Patent Publication Number: US-2013228492-A1

Title: Packaging System and Method

Description:
CROSS-REFERENCES 
     This application claims the benefit of U.S. Provisional Application No. 61/605,490, filed Mar. 1, 2012, the content of which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     Different forms of self-service merchandise packaging are commonly used to both package products and display the products/packaging in a desirable configuration for viewing by customers. Some types of these display packaging systems are useful for providing access to successively displayed product items. They may also be useful for packaging and securing products. For example, some products for sale may be too large to hang on a peg board display, or may be too small (e.g., a gift card) to be left out on a counter unpackaged. 
     One example of this type of self-service packaging includes the readily known example of plastic “blister pack” displays. In such cases the products may be encased in a transparent plastic blister pack (e.g., a heat-sealed plastic, transparent clamshell). In the case of small products, such a blister pack can provide the product with a larger integral packaging to reduce the risk of theft. In the case of larger products, the blister pack can provide an integral display methodology as an alternative to hanging a product on a pegboard. 
     Blister packs are commonly stocked in cardboard or plastic trays and arranged in a series or row from the front of the tray to the back. As a customer picks out one product in the series, the next product package is immediately exposed and visible to a new customer without the need for restocking or product rearranging by store clerks. One problem recognized with trays and blister packs is the tendency for the product/packaging to tip over after one or more have been removed by customers. A common technique to address this problem is to include slots on each side of the tray into which the blister pack edges are inserted to keep the package upright. While blister packs have proven useful and popular to some extent as packaging, they are also notoriously hard and frustrating to open and are generally not recycled by customers. 
     SUMMARY 
     Some embodiments of the invention provide a packaging system that is generally easy to open, provides a measure of theft deterrence, may be manufactured from a minimum number of materials, and/or is relatively easy to recycle. In some embodiments, the packaging system is configured to maintain several individual products within individual packages, displayed upright in a tray without the aid of packaging edges engaging slots in the opposing sides of the tray. 
     An example of one embodiment of the invention provides a system for packaging and displaying multiple products. The system includes multiple package elements and a support tray configured to support the package elements arranged adjacently in a row upon the support tray. Each of the package elements is generally configured to hold at least one product. The support tray has a first side wall, a second side wall, and a support surface extending between and joined to the first and the second side walls. Each side wall has an inner wall surface facing the package elements supported by the tray and an outer wall surface facing away from the package elements. The support tray is configured to support the multiple package elements in the row upon the support tray without the package elements extending through the first inner wall surface into the first side wall and without the package elements extending through the second inner wall surface into the second side wall. 
     Another example of an embodiment is a packaging system for transporting and displaying products. The packaging system includes a plurality of package elements, a support tray for supporting the package elements, and a removable cover configured to fit about the package elements and the support tray. Encasing the package elements and the tray with the cover provides an integrated packaging assembly with additional strength and security for transporting the package elements with the support tray. 
     In this example, each package element is configured to substantially enclose at least one product. The package element also includes a height, a width, and a thickness that is less than half the height and less than half the width of the package element. The package element also includes at least a partial front surface and a partial back surface. 
     The support tray in this example embodiment includes a support surface extending between and joining first and second side walls. The first side wall has a first inner wall surface and the second side wall has a second inner wall surface. The support tray also includes multiple support tabs located along the first inner wall surface, the second inner wall surface, or both inner wall surfaces. The support tabs are configured to engage the front surface and/or the back surface of one or more of the package elements. The support tabs can thus assist in supporting the package elements in a row configuration with the package elements arranged adjacently front-to-back along the support tray. Typically the height of each package element extends upward from the support tray in this type of example, such that the package elements rest on their bottom surfaces. The length of the bottom surfaces is the smaller thickness of the package element, meaning that the much longer height of the package elements can tend to tip the package elements over without the aid of the support tabs. 
     Another example of the type of embodiments provided by the invention is an exemplary method for packing and displaying products. The method includes providing a plurality of package elements, with each package element holding at least one product. The method further includes providing a support tray such as one of those described above with a first side wall, a second side wall, a support surface, a first inner wall surface, and a second inner wall surface. The plurality of package elements are arranged adjacently in a row upon the support surface of the support tray between the first side wall and the second side wall. The method further includes retaining the plurality of package elements in the row in the support tray and between the first side wall and the second side wall without extending the package elements through the first inner wall surface into the first side wall and without extending the package elements through the second inner wall surface into the second side wall. 
     Some embodiments may optionally provide none, some, or all of the following advantages, though other advantages not listed here may also be provided. 
     In some embodiments providing support tabs, the support tabs can be located along at least one of the first inner wall surface and the second inner wall surface. Optionally, the support tabs located along one of the inner wall surfaces are positioned in front of only half or less of the maximum number of package elements supported by the packaging system. Thus, a support tab need not be provided along each side wall of the support tray for every package element being displayed. In some cases each group of support tabs located along each of the first inner wall surface and the second inner wall surface are positioned in front of half or less of the plurality of package elements. One possible configuration provided in some embodiments includes a number of support tabs spaced along the first inner wall surface and the second inner wall surface in an alternating configuration, e.g., alternating between successive package elements. 
     A possible feature of some embodiments includes one or more support tab that are formed from a partial cut-out portion of one of the first and the second side walls. The partial cut-out portion can be folded out from the side wall along a fold line to provide the tab, leaving behind a hole in the side wall that may be present but not needed or used. For example, a package element may be supported by a support tab but may not extend into the hole left behind from the support tab after it is folded away from the side wall. 
     Some embodiments may be optionally configured to provide the package elements with a reclining angle while supported in the support tray, to provide a more convenient viewing angle for prospective buyers. As one example, in some cases a package element is formed with a front surface, a back surface, and a bottom surface, and the bottom surface is configured to engage the support tray with the package element reclining such that a centerline extending through the package element forms a reclining angle with respect to a plane perpendicular to the support tray support surface. In some cases the angle may be at least about five degrees, or between about five and about ten degrees. In some cases the angle is about seven degrees. 
     These and various other features and advantages will be apparent from a reading of the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate some particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Some embodiments will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements. 
         FIG. 1  is a perspective view of a packaging system according to an embodiment of the invention. 
         FIG. 2  is a side elevation view of a packaging system according to an embodiment of the invention. 
         FIG. 3  is a partial perspective view of a packaging system illustrating a support tab according to an embodiment of the invention. 
         FIG. 4  is a partial view of a packaging element according to an embodiment of the invention. 
         FIG. 5A  is a schematic, side view of a packaging system according to an embodiment of the invention. 
         FIG. 5B  is a schematic, side view of a portion of a support tray according to an embodiment of the invention. 
         FIG. 6  is a schematic, partial top view of a packaging system according to an embodiment of the invention. 
         FIG. 7  is an exploded assembly view of a packaging system including a support tray, a plurality of package elements, and a cover according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations for implementing some embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of ordinary skill in the field of the invention. Those skilled in the art will recognize that many of the noted examples have a variety of suitable alternatives. 
     Embodiments described herein generally relate to self-service product display packaging and methods for packing products and/or displaying products using such packaging. Basic goals of such display packaging will be familiar to those skilled in the art, and include among other things, positioning successive product items in a row for viewing by customers so that as one product item is removed, the next product item is revealed and readily displayed for viewing by the next customer. 
     Embodiments of the invention, while in some cases addressing the basic goals of self-service display packaging, also provide one or more additional features, advantages, benefits, and/or differences from existing product display packaging such as, e.g., plastic blister pack display pack systems. As just a few examples, in some embodiments a packaging system may include package elements that are generally easy to open and/or that provide a measure of theft deterrence. In some cases all or most components of a packaging system may be manufactured from a minimum number of materials and/or is relatively easy to recycle. In some embodiments, the packaging system is configured to maintain several individual products within individual packages, displayed upright in a tray without the aid of packaging edges engaging slots in the opposing sides of the tray. Of course these are just a few examples and those skilled in the art will appreciate a number of other features, advantages and/or differences from a reading of this disclosure. 
       FIGS. 1-3  provide various views of a packaging system  100  according to one possible embodiment.  FIG. 1  is a perspective view of the packaging system  100 ,  FIG. 2  is a side elevation view of the packaging system  100 , and  FIG. 3  is a partial perspective view of the packaging system  100 . As can be seen in the  FIGS. 1-3 , the packaging system  100  generally includes a support tray  102  and multiple package elements  104  positioned in and supported by the support tray  102 . As shown best in  FIGS. 1 and 2 , the support tray  102  is configured to support the package elements  104  in a row, with the package elements arranged adjacently front-to-back within the support tray  102 . Thus, as a customer pulls the front-most package element out of the support tray  102 , the next successive package element is revealed for viewing. 
     Continuing with reference to  FIGS. 1-3 , the support tray  102  is configured to hold the package elements  104  in an upright orientation as illustrated. The support tray  102  depicted in the figures generally includes a first side wall  110 , a second side wall  112 , a back wall  114 , and a front wall  116 . A bottom support surface  118  extends between and joins the walls of the tray, including the first side wall and the second side wall. As shown in  FIGS. 1 and 3 , in some cases the front wall may include a cut away portion that allows for more complete viewing of the package elements  104 , though this is not a required feature. The height of the tray walls  110 ,  112  may be determined in some cases based on, e.g., the height, width, thickness, overall shape, and/or center of gravity of the package elements  104 . 
     As best seen in  FIG. 2 , in some embodiments such as the depicted example, the support tray  102  and the package elements  104  may be configured to allow the package elements  104  to recline from the vertical, which can be useful for providing a comfortable viewing angle for a person looking at the display system. As will be discussed, in some cases a bottom surface (not shown) of a package element is angled with respect to other surfaces of the package element. The package element bottom surface then engages the support surface  118  of the tray with the package element reclining away from the vertical. In some cases the back wall  114  of the support tray  102  can support the last packaging element in the row, thus helping to keep all of the packaging elements upright while also reclining. 
     Generally, a package element  104  may be configured to hold at least one product. As shown in  FIG. 1 , in this case each package element  104  is configured to hold two products in the form of coaxial cable windings  120 .  FIG. 4  is a partial view of one of the packaging elements  104  shown in  FIGS. 1-3 . In this embodiment a package element  104  is configured as a shallow box  122  with a fold-over top  124  having top sides that fit within the box sides to enclose about the products  120  within the package element  104 . Optional mounting structure may be included within the box  122  in order to hold one or more products within the package element  104 . By securing the top  124  to the box  122  with a fastener (e.g., adhesive, tape, wire, etc.) the package element  104  can be relatively secured, thus providing a measure of theft deterrence given the increased size that the package element provides about the products  120 . 
     With the package element  104  in an upright orientation as shown in the figures, the extent of the package element  104  defines an overall height H, a width W, and a thickness T for the package element. In some cases, the thickness of the package element  104  may be less than half the height and also less than half the width of the package element, which gives the package element  104  the elongated box shape shown in the figures. As mentioned above, in some cases the height of the tray walls  110 ,  112  can be designed based on the shape and center of gravity of the package element, thus taking into account the height, width, and thickness of the package element  104 . 
     Referring to  FIGS. 1 and 2 , each package element (as described in the upright orientation) generally includes a number of outside surfaces, including a front surface  130 , a back surface  132 , a top surface  134 , and a bottom surface (not shown). In addition, the package element generally defines two side surfaces  136 ,  138 . In this embodiment with the package element  104  taking the form of a box and fold over cover, the surfaces are provided by the corresponding sides of the box and cover. Of course this is just one example of a package element configuration and a package element may have one of a variety of configurations while still having one or more surfaces, including one or more of a front, back, top, and/or bottom surface. 
     As shown in  FIGS. 2 and 3 , each side wall of the support tray includes an inner wall surface  140 ,  142 . With respect to the figures, these are referred to herein as a first inner wall surface  140  on the first side wall  110  that faces the package elements  104  and a second inner wall surface  142  on the second side wall  112  that also faces the package elements  104  as well as the first side wall  110 . According to some embodiments, the support tray  102  is configured to support the package elements  104  in an upright row upon the support tray  102  without needing slots or other apertures in the first inner wall surface  140  or the second inner wall surface  142  for holding the sides of the packaging elements  104 . Thus, with each package element  104  having two side surfaces  136 ,  138 , in some embodiments the side surfaces simply abut or are positioned adjacent to the first inner wall surface  140  and the second inner wall surface  142 , respectively. In these cases the first side surface  136  of the package element does not extend through the first inner wall surface  140  into the first side wall  110  and the second side surface  138  does not extend through the second inner wall surface  142  into the second side wall  112  in the same manner that a blister pack may be supported by slots in the sides of a blister pack tray. 
     Turning to  FIG. 3 , in some embodiments the display package system  100  includes one or more support tabs  150  that are configured to support the package elements  104  and help maintain them in an upright orientation within the support tray  102 . In some cases a support tab  150  is configured to engage with the front surface of a package element and/or a back surface of a package element to support the package element in an upright orientation. As shown in  FIG. 3 , the support tab  150  is engaged with a portion of the front surface  130  of the front-most package element  104 . The tab  150  thus provides the package element  104  with support by preventing the bottom portion of the package element  104  from sliding forward. 
     According to some embodiments, a system may incorporate multiple support tabs configured to engage multiple package elements to help ensure that the entire row of package elements remains in an upright orientation, e.g., without undesirably tipping forward or backward. In some cases the support tabs can be located along at least one of the first and second inner wall surfaces.  FIG. 3  shows an example of the support tab  150  being located along the first inner wall surface  140 . Support tabs  150  can be provided as part of the support tray  102  in a number of manners. As one example, in some cases support tabs may be positioned along the first inner wall surface  140 , the second inner wall surface  142 , or both inner wall surfaces. In addition, a support tab  150  may not correspond with every package element. For example, a number of support tabs  150  can be located along both the first inner wall surface  140  and the second inner wall surface  142 , but for both surfaces, the tabs  150  may only be positioned in front of half or less of the maximum number of package elements  104  that fit within the support tray  102 . In some cases a support tab  150  on one inner wall surface may not be matched by a support tab in a corresponding location on the other inner wall surface. As one example, in some cases the support tabs  150  may be spaced along the first inner wall surface  140  and the second inner wall surface  142  in an alternating configuration. 
       FIGS. 5A ,  5 B, and  6  are schematic illustrations of portions of a packaging system  500  that illustrate various support tab placements according to some embodiments.  FIG. 5A  is a schematic, side view of a packaging system  500 , while  FIG. 5B  is a schematic, partial side view of a portion of the support tray  502  shown in  FIG. 5A . In particular,  FIG. 5B  depicts a cut-away view of the support tray  502  rotated 180 degrees, showing the first side wall inner surface  540 , with the location of the support tabs  550  illustrated in  FIG. 5A .  FIG. 6  is a schematic, partial top view of a packaging system  600  according to an embodiment. It should be appreciated that  FIGS. 5A ,  5 B, and  6  are not drawn to scale and one or more features may be enlarged for purposes of illustration. 
       FIG. 5A  is a schematic side view of the packaging system  500 , from a perspective similar to the side view of the system  100  in  FIG. 2 . The side view in  FIG. 5A  illustrates a first side wall  510  of a support tray  502  and also depicts from the side several package elements  504  positioned within the support tray  502  (with the portions within the support tray shown in dotted line). Shown between certain package elements  504  is a side representation (e.g., on edge view) of three support tabs  550 , illustrating their position in front of every other package element  504 . The support tabs  550  are configured to help maintain the upward and generally vertical orientation of the package elements  504  within the support tray  502 . As is shown, in this case, each of the support tabs  550  engages with the packaging element  504  directly in front of it and the packaging element  504  directly behind it. Thus, the support tabs  550  are configured to engage a portion of the front surface and a portion of the back surface of the package elements, thereby supporting the package elements  504  in a generally upright orientation with respect to the support tray  502 . 
       FIG. 5A  illustrates an embodiment in which support tabs  550  are located in front of just half of the package elements  504  in an alternating configuration. Turning to  FIG. 6 , in some cases support tabs  650  may be alternately located between the first inner wall surface  640  and the second inner wall surface  642 .  FIG. 6  illustrates a top-down schematic view of a support tray  602  with four tabs  650  and the location of the bottom surfaces of four package elements  604  outlined in dashed lines. As shown, the support tabs  650  are spaced along the first inner wall surface  640  and the second inner wall surface  642  in an alternating configuration. 
     Of course, many configurations and positions of support tabs are contemplated and it should be appreciated that the invention is not necessarily limited to any of the examples described herein. For example, it is contemplated that support tabs could be provided for every package element on each of the inner wall surfaces, thus providing pairs of support tabs for each package element. 
     In addition, when one or more support tabs are provided in some embodiments, the support tabs may be configured in a variety of manners. As shown in  FIGS. 3 and 5B , in some cases one or more support tabs can be formed from a partial cut-out portion of one of the first and the second side walls. In the illustrated examples, a semi-circular cutout  160 ,  560  is depicted, though other shapes and sizes may be chosen. After creating the cut line  562  in the inner wall surface, the partial cut-out portion is folded out from the respective side wall along a fold line  164 ,  564 , leaving a corresponding aperture in the side wall inner surface. Although a hole is left in the side wall inner surface, the package elements engage with the support tab surfaces rather than being inserted into the apertures in the style of a blister pack and tray with slots. Those skilled in the art will appreciate that other mounting options for support tabs can also be used, including attaching separate support tabs to the inner wall surfaces with a fastener such as, for example, an adhesive. 
     As discussed above, in some cases package elements and a support tray can be configured to allow the package elements to recline from the vertical. For example, in some cases a bottom surface of a package element may be angled with respect to other surfaces of the package element.  FIG. 5A  provides a more detailed view of an angular relationship of this sort according to some embodiments. As shown, each of the package elements  504  is reclining at a reclining angle  570  with respect to a plane  572  (represented by a dashed line) perpendicular to the support tray  502  support surface  518 . The bottom surface  574  of each package element  504  is configured to engage the support surface  518  of the tray  502  with the package element reclining such that a centerline  576  extending through the package element  504  forms the reclining angle  570  with respect to the perpendicular plane  572 . In some embodiments, the reclining angle  570  is at least about five degrees, while in some embodiments the reclining angle  570  is between about five degrees and about ten degrees. In some embodiments the reclining angle  570  is about seven degrees. 
     In addition, in the depicted embodiment the bottom surface  574  of each package element  504  forms an acute angle  580  with the front surface  530  of the package element  504  and an obtuse angle  582  with the back surface  532  of the package element. Thus, in this case the front surface  530  and the back surface  532  of the package element are also reclining away from the perpendicular plane  572  at the reclining angle  570 , though this may not be the case in all embodiments (e.g., due to irregularly shaped or non-square package surfaces). Further, in some cases the support tabs  550  may also be oriented at the reclining angle to provide a more complete engagement with the package elements  504  in the reclining state, which can be useful in cases where the surfaces of the package element  504  that normally engage with the support tabs  550  are also reclining. For example, as shown in  FIG. 5B , in the case where the support tabs  550  are partially cut out of the side walls and folded out, the fold line  564  may be oriented at the reclining angle with respect to the perpendicular plane. 
     According to some embodiments, in some cases some or all of the components of a packaging system may be formed from a limited number of materials, or in some cases from a single material. For example, in some embodiments substantially all of the structurally components of the packaging/display system are formed from a single material such as cardboard, plastic, or another suitable material. Exceptions may be made for small components or non-structural components, such as fasteners (e.g., glues, tapes, staples, adhesives, ties, etc.). As depicted in the embodiments shown in  FIGS. 1-4 , the support tray  102  and substantially all of the package elements  104  are made from cardboard. Utilizing a single material or substantially a single material can make the manufacturing process simpler and more cost effective. In addition, using a single material, such as cardboard, may increase the likelihood that a consumer will recycle the package element post-sale. 
     Turning to  FIG. 7 , in some embodiments a packaging system  700  can include multiple package elements  704  and a support tray  702  as previously discussed, and may further include a removable cover  715  configured to fit about the package elements  704  and the support tray  702 . The removable cover  715  can be made from the same material or a different material as the other parts of the packaging system  700 . The cover can be useful for protecting the contents of the support tray and package elements, and readying them for shipping. For example, in some cases the cover  715  includes an open box that slips over the outside of the package elements  704  and the support tray  702 . The cover can then be secured about the support tray and package elements using a fastener to form an integrated packaging assembly for transporting the package elements with the support tray. Upon arriving at its intended destination, a store clerk can simply remove the cover  715  and position the support tray  702  and package elements  704  in a desirable location with ease. 
     According to some embodiments, methods for packing and/or displaying products are also provided. In some cases a method for packing and displaying products includes packing products using one type of package elements described herein and then positioning multiple package elements within a single support tray, optionally placing a cover over the package elements and support tray for transport or removing the cover for store display. 
     In some embodiments, a method for packing and displaying products includes providing a plurality of package elements with each package element holding at least one product. The method also includes providing a support tray having a first side wall, a second side wall, and a support surface extending between and joining the first and the second side walls, the first side wall comprising a first inner wall surface and the second side wall comprising a second inner wall surface. The method further provides for arranging the plurality of package elements adjacently in a row upon the support surface of the support tray between the first side wall and the second side wall and retaining the package elements in the row in the support tray upon the support surface and between the first side wall and the second side wall without extending the package elements through the first inner wall surface into the first side wall and without extending the package elements through the second inner wall surface into the second side wall. 
     In some embodiments a display/packing method also includes separating portions of at least one of the first side wall and the second side wall of a support tray and then folding the portions along respective fold lines and inward away from the respective inner side wall to form support tabs located along at least one of the first inner wall surface and the second inner wall surface. The method may also provide reclining the plurality of package elements at a reclining angle from a plane perpendicular to the support tray support surface. In some cases the method includes removing a cover from about the plurality of package elements and the support tray to display the plurality of package elements with the support tray in a retail setting, while in some cases the method includes fitting a removable cover about the plurality of package elements and the support tray to transport the plurality of package elements with the support tray. 
     Thus, embodiments of the invention are disclosed. Although the present invention has been described in considerable detail with reference to certain disclosed embodiments, the disclosed embodiments are presented for purposes of illustration and not limitation and other embodiments of the invention are possible. One skilled in the art will appreciate that various changes, adaptations, and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.