Patent Publication Number: US-9422094-B2

Title: Packaging for headphones, packaged headphones, and related methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 61/560,156, filed Nov. 15, 2011 and entitled “Packaging for Headphones, Packaged Headphones, and Related Methods,” the disclosure of which application is hereby incorporated herein in its entirety by reference. 
    
    
     FIELD 
     Embodiments of the disclosure generally relate to packaging structures and assemblies for headphones, and to methods of packaging headphones using such packaging structures and assemblies. 
     BACKGROUND 
     Headphones are commonly packaged in different packaging configurations. For example, many headphones are packaged in pockets (such pockets may also be referred to as “bubbles” or “blisters”) formed between two plastic sheets of similar size and shape, which are secured together around the periphery of the plastic sheets. Such plastic sheets may be portions of an integral plastic sheet, which is folded over upon itself in a clamshell configuration. This type of packaging is often referred to in the art as “blister packaging.” In another packaging configuration, a headphone may be placed in a tray, which then may be inserted in a rectangular box. 
     BRIEF SUMMARY 
     In some embodiments, the present disclosure includes a packaging insert for a headphone. The packaging insert includes a unitary body having a first integral portion and a second integral portion adjoining the first integral portion along a fold line. The first integral portion includes a central support feature sized and configured to be disposed within and provide support to a headphone to be packaged using the packaging insert. The second integral portion including a retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain a portion of a headphone to be packaged using the packaging insert when the first integral portion and the second integral portion are folded relative to one another along the fold line. 
     In additional embodiments, the present disclosure includes a method of packaging a headphone. A headphone is positioned on a headphone support feature of a packaging insert having a unitary body, and the unitary body is folded along a fold line to rotate an integral end portion of the unitary body relative to the headphone support feature to secure at least a portion of the headphone between the integral end portion and the headphone support feature. 
     In yet further embodiments, the present disclosure includes a packaged headphone assembly that comprises a packaging insert and a headphone retained within the packaging insert. The packaging insert comprises a unitary body including a first integral portion folded relative to a second integral portion along a fold line there between. The first integral portion includes a central support feature partially surrounded by and supporting the headphone. The second integral portion includes a retaining feature cooperating with the central support feature of the first integral portion to retain a portion of the headphone within the folded unitary body between the first integral portion and the second integral portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure may be understood more fully by reference to the following detailed description of example embodiments, which are illustrated in the appended figures in which: 
         FIG. 1  is a front perspective view of a packaging insert that may be used in packaging of headphones; 
         FIG. 2  is a back perspective view of the packaging insert of  FIG. 1 ; 
         FIG. 3  is a side view of the packaging insert of  FIG. 1  in an unfolded configuration; 
         FIG. 4  is a side view of the packaging insert of  FIG. 1  in a folded configuration; 
         FIG. 5  is a front view of the packaging insert of  FIG. 1  in the folded configuration of  FIG. 4 ; 
         FIG. 6  is a plan view of a front side of the packaging insert of  FIG. 1  with a headphone resting thereon; 
         FIG. 7  is a front view of the packaging insert shown in  FIG. 7  folded around the headphone; and 
         FIG. 8  illustrates the headphone and folded packaging insert of  FIG. 7  disposed within a rectangular box container. 
     
    
    
     DETAILED DESCRIPTION 
     The illustrations presented herein are not meant to be actual views of any particular packaging, headphone, or component of packaging or headphones, but are merely idealized representations that are employed to describe embodiments of the present disclosure. Throughout this specification, like reference numbers refer to like elements. 
     Embodiments of the present disclosure may be used to package headphones in a manner that securely retains the headphones within the packaging, provides physical protection to the headphones from damage during shipment and storage, and that allows at least a portion of the headphones to be visible through the packaging to a consumer. Additionally, the packaging may be relatively easy to open to obtain access to the headphones therein. 
     In general, embodiments of the disclosure include a packaging insert that comprises a unitary body having two or more integral portions with fold lines between adjacent integral portions. A headphone may be positioned on the packaging insert, and the packaging insert may be folded along the fold line to cause relative movement between the two integral portions of the unitary body. As the packaging insert is folded along the fold line, at least a portion of the headphone is secured and retained between complementary features on the two integral portions of the unitary body. At least a portion of the headphone may be exposed when the headphone is retained in the folded unitary body of the packaging insert. The packaging insert with the headphone retained therein may be inserted into another container, such as a rectangular packaging box. A portion of the container may be transparent to allow at least a portion of the headphone to be viewed through the container when the packaging insert and the headphone retained therein are disposed within the container and the container is closed. 
     An example embodiment of such a packaging insert  100  is illustrated in  FIGS. 1 through 7 . Referring to  FIGS. 1 through 3 , the packaging insert  100  includes a unitary body  102  having an integral central portion  104 , an integral first end portion  106 , and an integral second end portion  108 . The unitary body  102  may be fabricated from and comprise, for example, a plastic material or a paper-based packaging material (e.g., cardboard, molded paper pulp, etc.). In some embodiments, the material of the unitary body  102  may be recyclable and/or biodegradable. 
     Optionally, a volume of material that exhibits a reduced coefficient of friction relative to the paper pulp material may be disposed over at least a portion of the unitary body. Such a volume of material may be used to reduce the likelihood that the headphone retained in the packaging insert  100  could be scuffed, scratched, or otherwise marked or damage by rubbing of the headphone against the packaging insert  100  during transportation and/or storage. The volume of material may comprise a polymer material such as polytetrafluoroethylene (PTFE), ultra-high molecular weight polyethylene (UHMW PE), or polyoxymethylene (POM). In some embodiments, the volume of material may comprise one or more pieces of woven or knit fabric material. In some embodiments, the volume of material may comprise a substantially homogenous sheet of material. The volume of material may comprise a coating disposed or otherwise formed on a least a portion of the unitary body  102  by spraying, dip-coating, painting, etc., the volume of material (or a precursor thereto) onto unitary body  102 . In other embodiments, the volume of material may comprise a body separate from the unitary body  102 , and may be adhered to the unitary body  102 , or simply disposed between the unitary body  102  and the headphone retained in the unitary body  102 . 
     A first fold line  110  may be defined between the integral central portion  104  and the first end portion  106 , and a second fold line  112  may be defined between the integral central portion  104  and the second end portion  108 . In some embodiments, the unitary body  102  may be thinned, perforated, or otherwise weakened along the first fold line  110  and the second fold line  112  so as to facilitate folding of the unitary body  102  along the first fold line  110  and the second fold line  112 . The first fold line  110  and the second fold line  112  may be at least substantially coplanar and may extend at least substantially parallel to one another in some embodiments across substantially the entire width of the packaging insert  100 , as shown in  FIGS. 1 through 3 . The central portion  104  of the unitary body  102  may include a planar peripheral area  114 . The first fold line  110  may extend along a peripheral boundary at one end of the planar peripheral area  114 , and the second fold line  112  may extend along another peripheral boundary at an opposing end of the planar peripheral area  114 . The fold lines  110 ,  112  may be formed by creating perforations, molding a groove, or reducing the thickness of the packaging insert  100  along a desired fold path to create a natural and consistent bending point when rotational force is applied to the first and second end portions  106 ,  108  in a direction toward the integral central portion  104 . 
     Each of the central portion  104 , the first end portion  106 , and the second end portion  108  includes one or more three-dimensional features having geometries configured to cooperate with (e.g., mate or conform to) features of a headphone so as to retain and protect the headphone within the packaging insert  100 , as discussed in further detail below. The unitary body  102  of the packaging insert  100  may be formed using a stamping or molding process, for example. The unitary body may comprise a non-planar, three-dimensional sheet of material that defines complementary protrusions and recesses on opposing sides of the unitary body  102 . The non-planar, three-dimensional sheet of material may have a generally uniform thickness in some embodiments. 
     The front side of the unitary body  102  (shown in  FIG. 1 ) is the side on which the headphone is disposed when the packaging insert  100  is folded around the headphone, as discussed in further detail below. 
     As shown in  FIGS. 1 and 3 , the central portion  104  of the unitary body  102  includes a central support feature  120  defined by a protrusion on the front side of the unitary body  102  and a complementary recess on the back side of the unitary body  102 . The central support feature  120  is designed and configured to be disposed centrally within and provide support to a headphone to be mounted therein. The central support feature  120  may include an arcuate surface  122  having a size and shape complementary to a headband of a headphone that includes two earphones attached to opposite ends of the headband. The headband may be configured to rest over the top of the head of a person wearing the headphone. Thus, the arcuate surface  122  may have a geometry similar to that of a portion of the head of a person. The central support feature  120  also may include and define two ear cup receptacle cavities  124 A,  124 B on the front side of the unitary body  102  that are sized and configured to receive ear cups  204 A,  204 B ( FIGS. 6 and 7 ) of the earphones when the headphone is disposed around and supported by the central support feature  120 . 
     Referring to  FIG. 1 , the first end portion  106  of the unitary body  102  includes a headband retaining feature  130 . The headband retaining feature  130  includes a concave headband recess  132  formed in a protrusion on the front side of the unitary body  102  that has a size and shape generally complementary to a portion (e.g., a top, central portion) of the arcuate surface  122  of the central support feature  120 . When a headphone is mounted around the central support feature  120  and the first end portion  106  is rotated relative to the central portion  104  by folding the unitary body  102  along the first fold line  110  as discussed below, the headband of the headphone is disposed and retained between the complementarily-shaped headband retaining feature  130  (e.g., a concave recess) and arcuate surface  122  to securely retain the headphone within the folded unitary body  102  and impede movement of the headphone therein. 
     With continued reference to  FIG. 1 , the second end portion  108  of the unitary body  102  includes a headphone retaining feature  140 . The headphone retaining feature  140  includes two concave ear cup recesses  142 A,  142 B formed in a protrusion on the front side of the unitary body  102  that have sizes and shapes generally complementary to lower portions of the ear cups  204 A,  204 B ( FIGS. 6 and 7 ) of the headphone configured to be supported within the packaging insert  100 . When a headphone is mounted around the central support feature  120  and the second end portion  108  is rotated relative to the central portion  104  by folding the unitary body  102  along the second fold line  112  as discussed below, each ear cup of the headphone may be disposed partially within one of the ear cup receptacle cavities  124 A,  124 B of the central support feature  120  and a corresponding one of the concave headphone recesses  142 A,  142 B in the headphone retaining feature  140 . Thus, the headphones are retained between the central support feature  120  of the central portion  104  and the headphone retaining feature  140  of the second end portion  108  in the folded configuration of the unitary body  102  to further retain and protect the headphone therein and prevent relative movement between the headphone and the packaging insert  100  during transport and display. 
     The first end portion  106  optionally may further include an alignment feature  146  having one or more surfaces that are complementary in size and shape to a portion of the central support feature  120 , such as the arcuate surface  122 , as shown in  FIGS. 1 and 3 . As the first end portion  106  is rotated relative to the central portion  104  by folding the unitary body  102  along the first fold line  110 , the alignment feature  146  may abut against or be disposed proximate arcuate surface  122  to align the first end portion  106  with the central portion  104  and provide further structural rigidity to the folded unitary body  102  to protect the headphone retained therein. 
     Similarly, the second end portion  108  optionally may further include an alignment feature  144  having one or more surfaces that are complementary in size and shape to a portion of the central support feature  120 , such as a lower nose portion  126  disposed between the ear cup receptacle cavities  124 A,  124 B, as shown in  FIGS. 1 and 3 . As the second end portion  108  is rotated relative to the central portion  104  by folding the unitary body  102  along the second fold line  112 , the alignment feature  144  may abut against or be disposed proximate the lower nose portion  126  to align the second end portion  108  with the central portion  104  and provide further structural rigidity to the folded unitary body  102  to protect the headphone retained therein. 
       FIGS. 4 and 5  are side and front views, respectively, illustrating the packaging insert  100  in the folded configuration as described above with reference to  FIGS. 1 through 3 . 
     Use of the packaging insert  100  to package a headphone is described below with reference to  FIGS. 6 and 7 .  FIG. 6  is a plan view of the front side of the packaging insert  100 , which is that side also illustrated in  FIG. 1 . As shown in  FIG. 6 , a headphone  200  may be positioned on the packaging insert  100 . For example, the headphone  200  may be mounted around the central support feature  120  on the central portion  104  of the unitary body  102 , such that a headband  202  of the headphone  200  extends around the periphery of the central support feature  120  adjacent the arcuate surface  122  thereof. A first ear cup  204 A of the headphone  200  may be disposed within the first ear cup receptacle cavity  124 A of the central support feature  120 , and a second ear cup  204 B of the headphone  200  may be disposed within the second ear cup receptacle cavity  124 B of the central support feature  120 . 
     Optionally, before or after positioning the headphone  200  around the central support feature  120 , a paper or cardboard insert (not shown) may be disposed on the central portion  104  around the central support feature  120 , such as to cover at least a portion of the planar peripheral area  114 . Such an insert may not be transparent, and optionally may be provided with printed graphics and/or text thereon. Wires, batteries, accessories, and/or printed materials (e.g., warranty materials, instructions for use, etc.) may be positioned behind the paper or cardboard insert on an opposite side thereof relative to the headband  202  and ear cups  204 A,  204 B so as to be hidden from view in the final packaged configuration (see, e.g.,  FIG. 8 ). 
     After mounting the headphone  200  around the central support feature  120 , the unitary body  102  of the packaging insert  100  may be folded along each of the first fold line  110  and the second fold line  112  by rotating the first end portion  106  and the second end portion  208  relative to the central portion  104  of the unitary body  102  to provide a packaged headphone assembly  300  shown in  FIG. 7 . In the packaged headphone assembly  300  shown in  FIG. 7 , the headphone  200  is retained and protected within the folded packaging insert  100 . In particular, the headband  202  of the headphone  200  is disposed between the arcuate surface  122  of the central support feature  120  and the surfaces of the headband retaining feature  130  within the concave headband recess  132 . Similarly, the ear cups  204 A,  204 B of the headphone  200  are respectively disposed within the ear cup receptacle cavities  124 A,  124 B of the central support feature  120  and the concave headphone recesses  142 A,  142 B of the headphone retaining feature  140 . In this configuration, surfaces of the headphone abut against, and are supported and protected by, adjacent surfaces of each of the central support feature  120 , the headband retaining feature  130 , and the ear cup retaining feature  140 . Additionally, the headphone  200  may not be removed from the folded packaging insert  100  without unfolding, deforming, or damaging the packaging insert  100 . Thus, to remove the headphone  200  from the folded packaging insert  100 , the folded packaging insert is first unfolded. 
     Referring to  FIG. 8 , the packaged headphone assembly  300  of  FIG. 7  may be inserted into a container  302  to provide a finished packaged headphone assembly  304  suitable for shipment, storage, and/or display for sale. As shown in  FIG. 8 , the container  302  may comprise a generally rectangular box. In some embodiments, at least a portion of the container  302  may be transparent to allow at least a portion of the headphone  200  to be viewed through the container  302  when the packaging insert  100  and the headphone  200  retained therein are disposed within the container  302  and the container  302  is closed. For example, a majority of the container  302  may comprise a paper or cardboard box, and a plastic transparent window  306  may be provided in one or more walls of the box. 
     Although the packaging insert  100  described hereinabove includes three integral portions separated by fold lines, additional embodiments of the packaging insert  100  may include less or more integral portions with fold lines there between. For example, in additional embodiments, the packaging insert  100  may only include the central portion  104  and the first end portion  106 , and may not include the second end portion  108 . In yet further embodiments, the packaging insert  100  may only include the central portion  104  and the second end portion  108 , and may not include the first end portion  106 . In such embodiments, separately formed insert components, similar to the integral portions described herein but separate from the central portion  104 , optionally may be employed in conjunction with a foldable packaging insert as described herein. In additional embodiments, a packaging assembly may include three or more separately formed packaging inserts similar to the central portion  104  and the end portions  106 ,  108  described herein but separate from each other. In such embodiments, the separately formed packaging inserts may be complementarily coupled together to retain a headphone and inserted into another container, such as a rectangular packaging box, similar to the description above but without folding the packaging inserts relative to one another. In other embodiments, one of the end portions  106  and/or  108  may not include protrusions or features that complement the central support feature  120 . Such an end portion may be generally flat and configured to rest against and support an adjacent surface of a container  308  in which the insert  100  is to be disposed. Further, the packaging insert  100  as described herein optionally could include additional integral side portions on the lateral sides of the central portion  104 , which integral side portions could be configured to fold relative to the central portion  104  so as to provide lateral support and protection to a headphone  200  retained therein. 
     Additional non-limiting examples of embodiments of the disclosure are set forth below. 
     Embodiment 1 
     A packaging insert for a headphone, comprising: a unitary body including a first integral portion and a second integral portion adjoining the first integral portion along a fold line, the first integral portion including a central support feature sized and configured to be disposed within and provide support to a headphone to be packaged using the packaging insert, the second integral portion including a retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain a portion of a headphone to be packaged using the packaging insert when the first integral portion and the second integral portion are folded relative to one another along the fold line. 
     Embodiment 2 
     The packaging insert of Embodiment 1, wherein the retaining feature of the second integral portion of the unitary body comprises a headband retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain a headband of a headphone to be packaged using the packaging insert when the first integral portion and the second integral portion are folded relative to one another along the fold line. 
     Embodiment 3 
     The packaging insert of Embodiment 2, wherein the central support feature comprises an arcuate surface having a size and shape complementary to a size and shape of at least a portion of a headband of a headphone to be packaged using the packaging insert. 
     Embodiment 4 
     The packaging insert of Embodiment 3, wherein the headband retaining feature of the second integral portion of the unitary body comprises another arcuate surface having a size and shape complementary to a size and shape of at least a portion of a headband of a headphone to be packaged using the packaging insert. 
     Embodiment 5 
     The packaging insert of any one of Embodiments 1 through 4, wherein the retaining feature of the second integral portion of the unitary body comprises an ear cup retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain an ear cup of the headphone to be packaged using the packaging insert when the first integral portion and the second integral portion are folded relative to one another along the fold line. 
     Embodiment 6 
     The packaging insert of Embodiment 5, wherein the central support feature comprises an ear cup receptacle cavity having a size and shape configured to receive and support therein at least a portion of the ear cup of the headphone to be packaged using the packaging insert. 
     Embodiment 7 
     The packaging insert of Embodiment 6, wherein the ear cup retaining feature of the second integral portion of the unitary body comprises a concave ear cup recess having a size and shape configured to receive and support therein at least a portion of the ear cup of the headphone to be packaged using the packaging insert. 
     Embodiment 8 
     The packaging insert of any one of Embodiments 1 through 7, further comprising a third integral portion adjoining the first integral portion along another fold line, wherein the first integral portion comprises a central portion of the unitary body, the second integral portion comprises a first end portion of the unitary body disposed at a first end of the unitary body, and the third integral portion comprises a second end portion of the unitary body disposed at an opposing second end of the unitary body from the first end of the unitary body. 
     Embodiment 9 
     The packaging insert of Embodiment 8, wherein the retaining feature of the second integral portion of the unitary body comprises a headband retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain a headband of the headphone to be packaged using the packaging insert when the first integral portion and the second integral portion are folded relative to one another along the fold line. 
     Embodiment 10 
     The packaging insert of Embodiment 9, wherein the third integral portion of the unitary body comprises an ear cup retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain an ear cup of a headphone to be packaged using the packaging insert when the first integral portion and the third integral portion are folded relative to one another along the another fold line. 
     Embodiment 11 
     The packaging insert of any one of Embodiments 1 through 10, wherein the unitary body comprises paper pulp material. 
     Embodiment 12 
     The packaging insert of Embodiment 11, further comprising a volume of material disposed over at least a portion of the unitary body, the volume of material comprising a material exhibiting a reduced coefficient of friction relative to the paper pulp material. 
     Embodiment 13 
     The packaging insert of Embodiment 12, wherein the volume of material comprises a coating disposed on a least a portion of the unitary body. 
     Embodiment 14 
     A method of packaging a headphone, comprising: positioning a headphone on a headphone support feature of a packaging insert having a unitary body; and folding the unitary body along a fold line to rotate an integral end portion of the unitary body relative to the headphone support feature to secure at least a portion of the headphone between the integral end portion and the headphone support feature. 
     Embodiment 15 
     The method of Embodiment 14, further comprising inserting the folded unitary body with the headphone therein into a container. 
     Embodiment 16 
     The method of Embodiment 15, further comprising selecting at least a portion of the container to include a transparent window through which at least a portion of the headphone may be viewed when the folded unitary body and the headphone are disposed in the container. 
     Embodiment 17 
     The method of any one of Embodiments 14 through 16, further comprising folding the unitary body along another fold line to rotate another integral end portion of the unitary body relative to the headphone support feature to secure at least another portion of the headphone between the another integral end portion and the headphone support feature. 
     Embodiment 18 
     The method of any one of Embodiments 14 through 17, further comprising: selecting the unitary body to comprise paper pulp material; and providing a volume of material between at least a portion of the unitary body and the headphone, the volume of material comprising a material exhibiting a reduced coefficient of friction relative to the paper pulp material. 
     Embodiment 19 
     The method of Embodiment 18, further comprising selecting the volume of material to comprise a coating disposed on a least a portion of the unitary body. 
     Embodiment 20 
     A packaged headphone assembly, comprising: a packaging insert; and a headphone retained within the packaging insert; wherein the packaging insert comprises a unitary body including a first integral portion folded relative to a second integral portion along a fold line there between, the first integral portion including a central support feature partially surrounded by and supporting the headphone, the second integral portion including a retaining feature cooperating with the central support feature of the first integral portion to retain a portion of the headphone within the folded unitary body between the first integral portion and the second integral portion. 
     Embodiment 21 
     The packaged headphone assembly of Embodiment 20, further comprising a container, the packaging insert with the headphone retained therein disposed within the container. 
     Embodiment 22 
     The packaged headphone assembly of Embodiment 20 or Embodiment 21, wherein the central support feature comprises an arcuate surface having a size and shape complementary to a size and shape of at least a portion of a headband of the headphone. 
     Embodiment 23 
     The packaged headphone assembly of Embodiment 22, wherein the retaining feature of the second integral portion comprises a headband retaining feature including another arcuate surface having a size and shape complementary to a size and shape of at least a portion of the headband of the headphone. 
     Embodiment 24 
     The packaged headphone assembly of any one of Embodiments 20 through 23, wherein the retaining feature of the second integral portion of the unitary body comprises an ear cup retaining feature sized and configured to cooperate with the central support feature of the first integral portion to retain an ear cup of the headphone between the first integral portion and the second integral portion. 
     Embodiment 25 
     The packaged headphone assembly of any one of Embodiments 20 through 24, wherein the packaging insert further comprises a third integral portion adjoining the first integral portion along another fold line, wherein the first integral portion comprises a central portion of the unitary body, the second integral portion comprises a first end portion of the unitary body disposed at a first end of the unitary body, and the third integral portion comprises a second end portion of the unitary body disposed at an opposing second end of the unitary body from the first end of the unitary body. 
     The embodiments of the invention described above do not limit the scope the invention, since these embodiments are merely examples of embodiments of the invention, which is defined by the scope of the appended claims and their legal equivalents. Any equivalent embodiments are intended to be within the scope of this invention. Indeed, various modifications of the disclosed embodiments, such as alternate useful combinations of the described elements of the embodiments, will become apparent to those skilled in the art from the description. Such modifications are also intended to fall within the scope of the appended claims.