket 316 compared to the tray 212 in FIGS. 7A-C.
[0130] Another embodiment of a package 410 in accordance with the present disclosure is shown in FIGS. 9-13 The package 410 is substantially similar to the package 10 shown in FIGS. 1-6 and described herein. Accordingly, similar reference numbers in the 400 series indicate features that are common between the package 10 and the package 410. The description of the package 10 is incorporated by reference to apply to the package 410, except in instances when it conflicts with the specific description and the drawings of the package 10.
[0131] The package 410 includes a tray 412 and a tray cover 414 as shown in FIGS. 9-13. The tray 412 is formed to define a pocket 416 configured to receive the products 13 as shown in FIGS. 9-13. The tray 412 includes a base 422 and a planar lip 424 that extends from and around an edge of the base 422 as shown in FIGS. 9-13. The base 422 defines the pocket 416 configured to receive one or more products 413 therein. In the illustrative embodiment, the package 410 is configured to receive more than one product 413 as shown in FIGS. 9-13.
[0132] The base 422 and the lip 424 of the tray 412 cooperate to provide the support means for supporting the package 410 on the planar surface 11 in the upright orientation. In this way, the package 410 is free-standing in the upright orientation. In the illustrative embodiment, the pocket 416 is shallower than the embodiment of FIGS. 1-6. In other words, more of the product 413 extends out of the pocket 416 compared to the product 13 in FIGS. 1-6. Even still, the self-support structure 420 shifts or distributes the weight of the product 413 to balance the overall weight of the package 410 and the product 413 when the package 410 is moved to the upright orientation so that the package 410 is free-standing in the upright orientation.
[0133] The base 422 of the tray 412 includes a bottom wall 426, a top wall 428, and interconnecting side walls 430, 432, 434 as shown in FIGS. 9-13. The top wall 428 is spaced apart from the bottom wall 426. The interconnecting side walls 430, 432, 434 extend between and interconnect the bottom wall 426 and the top wall 428. The bottom wall 426, the top wall 428, and interconnecting side walls 430, 432, 434 cooperate to define the pocket 416.
[0134] The bottom wall 426 of the base 422 extends at an angle 436 relative to the planar surface 11 as shown in FIGS. 9-13. The angle 436 of the bottom wall 426 causes the weight of the product 413 located in the pocket 416 of the tray 412 to shift towards the back side wall 434 of the tray 412 to balance the overall weight of the package 410 and the product 413 when the package 410 is moved to the upright orientation so that the package 410 is free-standing in the upright orientation. The package 410 distributes the weight of the product 413 located in the pocket 416 of the tray 412 to balance the weight of the package 410 and product 413 so that the package 410 is self-supported in the upright orientation.
[0135] The lip 424 has a bottom section 438, a top section 440, and side sections 442, 444 as shown in FIGS. 7A-C. The bottom section 438 of the lip 424 extends from the bottom wall 426 of the base 422 and rests on the planar surface 11 when in the package 410 is in the upright position. The top section 440 of the lip 424 extends from the top wall 28 such that the top section 440 is spaced apart from the planar surface 11 on which the package 10 is supported. The side sections 442, 444 extend between and interconnect the bottom and top sections 438, 440 of the lip 424.
[0136] In the illustrative embodiment, the base 422 further include additional windows 418, 419 for the products 413 as shown in FIGS. 11-13. Additional windows 419 may be included based on the size and shape of the product 413 in the pocket 416 of the base 422.
[0137] In the illustrative embodiment, the tray 412 includes a hole 450 as shown in FIGS. 12 and 13. The hole 450 is configured to receive a hook or a hanger of a displace stand to optionally hang the package 410 instead of standing the package 10 on a planar surface 11.
[0138] Another embodiment of a package 510 in accordance with the present disclosure is shown in FIGS. 14-19. The package 510 is substantially similar to the package 10 shown in FIGS. 1-6 and described herein. Accordingly, similar reference numbers in the 500 series indicate features that are common between the package 10 and the package 510. The description of the package 10 is incorporated by reference to apply to the package 510, except in instances when it conflicts with the specific description and the drawings of the package 10.
[0139] The package 510 includes a tray 512 and a tray cover 514 as shown in FIGS. 14-19. Unlike the tray 12 in FIGS. 1-6, the tray 512 is formed to define two pockets 516A, 516B. Each pocket 516A, 516B is configured to receive one product 13 as shown in FIGS. 9-13. The tray 512 includes a first base 522A, a second base 522B, and a planar lip 524 that extends from the bases 522A, 522B. The planar lip 524 extends around and between the bases 522A, 522B as shown in FIGS. 14-19. The planar lip 524 defines the outer boundary of the tray 512.
[0140] Each base 522A, 522B defines a pocket 516A, 516B as shown in FIGS. 15-19 each configured to receive a product 513 therein. The pockets 516A, 516B, and thus the bases 522A, 522B, is formed by pressing a flat paperboard blank 12 in the press 50. The bases 522A, 522B and the planar lip 524 of the formed paperboard tray 512 cooperate to provide support means for supporting the package 510 on the planar surface 11 in the upright orientation so that the package 10 is free-standing in the upright orientation. The support means or product self-support structure 520 holds the package 10 in the upright orientation without any external supports so that the package 510 is free-standing or self-supported.
[0141] Each of the bases 522A, 522B of the tray 512 includes a bottom wall 526A, 526B, a top wall 528A, 528B, and interconnecting side walls 530A, 530B, 532A, 532B, 534A, 534B as shown in FIGS. 15-19. The top wall 528A, 528B is spaced apart from the bottom wall 526A, 526B. The interconnecting side walls 530A, 530B, 532A, 532B, 534A, 534B extend between and interconnect the respective bottom wall 526A, 526B and the respective top wall 528A, 528B as shown in FIGS. 15-19. Each bottom wall 526A, 526B, the top wall 528A, 528B, and interconnecting side walls 530A, 530B, 532A, 532B, 534A, 534B of the respective base 522A, 522B cooperate to define the associated pocket 516A, 516B.
[0142] The bottom wall 526A, 526B of the each base 522A, 522B extends at an angle 536A, 536B relative to the planar surface 11 as shown in FIGS. 15-19. The angle 536A, 536B of the bottom wall 526A, 526B causes the weight of the product 513 located in the pocket 516A, 516B of the tray 512 to shift towards the back side wall 534A, 534B of the tray 512 to balance the overall weight of the package 510 and the product 513 when the package 510 is moved to the upright orientation so that the package 510 is free-standing in the upright orientation. The package 510 distributes the weight of the product 513 located in the pocket 516 of the tray 512 to balance the weight of the package 510 and product 513 so that the package 510 is self-supported in the upright orientation.
[0143] The first base 522A is spaced apart from the second base 522B as shown in FIGS. 15-19. The side wall 532A of the first base 522A faces the side wall 530B of the second base 522B. A portion of the lip 524 extends between the interconnects the side wall 532A of the first base 522A and the side wall 530B of the second base 522B.
[0144] The lip 524 has a bottom section 538, a top section 540, side sections 542, 544, and an interconnecting section 546 as shown in FIGS. 15-19. The bottom section 538 of the lip 524 that extends from the bottom walls 526A, 526B of the bases 522A, 522B and rests on the planar surface 11 when in the package 510 is in the upright position. The top section 540 of the lip 524 that extends from the top walls 528A, 528B of the bases 522A, 522B such that the top section 540 is spaced apart from the planar surface 11 on which the package 510 is supported. The side sections 542, 544 extend between and interconnect the bottom and top sections 538, 540 of the lip 524. The interconnecting section 546 extends between the side wall 532A of one base 522A and the side wall 530B of the base 522B.
[0145] In the illustrative embodiment, the bottom section 538 of the lip 524 has separate portions 538A, 538B and the top section 540 of the lip 524 has separate portions 540A, 540B as shown in FIGS. 18 and 19. The separate portions 538A, 538B of the bottom section 538 each extend from the bottom walls 526A, 526B of the bases 522A, 522B and rests on the planar surface 11 when in the package 510 is in the upright position. The separate portions 540A, 540B of the top section 540 each extend from the top walls 528A, 528B of the bases 522A, 522B such that the top section 540 is spaced apart from the planar surface 11 on which the package 510 is supported.
[0146] The bottom wall 526A, 526B of the first and second bases 522A, 522B and the bottom section 538 of the lip 524 cooperate to provide the support means 520 or self-support structure 520. In the illustrative embodiment, a point on the first base 522A, a point on the second base 522B, and the bottom section 534 of the lip 524 cooperate to provide the self-support structure 520.
[0147] Another embodiment of a package 610 in accordance with the present disclosure is shown in FIGS. 20-25. The package 610 is substantially similar to the package 10 shown in FIGS. 1-6 and described herein. Accordingly, similar reference numbers in the 600 series indicate features that are common between the package 10 and the package 610. The description of the package 10 is incorporated by reference to apply to the package 610, except in instances when it conflicts with the specific description and the drawings of the package 10.
[0148] The package 610 includes a tray 612 and a tray cover 614 as shown in FIGS. 20-25 The tray 612 of the package 610 is a formed paperboard tray 612 formed from a flat paperboard blank or sheet 612 via a press 650 as shown in FIGS. 30 and 34A-36. The flat paperboard blank 612 has predetermined dimensions (e.g., size and shape) based on a product type or product 613 to be held or stored within the package 610. The flat paperboard blank 612 is pressed between mold tools 652, 654 of the press 650 while applying heat at a predetermined temperature to the paperboard blank 612 to provide the formed paperboard tray 612.
[0149] The resulting formed paperboard tray 612 includes a base 622 and a planar lip 624 that extends from and around the base 622 as shown in FIGS. 20-25. The base 622 defines a pocket 616 configured to receive one or more products 613 therein. The pocket 616, and thus the base 622, is formed by pressing the flat paperboard blank 612 in the press 650. The flat paperboard blank 612 has one or more creases 615 configured to aid in forming the paperboard blank 612 into the formed paperboard tray 612 without tearing or destroying the paperboard blank when pressed in the press 650.
[0150] Unlike the embodiment in FIGS. 1-19, the base 622 and the planar lip 624 do not cooperate to provide support means for the package 610. Rather, the product(s) 613 in the package 610 is substantially centered between the top and bottom of the package 610 as shown in FIGS. 20-25. The planar lip 624 defines the outer boundary of the tray 612. The tray cover 614 is coupled directly to the planar lip 624, also referred to as the outer rim 624, of the tray 612.
[0151] The base 622 includes a bottom wall 626, a top wall 628, and interconnecting side walls 630, 632, 634 as shown in FIGS. 21-25. The top wall 628 is spaced apart from the bottom wall 626. The interconnecting side walls 630, 632, 634 extend between and interconnect the bottom wall 626 and the top wall 628 as shown in FIGS. 21-25. The bottom wall 626, the top wall 628, and interconnecting side walls 630, 632, 634 of the base 622 cooperate to define the pocket 616.
[0152] The bottom wall 626 and the top wall 628 each include a sloped section 626S, 628S and a product-supporting section 626P, 628P as shown in FIGS. 21-25. The sloped section 626S of the bottom wall 626 extends from the planar lip 624 at an angle 636A toward the top wall 628 as shown in FIGS. 21-25. The product-supporting section 626P extends from the sloped section 626S. The sloped section 628S of the top wall 628 extends from the planar lip 624 at an angle 636B toward the bottom wall 626 as shown in FIGS. 21-25. The product-supporting section 628P extends from the sloped section 628S.
[0153] The angle 636A of the bottom wall 626 is equal to the angle 636B of the top wall 628 in the illustrative embodiment. In other embodiments, the angles 636A, 636B may be different. For example, the angle 636A of the bottom wall 626 may be greater than or less than the angle 636B of the top wall 628.
[0154] The interconnecting side walls 630, 632, 634 include a first side wall 630, a second side wall 632, and a back side wall 634 as shown in FIGS. 21-25. The first side wall 630 extends from the planar lip 624 at an angle 636C toward the second side wall 632 and the second side wall 632 extends from the planar lip 624 at an angle 636D toward the first side wall 630 as shown in FIGS. 21-25. The first side wall 630 and the second side wall 632 each extend between the sloped sections 626S, 628S of the bottom and top walls 626, 628 on opposite sides thereof. The third side wall 634 extends between and interconnects the product-supporting section 626P of the bottom wall 626, the product-supporting section 628P of the top wall 628, the first side wall 630, and the second side wall 632 as shown in FIGS. 21-25.
[0155] In the illustrative embodiment, the back side wall 634 is curved. The curvature of the back side wall 634 may match the curvature of the one or more products 613 located in the pocket 616. In other embodiments, the back side wall 634 may be substantially planar or may have another suitable shape to match the shape of the product 613 located therein.
[0156] The angle 636C of the first side wall 630 is equal to the angle 636D of the second side wall 632 in the illustrative embodiment. In other embodiments, the angles 636C, 636D may be different. The angles 636C, 636D may be equal to the angles 636A, 636B of the bottom and top walls 626, 628. In some embodiments, the angles 636C, 636D may be greater than or less than the angles 636A, 636B of the bottom and top walls 626, 628.
[0157] In the illustrative embodiment, the first and second side walls 630, 632 may also be formed to include sections 630S, 632S with a different contour than the rest of the wall 630, 632 as shown in FIG. 24. The sections 630S, 632S may make it easier for a consumer to remove the products 613 from the pocket 616 of the tray 612.
[0158] The base 622 of the tray 612 can be divided into two sections: a product-supporting section 660 and an interconnecting section 662 as shown in FIGS. 21-25. In the product-supporting section 660, the base 622 has a contour that matches the outline of the product(s) 613 and the product(s) 613. The product(s) 613 rest on the base 622 in the product-supporting section 660. The interconnecting section 662 extends between and interconnects the product-supporting section 660 and the planar lip 624. The product(s) 613 located in the product-supporting section 660 extend into the interconnecting section 662.
[0159] In the illustrative embodiment, the depth of base 622, i.e., the product-supporting section 660 and the interconnecting section 662, is equal to a dimension of the product(s) so that the product(s) 613 do not extend past the planar lip 624. The tray cover 614 is coupled to the lip 624 over the product(s) 613 located in the pocket 616 as shown in FIG. 23. In some embodiments, the product(s) 613 extend past the planar lip 624 and through a window 618 in the tray cover 614. As shown in FIG. 29, the tray cover 614 may be a formed/pressed paperboard tray cover 714 instead of a paperboard sheet.
[0160] The lip 624 has a bottom section 638, a top section 640, and side sections 642, 644 as shown in FIGS. 21-25. The bottom section 638 of the lip 624 that extends from the bottom wall 626 of the base 622. The top section 640 of the lip 624 that extends from the top wall 628 of the base 622 such that the top section 640. The side sections 642, 644 extend between and interconnect the bottom and top sections 638, 640 of the lip 624.
[0161] The method 100 of forming and assembling the package 610 with the product 613 arranged therein is substantially similar to the method of forming and assembling the package 10. The paperboard blank 612 is selected based on the product 613 to be packaged. The paperboard blank 612 has predetermined dimensions (e.g., size and shape) based on the products 613 to be held or stored within the package 10. For example, the paperboard blank 612 as shown in FIGS. 34A and 34B may be for products 613 compared to the paperboard blank 12 as shown in FIGS. 31A and 31B for the product 13. The tray cover 614 has predetermined dimensions based on the formed paperboard tray 612.
[0162] In the pre-processing stage 120, graphics, logos, and/or colors 617 may be applied to the paperboard blank 612 as suggested by block 122, the windows 618 may be cut from the paperboard blank 612 as suggested by block 124, and creases or score lines 615 may be applied in strategic locations to the paperboard blank 612 as suggested by block 126 as suggested in FIG. 30. The creases 615 are configured to aid in the forming the formed paperboard tray 612 via a press 650 in the pressing/forming stage 130. After the paperboard blank 612 is pressed into the formed paperboard tray 612, the creases or score lines 15 are creases 615 in the tray 612 as shown in FIGS. 34A and 34B.
[0163] In the pressing or forming stage 130, the paperboard blank 612 is fed through the press 650 to be formed into the formed paperboard tray 612. The paperboard blank 612 is pressed between two mold tools 652, 654 of the press 650 that cooperate to form a mold cavity 656 that has the desired shape of the formed paperboard tray 612 as shown in FIG. 35. The mold tools 652, 654 used are based on the paperboard tray 612 to be formed. For instance, the mold tools 52, 54 in FIGS. 32 and 33 is different compared to the mold tools 652, 654 in FIGS. 35 and 36. The mold tools 652, 654 are the female and male tools 652, 654 of the tray 612.
[0164] Once the paperboard tray 612 is formed, the products 613 may be packaged therein in the packaging stage 140 as shown in FIG. 30. In the packaging stage 140, the products 613 are arranged in the pocket 616 in the formed paperboard tray 612. The products 613 are arranged in the product-supporting section 660 of the base 622 so that the products 613 extend into the interconnecting section 664. The tray cover 614 is then coupled to the paperboard tray 612 with the products 613 in the pocket 616 to trap the products 613 therebetween as suggested by block 144 as shown in FIGS. 30 and 36.
[0165] The tray cover 614 is coupled to the tray 612 by heat sealing the tray cover 614 to the planar lip 624 of the tray 612 as suggested in FIG. 36. The shape of the tray 612 makes heat sealing the tray cover 614 to the tray 612 easier because the same mold tool 652, 654 may be used. In other words, the mold tool 652, 654 need not be changed out for heat sealing equipment. In other embodiments, the tray cover 614 may be coupled to the planar lip 624 using another suitable method.
[0166] Another embodiment of a package 710 in accordance with the present disclosure is shown in FIGS. 26-29. The package 710 is substantially similar to the packages 10, 610 shown in FIGS. 1-6 and 20-25 and described herein. Accordingly, similar reference numbers in the 700 series indicate features that are common between the packages 10, 610 and the package 710. The description of the packages 10, 610 is incorporated by reference to apply to the package 710, except in instances when it conflicts with the specific description and the drawings of the packages 10, 610.
[0167] The package 710 includes a tray 712 and a tray cover 714 as shown in FIGS. 26-29. The tray 712 of the package 710 is substantially similar to the tray 612 in FIGS. 20-25. The tray 712 is a formed paperboard tray 712 formed from a flat paperboard blank or sheet 612 via a press 650. However, the tray cover 714 is a formed paperboard tray cover 714 instead of a paperboard sheet 614 like in FIGS. 20-25. The tray cover 714 is a formed paperboard tray cover 714 formed from another paperboard blank 612 having one or more creases 615 configured to aid in forming the paperboard blank 612 into the formed paperboard tray cover 714 without tearing or destroying the paperboard blank 612 when pressed in the press 650 like the tray cover 714.
[0168] The formed paperboard tray 712 includes a base 722 and a planar lip 724 as shown in FIGS. 27-29. The base 722, also referred to as the tray base 722, defines a tray pocket 716 configured to receive one or more products 713 therein. The planar lip 724, also referred to as the tray lip 724, extends from and around the tray base 722. The tray lip 724 defines the outer boundary of the tray 712.
[0169] The formed paperboard tray cover 714 includes a base 772 and a planar lip 774 as shown in FIGS. 27-29. The base 772, also referred to as the cover base 772, defines a cover pocket 776 configured to receive one or more products 713 therein. The planar lip 774, also referred to as the cover lip 774, extends from and around the cover base 772. The cover lip 774 defines the outer boundary of the tray cover 714. The tray lip 724 is coupled to the cover lip 774 so that the tray pocket 716 and the cover pocket 776 trap the one or more products 613 therebetweeen.
[0170] The tray base 722 includes a bottom wall 726, a top wall 728, and interconnecting side walls 730, 732, 734 as shown in FIGS. 27-29. The top wall 728 is spaced apart from the bottom wall 726. The interconnecting side walls 730, 732, 734 extend between and interconnect the bottom wall 726 and the top wall 728 as shown in FIGS. 27-29. The bottom wall 726, the top wall 728, and interconnecting side walls 730, 732, 734 of the base 722 cooperate to define the tray pocket 716.
[0171] The bottom wall 726 and the top wall 728 each include a sloped section 726S, 728S and a product-supporting section 726P, 728P as shown in FIGS. 27-29. The sloped section 726S of the bottom wall 726 extends from the planar lip 724 at an angle 736A toward the top wall 728 as shown in FIGS. 27-29. The product-supporting section 726P extends from the sloped section 726S. The sloped section 728S of the top wall 728 extends from the planar lip 724 at an angle 736B toward the bottom wall 726 as shown in FIGS. 27-29. The product-supporting section 728P extends from the sloped section 728S.
[0172] The interconnecting side walls 730, 732, 734 include a first side wall 730, a second side wall 732, and a back side wall 734 as shown in FIGS. 27-29. The first side wall 730 extends from the planar lip 724 at an angle toward the second side wall 732 and the second side wall 732 extends from the planar lip 724 at an angle toward the first side wall 730 as shown in FIGS. 27-29. The first side wall 730 and the second side wall 732 each extend between the sloped sections 726S, 728S of the bottom and top walls 726, 728 on opposite sides thereof. The third side wall 734 extends between and interconnects the product-supporting section 726P of the bottom wall 726, the product-supporting section 728P of the top wall 728, the first side wall 730, and the second side wall 732 as shown in FIGS. 27-29.
[0173] The base 722 of the tray 712 can be divided into two sections: a product-supporting section 760 and an interconnecting section 762 as shown in FIGS. 27-29. In the product-supporting section 760, the base 722 has a contour that matches the outline of the product(s) 713 and the product(s) 713. The product(s) 713 rest on the base 722 in the product-supporting section 760. The interconnecting section 762 extends between and interconnects the product-supporting section 760 and the planar lip 724. The product(s) 713 located in the product-supporting section 760 extend into the interconnecting section 762.
[0174] Unlike the embodiment in FIGS. 20-25, the depth of tray base 722, i.e., the product-supporting section 760 and the interconnecting section 762, is less than a dimension of the products 713 so that the products 713 extend past the planar lip 724. The part of the products 713 that extends past the planar lip 724 extends into the cover pocket 776 of the tray cover 714 as shown in FIG. 29 such that the tray pocket 716 and the cover pocket 776 trap the one or more products 613 therebetweeen.
[0175] The tray lip 724 has a bottom section 738, a top section 740, and side sections 742, 744 as shown in FIGS. 27-29. The bottom section 738 of the tray lip 724 that extends from the bottom wall 726 of the tray base 722. The top section 740 of the tray lip 724 that extends from the top wall 728 of the tray base 722 such that the top section 740. The side sections 742, 744 extend between and interconnect the bottom and top sections 738, 740 of the tray lip 724.
[0176] The shape of the tray cover 714 is substantially similar to the tray 712 as shown in FIGS. 26-29. The shape of the tray cover 714 is substantially similar to the tray 712 because the products 713 are uniform in shape. Therefore, the cover base 772 of the tray cover 714 includes a bottom wall 778, a top wall 780, and interconnecting side walls 782, 784, 786 as shown in FIGS. 27-29. The top wall 780 is spaced apart from the bottom wall 778. The interconnecting side walls 782, 784, 786 extend between and interconnect the bottom wall 778 and the top wall 780 as shown in FIGS. 27-29. The bottom wall 778, the top wall 780, and interconnecting side walls 782, 784, 786 of the cover base 772 cooperate to define the cover pocket 776.
[0177] The cover lip 774 has a bottom section 788, a top section 790, and side sections 792, 794 as shown in FIGS. 27-29. The bottom section 788 of the lip 774 that extends from the bottom wall 778 of the cover base 772. The top section 790 of the cover lip 774 that extends from the top wall 780 of the cover base 772 such that the top section 790. The side sections 792, 794 extend between and interconnect the bottom and top sections 788, 790 of the cover lip 774.
[0178] The method 100 of forming and assembling the package 710 with the product 713 arranged therein is substantially similar to the method of forming and assembling the packages 10, 610. There are additional steps to form the formed paperboard tray cover 714. The tray cover 714 is formed using a similar process as forming the tray 712. The tray cover 714 is then arranged over the tray 712 with the products 713 in the tray pocket 716 so that a portion of the products 713 extend into the cover pocket 776 in the tray cover 714. The tray cover 714 is then coupled to the tray 712 to trap the products 713 therebetween. The tray cover 714 is coupled to the tray 712 by heat sealing the cover lip 774 of the tray cover 714 to the tray lip 724 of the tray 712. In other embodiments, the tray cover 714 may be coupled to the tray 712 using another suitable method.
[0179] The present disclosure relates to packaging. Specifically, the present disclosure provides formed paperboard packaging 10, 210, 310, 410, 510, 610, 710. The paperboard packaging 10, 210, 310, 410, 510, 610, 710 may have one or more windows 18, 418, 518, 618, 718 for viewing products 13, 213, 313, 413, 513, 613, 713 contained therein. The one or more windows 18, 418, 518, 618, 718 may be covered via transparent, translucent, or other material to prevent access therein but maintain visibility and security of the products 13, 213, 313, 413, 513, 613, 713 contained therein.
[0180] Referring now to the drawings, FIG. 1 illustrates a perspective view of a package 10 according to an embodiment of the present disclosure. The package 10 includes support means for supporting the package 10 on a planar surface 11 in an upright orientation so that the package 10 is free-standing in the upright orientation as shown in FIGS. 2-5. The support means or product self-support structure 20 holds the package 10 in the upright orientation without any external supports so that the package 10 is free-standing or self-supported.
[0181] The package 10 includes a tray 12 and a tray cover 14 as shown in FIGS. 1-6. The tray 12 is formed to define a pocket 16 configured to receive one or more products 13. The tray cover 14 couples to the tray 12 over at least a portion of the product 13 in the pocket 16 to close an opening to the pocket 16. The tray cover 14 may include at least one window 18 disposed therein for viewing product 13 that may be contained in the package 10, as illustrated in FIG. 1.
[0182] The tray 12 may be a formed paperboard tray 12. The formed paperboard tray 12 may be generally formed by taking a flat paperboard blank, applying graphics 17 and/or colors thereto, and applying creases or score lines 15 thereto in strategic locations on the paperboard blank 12 to form a printed paperboard blank 12 having creases 15. The creases 15 may aid in the forming the formed paperboard tray 12 via a press 50. The creases 15 may be near corners of pockets or depressions 16 that are to be formed therein via a press 50, as illustrated in FIGS. 1-6.
[0183] The creases 15 in the paperboard blank 12 may aid in forming the paperboard blank 12 into a three-dimensional tray 12 having a pocket 16 or depression 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. The resulting paperboard tray 12 has creases 15 after the tray 12 is formed in the press 50 as suggested in FIG. 31B.
[0184] In some embodiments, the formed paperboard tray 12 may be formed by cutting at least one window 18 therein instead of the tray cover 14 to form a printed paperboard blank 12 having creases 15 and a plurality of windows 18 cut therein as suggested in FIG. 31A. The printed paperboard blank 12 having creases 15 and at least one window 18 may be formed into the formed paperboard tray 12 via a press. The resulting paperboard tray 12 has creases 15 after the tray 12 is formed in the press 50 as suggested in FIG. 31B.
[0185] The paperboard tray 12 may be made from any paperboard apparent to one of ordinary skill in the art. In the illustrative embodiment, the paperboard material is a dray paperboard material. The paperboard material is curbside recyclable and compostable. The tray cover 14 may also be made from any paperboard apparent to one of ordinary skill in the art. Preferably, the paperboard tray 12 may include paperboard of any type suitable for storing various products as provided herein.
[0186] The creases or score lines 15 may be imposed on the paperboard blank 12 using a press or another suitable tool. In some embodiments, the window 18 may be cut into the paperboard blank 12 using a die-cut apparatus. The window 18 may be cut into the tray cover 14 using a die-cut apparatus; however, the windows 18 may be imposed via any method that is useful, including blade cutting, laser cutting, or other like cutting techniques, and the present disclosure should not be limited as described.
[0187] The tray cover 14 or panel 14 may be adhered to the tray 12. The tray cover 14 adhered to the tray 12 may also be a formed paperboard cover as described above. In some embodiments, the tray cover 14 is another suitable material.
[0188] The paperboard packaging 10 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, including a tray 12 and tray cover 14 as provided herein, may be adapted to be hung up on a retail store or be placed on a retail store shelf.
[0189] The 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. 2-6. The base 22 defines the pocket 16 configured to receive one or more products 13 therein. The pocket 16 may be formed in the tray 12 by pressing the paperboard tray 12 having the creases 15 therein to form the pocket 16. 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 pocket 16, as described herein, and the creases 15 may be contained around the pocket 16 formed therein or within the pocket 16.
[0190] FIGS. 7A-C illustrates another embodiment of a package 210 according to an embodiment of the present disclosure. The package 210 includes support means for supporting the package 210 on a planar surface 11 in an upright orientation so that the package 210 is free-standing in the upright orientation without any external supports.
[0191] FIGS. 8A-C illustrates another embodiment of a package 310 according to an embodiment of the present disclosure. The package 310 includes support means for supporting the package 310 on a planar surface 11 in an upright orientation so that the package 310 is free-standing in the upright orientation without any external supports.
[0192] FIGS. 9-13 illustrates another embodiment of a package 410 according to an embodiment of the present disclosure. The package 410 includes support means for supporting the package 410 on a planar surface 11 in an upright orientation so that the package 410 is free-standing in the upright orientation without any external supports. In the illustrative embodiment, the package 410 is configured to receive more than one product 413 as shown in FIGS. 9-13.
[0193] The paperboard packaging provided herein may easily be formed into desired shapes to hold products therein. The paperboard packaging that may be made from various types of paperboard dependent upon desired characteristics. The formed paperboard packaging may be formed into a three-dimension shape under heat, pressure and within a mold. As shown in FIGS. 1-19, the pocket 16, 216, 316, 416, 516A, 516B has a different shape or size based on the product(s) to be received therein.
[0194] The method 100 may be used to form and assemble any of the packages 10, 210, 310, 410, 510, 610 as shown in FIGS. 1-25. The paperboard blank 12, 612 may be different based on the type of product 13 to be packaged. In other words, the paperboard blank 12, 612 may be different for each package 10, 210, 310, 410, 510, 610.
[0195] The paperboard packaging 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, including a tray and tray cover or panel as provided herein, may be adapted to be hung up on a retail store or be placed on a retail store shelf.
[0196] 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.
[0197] 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.
