Patent Publication Number: US-11390439-B2

Title: Hardware packaging

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application Ser. No. 62/529,906 filed Jul. 7, 2017, the disclosure of which is hereby incorporated in its entirety by reference herein. 
    
    
     TECHNICAL FIELD 
     The application relates to packaging materials for hardware components. 
     BACKGROUND 
     Hardware such as wall plates for switches, receptacles, and other in-wall electrical installations, are typically packaged for shipping and display at a retail store. The packaging also holds fasteners, such as screws which are supplied with the wall plate. The packaging may also include instructions and marketing material about the hardware. Typically, packaged hardware may be held in the package between two packaging components such as in a blister pack with a plastic cover secured to with a back card. Other packaging for hardware retains the hardware in the package with an attachment screw or the like. 
     SUMMARY 
     According to at least one embodiment, a packaging assembly for hardware is provided with a connection portion that holds the hardware component in from a back side of the component so that the front appearance surface of the component is exposed. The connection portion provides a snap-fit feature to retain the hardware component in the packaging assembly. The hardware component may appear to float in order to view a surface finish on the appearance surface without a cover. The packaging assembly does not have any protrusions out of the back of the packaging assembly. 
     In another embodiment, the connection portion may be a protrusion formed to a shape to mate with an opening in the hardware component, where the opening is adapted to receive an electrical component on a consumer&#39;s wall. 
     In another embodiment, the connection portion may be at least one detent formed along side walls of a cavity. The detent engages a periphery of the hardware component to retain the hardware component in the cavity. 
     In another embodiment, the packaging assembly does not cover at least one edge of the hardware component, thereby giving more of a floating look and allowing the consumer to take the product home and hold it up to their wall while still in the package to get a good feel for how it will look or allowing comparison with paint swatches at the store level, for example. 
     According to at least one embodiment, packaging for a hardware component is provided. The packing has a backing with a forward receiving surface adapted to receive a backside of the hardware component. A retention feature is integrally formed with the backing and protrudes from the backing. The retention feature is formed to engage the hardware component with an interference fit so that a front appearance surface of the hardware component is exposed. 
     In another embodiment, the retention feature protrudes forward from the forward receiving surface. 
     In another embodiment, the retention feature has a protrusion having a hardware shape and is adapted to engage a hardware aperture in the hardware component. 
     In another embodiment, the hardware shape has at least one of a switch and an electrical receptacle. 
     In another embodiment, the retention feature includes at least one detent that is adapted to elastically deform and engage the aperture with a snap-fit. 
     In another embodiment, the backing has a cavity defined by a plurality of side walls extending from the forward receiving surface. 
     In another embodiment, the retention feature protrudes from at least one of the plurality of side walls. 
     According to at least one other embodiment, a hardware packaging assembly is provided. A hardware component has a front appearance surface and a back mounting surface. A package backing has a forward receiving surface to receive the back mounting surface of the hardware component. A retention feature protrudes from the package backing to engage the hardware component with an interference fit to retain the hardware component on the package backing while maintaining the front appearance surface exposed. 
     In another embodiment, the hardware component has an aperture extending from the back mounting surface through to the front appearance surface. The retention feature protrudes generally perpendicular from the front receiving surface of the package backing and extends through the aperture in the hardware component. 
     In another embodiment, the hardware packaging assembly has at least one hardware fastener. A fastener cavity for receiving the hardware fastener is defined in the backing. The hardware fastener does not retain the hardware component to the backing. 
     In another embodiment, the backing has a recessed cavity defined by a plurality of side walls extending from the forward receiving surface, wherein the recessed cavity has a depth greater than a depth dimension of the hardware component. 
     In another embodiment, the retention feature comprises a detent that protrudes from at least one of the plurality of side walls and extends generally parallel to the forward receiving surface of the backing, wherein the detent engages a periphery of the hardware component. 
     In another embodiment, the hardware packaging assembly has a display feature extending from the backing. 
     In another embodiment, the hardware component has a plurality of side edges the define a periphery of the hardware component, and wherein the backing does not cover at least one of the side edges. In another embodiment, the hardware component comprises a wall plate. 
     According to at least one other embodiment, a method of forming a hardware packaging assembly is provided. The method includes molding a package backing. A retention feature is integrally molded with and protruding from the package backing. A hardware component is attached to the package backing. The hardware component is retained on the package backing with an interference fit by the retention feature. 
     In another embodiment, the package backing is molded of at least one of pulp and plastic. 
     In another embodiment, the hardware component is retained on the package backing so a front appearance surface of the component is exposed and not covered by the package backing. 
     In another embodiment, the retention feature protrudes generally perpendicular from a front receiving surface of the package backing and the hardware component comprises has an aperture. The hardware component is attached by inserting the retention feature through the aperture in the hardware component. 
     In another embodiment, the package backing has a recessed cavity and the retention feature protrudes from a periphery of the recessed cavity. The hardware component is attached by inserting the hardware component into the recessed cavity so the retention feature engages a hardware periphery. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a front view of a hardware packaging assembly according to one embodiment. 
         FIG. 2  illustrates a front perspective of a hardware package backing in  FIG. 1 . 
         FIG. 3  illustrates a front view of the hardware package backing in  FIG. 2 . 
         FIG. 4  illustrates a section view of the hardware package backing along the section  4 - 4  in  FIG. 3 . 
         FIG. 5  illustrates a front perspective view of a hardware packaging assembly according to another embodiment. 
         FIG. 6  illustrates an exploded view of the hardware packaging assembly in  FIG. 5 . 
         FIG. 7  illustrates a front view of the hardware package backing in  FIG. 6 . 
         FIG. 8  illustrates a side section view of the hardware package backing along the section  8 - 8  in  FIG. 7 . 
         FIG. 9  illustrates a perspective view of a hardware packaging assembly according to another embodiment. 
         FIG. 10  illustrates an exploded view of a hardware packaging assembly according to another embodiment. 
         FIG. 11  illustrates a front view of the hardware package backing in  FIG. 10 . 
         FIG. 12  illustrates a side section view of the hardware package backing along the section  12 - 12  in  FIG. 11 . 
         FIG. 13  illustrates a rear perspective view of a hardware packaging assembly according to another embodiment. 
         FIG. 14  illustrates a front perspective of a hardware package backing in  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION 
     As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. 
     Surface finish and color tones of hardware may be important considerations when customers are purchasing hardware components, such as wall plates, for example, illustrated in  FIG. 1 . But typical packaging may prevent the customer from viewing the surface finish or color since the entire hardware component is covered. Even clear and transparent packaging may inhibit the customer from seeing true surface finish or color. 
     Typical hardware packaging has blister card having a clear plastic cover secured to a back card, where the plastic blister covers the appearance surface of the hardware. Some hardware packaging has a cutout in the plastic blister cover, but still does not allow the consumer to fully view the surface finish and color of the hardware component in the packaging. 
     The hardware packaging of the present application creates a retail package for hardware components, such as wall plates or other electrical enclosures, to be viewed by the consumer without a covering the entire hardware component with packaging. The packaging makes the entire appearance surface of the hardware component, including the edges, accessible without being covered, for interaction and to understand the exact color tones of the finish. Even though the appearance surface of the hardware component is accessible, the packaging still protects the hardware component from damage including scuffing or scratching. 
       FIG. 1  is a front perspective view of the packaging  10  for a hardware component  12 . The hardware component  12  shown is a single wall plate, however, the packaging according to the present application may be used for other hardware types and configurations including a plurality of sizes such as single, double, triple, and quad wall plates or other suitable hardware designs. 
     As shown in  FIG. 2 , the packaging  10  may include a backing  14  with a recessed cavity  16 . The backing has a forward receiving surface  18  that receives a backside, or the back mounting surface of the hardware component  12  that is typically mounted along the wall and concealed when in use. The backing  14  of the packaging includes a connection portion  20  for securing the hardware component  12  to the packaging  10 . The connection portion  20  includes a protrusion  24  that protrudes from the forward receiving surface  18 . The connection portion  20  is adapted to protrude through an aperture  22  in the hardware, as shown in  FIG. 1 . The aperture  22  may be a switch opening, as illustrated in  FIG. 2 , but the aperture  22  may also be an opening shaped for electrical outlets/receptacles the screw holes or other openings formed on the hardware component  12 . 
     As shown in the section view in  FIG. 4 , the connection portion  20  may include at least one detent  26  that provides an interference fit, or snap fit to secure the backing  14  to the hardware component  12 . The detent  26  folds or elastically deforms as the hardware opening  22  receives the connection portion  20  thereby securing the hardware component to the backing  14  of the packaging. The connection portion  20  does not require clips or screws to secure the hardware to the backing  14  of the packaging  10 . The protrusion  24  of the connection portion  20  can be a generic shape or be designed in a way to look like the product that will extend through the hardware component from the backside through to the front appearance surface once installed. For example, the protrusion  24  may be a hardware shape, such as a duplex, decorator, or switch, as shown in  FIGS. 1-4 . The protrusion  24  may also engage the backside of the hardware component. For example, the protrusion  24  may engage a ridge or groove formed on the backside of the hardware component or engage the periphery of the hardware component. 
     As shown in  FIG. 1 , a card  28  may be adhered or sealed to the backing  14 . The card  28  may be cardstock, corrugated, adhesive label or plastic to provide graphics or additional structure, if so desired. However, the card  28  is not required and may not provide any retention of the hardware component  12  in the package  10 . The front card  28  of the packaging may connect to the flanges  30  of the backing  14  or may adhered to other surfaces of the backing  14  that are not flat, depending on the material of the card  28 . The card  28  may have a decorative shaped area  32  which may provide more of any artistic feel and that conceals a portion of the hardware component  12  while still leaving most the hardware component&#39;s appearance surface open for viewing or interaction by the consumer. The card  28  be placed on the front of the backing  14 , as shown in  FIG. 1 . The card  28  may also be attached to the back or both the front and back of the backing  14  to give a “trapped look.” The card  28  can also have folds or additional geometry to add depth to give the impression the hardware component is “floating” inside of a box. 
     Additionally, the backing  14  may include a display feature  34  for displaying the packaging  10  including the hardware component  12 . For example, as shown in  FIGS. 1-3 , the backing  14  includes display feature  34  being a tab having a peg hole for hanging the packaging  10 . 
     The packaging may also retain hardware fasteners, such as screws. Fasteners may be placed inside a cavity  36  formed opposite the protrusion  24 . The cavity  36  in the backing  14  may be covered with a label, tape or a card to maintain the fasteners in the cavity  36 . The backing  14  may be formed of various suitable materials including thermoformed plastics, paperboard, corrugated, or molded pulp, or other materials having elastic pliability to allow for snap fit engagement with the hardware component. 
       FIGS. 5-8  illustrate hardware packaging  40  according to another embodiment.  FIG. 6  illustrates an exploded view of the packaging  40  that has a cover card  42  coupled to a backing  44 . The hardware component  46  is secured in the backing  44 . The packaging  40  may also include a label  48 . 
     The backing  44  of the packaging includes connection portions  50  for securing the hardware component  46  within the cavity  52  of the backing  44  with an interference fit. As shown in  FIG. 7 , the connection portions  50  include detents  56  along the side walls  54  that extend from the forward receiving surface  57  and form a periphery of the cavity  52 . The side walls  54  extend from the forward receiving surface  57  to define the recessed cavity  52 . The recessed cavity may have a depth greater than a depth dimension of the hardware component to help protect the exposed appearance surface during shipping and storage. 
     The detents  56  along the side walls  54  provide an interference fit, or snap fit to secure the backing  44  to the hardware component  46 . The detents  56  flex or fold inwards allowing the hardware component  46  to slide over them. Once passed, the detents  56  return to their original shape to create a ridge over an edge of the hardware component  46  thereby locking the hardware component  46  in the backing  44 . Any number of detents  56  may be provided. For example, one detent  56  along one side wall may provide enough retention. The detents  56  may be one millimeter and extend from the side walls  54  in a direction generally parallel to the forward receiving surface  57 . 
     To remove the hardware component  46 , the backing  44  is flexed to expose a corner of the hardware component  46  and pull to free it from the detents  56 . The backing  44  does not require clips or screws or the cover card to secure the hardware to the backing  44 . 
     As shown in  FIGS. 5-6 , a cover card  42  may be adhered or sealed to the backing  44 . The cover card  42  may be cardstock, corrugated, adhesive label or plastic to provide graphics or additional structure, if so desired. However, the cover card  42  is not required and does not retain the hardware component  46  in the backing  44 . The cover card  42  of the packaging may connect to the flanges  62  of the backing  44 . The cover card  42  may have a decorative shaped area that conceals a portion of the hardware component  46  while still leaving most the hardware component&#39;s appearance surface open for viewing or interaction by the consumer. 
     As shown in  FIG. 6-8 , a small cavity  58  for the hardware fasteners  60 , such as screws, may be added into the backing  44 . The fastener cavity  58  may extend inward from the front and may be covered by the cover card  42  to retain the fasteners in the cavity  58 . Alternatively, the cavity  58  may be extend from a back surface in a direction opposite the cavity  52  and may be covered by the label  48 , for example. 
     Additionally, the backing  44  may include a display feature  64  such as a tab with a peg opening or hook opening for hanging the packaging  40  including the hardware component  46 . The display feature may also allow the packaging to stand or be displayed on shelves. For example, the display feature may include feet or a base along a lower edge to allow the packaging to stand. It is also contemplated that slits may be formed into the sidewalls of the cavity  52  to slide in and out paint samples, if required. 
       FIG. 9-12  illustrate a hardware packaging assembly according to other embodiments to the application where the packaging does not extend significantly beyond the sides of the hardware component. These embodiments allow a consumer to see how the hardware component  72  would look on a wall before taking it out of the package backing. Additionally, paint samples or wall coverings may be easily compared up against the hardware component while still in the store. 
       FIGS. 9-12  illustrate one embodiment of a hardware packaging assembly  70  where the backing  74  of the packaging includes a recessed cavity  76  formed by side walls  78  without any flanges and minimized thickness. The connection portions include detents  80  that extend from the side walls  78  and are generally parallel to the forward receiving surface  82  of the backing. The detents  80  retain the hardware component to the backing with a snap fit. Four detents  80  are illustrated, however, any number of detents may be provided, even a single detent  80  along one side wall  78  may be used to retain the hardware component. The side walls  78  have minimal thickness to minimize the width and height of the packaging  70 . 
     The packaging assembly  70  does not require clips or screws or the cover card to secure the hardware component to the backing  74 . A small cavity  86  may extend into the backing  74  from the front along the display tab  88  and may be covered by the cover card  90  to retain the fasteners in the cavity  86 , as shown in  FIG. 10 . The packaging assembly  70  may also include a label  92  applied to a rear surface  94  of the backing  74 . Alternatively, the cavity  86  may be extend from the rear surface  94  in a direction opposite the cavity  76 , for example. 
       FIGS. 13-14  illustrate another embodiment of a hardware packaging assembly  100  where the packaging is minimized. The minimized packaging reduces packaging material costs, and allows the packaged hardware components  102  to be efficiently packed and stored during transportation and display. As shown in  FIG. 13 , the backing  104  does not cover at least a portion of the back mounting surface  106  of the hardware component  102 , and does not cover all of the side edges  120  that define the periphery of the hardware component  102 . Only the display feature  110  extends beyond the hardware component  102 . 
     As shown in  FIGS. 13-14 , the backing  104  includes a display feature  110  having a tab and a peg hole for hanging the packaging assembly  100 . The display tab  110  is connected to a backing strip  108  with a connection portion  112  for securing the hardware component  102  to the package backing  104 . The connection portion  112  includes a protrusion  116  adapted to protrude through an opening in the hardware component  102 . Similar to  FIG. 4 , the connection portion  112  includes at least one detent  118  that provides an interference fit, or snap fit to secure the backing  104  to the hardware component  102 . The backing strip  108  does not extend to the lateral edges  120  of the hardware component  102  has a width minimized to be only somewhat wider than the hardware opening  124  so that the backing  104  does not cover a portion of the back mounting surface  106  of the hardware component  102 . 
     While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.