Patent Description:
The invention relates to a product package including a tray provided with one or more cavities shaped and dimensioned to hold a product or products and a method for manufacturing such package.

Various packages are known for containing products, as shown in document <CIT>. It is known to provide a package having one or more open cavities conforming to a shape of a product to be packaged therein. There exists a need, however, for a package having one or more cavities to hold a product, which package features finished edges and cavities and provides a seamlessly wrapped assembly having a finished, upscale appearance.

The invention relates to a product package as defined in claim <NUM> including a tray provided with one or more cavities shaped and dimensioned to hold a product or products and a method for manufacturing such package.

A method for manufacturing a package according to an aspect of the invention as defined in claim <NUM> includes the step of providing a board platform including a flat top platform element made from a cardboard material and a separate flat bottom platform element made from a cardboard material. Each of the flat top platform element and the separate flat bottom platform element have a plurality of respective side portions. The flat top platform element has one or more cutout portions conforming to one or more shapes of a product or products to be packaged.

The method further includes the step of providing one or more flat product tray elements made from a cardboard material. The flat product tray element is shaped and dimensioned such that when folded, the product tray element forms an open cavity conforming to the shape of a product to be packaged.

The method further includes the step of providing a wrapper made from a paper material. The wrapper includes a platform wrapper conforming to the shape and dimensions of the flat top platform element and a product tray wrapper conforming to the dimensions of an interior side wall of the open cavity formed by the product tray element.

The method further includes the steps of folding the flat product tray element to form the open cavity conforming to the shape of the product to be packaged and folding the plurality of respective side portions of the flat top platform element and the separate flat bottom platform element to form respective box shapes.

The method further includes the steps of securing the folded product tray element forming the open cavity to at least one of the top platform element and the bottom platform element and assembling the top platform element and the bottom platform element to enclose the folded product tray element forming the open cavity between the top platform element and the bottom platform element.

The method further includes the steps of wrapping the interior side wall of the open cavity formed by the product tray element with the product tray wrapper and wrapping the exterior surfaces of the top platform element with the platform wrapper.

According to a further aspect of the invention, the flat product tray element includes a first product tray element and a second product tray element which are shaped and dimensioned such that when folded and assembled together, the first product tray element and the second product tray element together form an open cavity conforming to the shape of the product to be packaged.

According to a further aspect of the invention, the flat product tray element includes a plurality of flat product tray elements, each of which is shaped and dimensioned such that when folded, the respective product tray element forms an open cavity conforming to a respective shape of a respective product to be packaged.

According to a further aspect of the invention, a surface of the folded product tray element forming the open cavity is adhesively secured to a surface of the top platform element at the corresponding cutout.

According to a further aspect of the invention, a surface of the folded product tray element forming the open cavity is adhesively secured to a surface of the lower platform element.

According to a further aspect of the invention, a flat product pad made from a cardboard material is provided, is folded to form a box shape and the folded product pad is secured to the lower platform element.

A package according to an aspect of the invention includes a board platform having a top platform element made from a cardboard material and a bottom platform element made from a cardboard material. Each of the top platform element and the bottom platform element have a plurality of respective side portions. The top platform element has one or more cutout portions conforming to one or more shapes of a product or products to be packaged.

The package further includes one or more product tray elements made from a cardboard material. The product tray element is shaped and dimensioned to form an open cavity conforming to the shape of the product to be packaged. The product tray element is secured to at least one of the top platform element and the bottom platform element and is disposed between the top platform element and the bottom platform element;.

The package further includes a platform wrapper conforming to the shape and dimensions of the top platform element and covering the exterior surface of the top platform element and a product tray wrapper conforming to the dimensions of an interior side wall of the open cavity formed by the product tray element and covering the interior side wall of the open cavity.

An advantage of a package and method according to embodiments of the invention is the provision of a package made completely from cardboard and paper, which package is recyclable and sustainable. Another advantage of a package and method according to embodiments of the invention is the provision of a package featuring all finished edges and cavities which package is seamlessly wrapped assembly and has a finished, upscale appearance. The method of wrapping and assembly may result, for example in no exposed edges of cardboard greater than. <NUM>, and the finished appearance of the tray is such that it fits uniquely shaped products with no or only extremely small exposed edges in the product cavity of the tray.

Other benefits and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings.

In the drawings, wherein similar reference characters denote similar elements throughout the several views:.

Referring now in detail to the drawings, and in particular <FIG>, a package is manufactured by providing a board platform <NUM>. The board platform <NUM> includes an initially a flat top platform element <NUM> made from a cardboard material and a separate initially flat bottom platform element <NUM> made from a cardboard material. Each of the flat top platform element <NUM> and the separate flat bottom platform element <NUM> have a plurality of respective side portions <NUM> which can be folded to form a box-shaped component. The flat top platform element <NUM> has one or more cutout portions <NUM> conforming to one or more shapes of a product or products <NUM> (<FIG>) to be packaged. The product <NUM> may be, for example, a bottle of perfume or a bottle containing an alcoholic beverage or any product suitable to be packaged in a package according to the invention.

As shown in <FIG>, one or more initially flat product tray elements <NUM> made from a cardboard material are provided. The flat product tray elements <NUM> are shaped and dimensioned such that when folded, the product tray element <NUM> forms an open cavity <NUM> or well conforming to the shape of a product <NUM> to be received in the cavity <NUM> packaged.

As shown in <FIG>, a wrapper <NUM> is provided. The wrapper <NUM> is made from a paper material. The wrapper <NUM> includes a platform wrapper <NUM> conforming to the shape and dimensions of the flat top platform element <NUM>, including the one or more cutout portions <NUM> and a product tray wrapper <NUM> conforming to the dimensions of an interior side wall <NUM> (<FIG>) of the open cavity <NUM> formed by the product tray element <NUM>.

The flat product tray element or elements <NUM> are folded to form the open cavity <NUM> conforming to the shape of the product <NUM> to be packaged. The respective side portions <NUM> of the flat top platform element <NUM> and the separate flat bottom platform element <NUM> are folded to form respective box shapes.

The folded product tray element <NUM> forming the open cavity is secured to at least one of the top platform element <NUM> and the bottom platform element <NUM> and the top platform element <NUM> and bottom platform element <NUM> are assembled to enclose the folded product tray element <NUM> between the top platform element <NUM> and the bottom platform element <NUM>. For example, surface of the folded product tray element <NUM> forming the open cavity <NUM> may be adhesively secured to a surface of the top platform element <NUM> at a corresponding cutout <NUM> or a surface of the folded product tray element <NUM> forming the open cavity <NUM> may be adhesively secured to a surface of the lower platform element <NUM>. An exemplary assembly of the top platform element <NUM> and bottom platform element <NUM> with folded product tray elements <NUM> enclosed therebetween is shown in <FIG>.

The interior side wall <NUM> of the open cavity <NUM> formed by the product tray element <NUM> is wrapped or covered with the product tray wrapper <NUM> as shown, for example in <FIG>. The product tray wrapper <NUM> may, for example have a length conforming to the perimeter of the cavity <NUM> and a foldable top portion which is folded over a top surface of the assembled top platform element <NUM> and may be secured thereto. Exterior surfaces of the top platform element <NUM> are then wrapped or covered with the platform wrapper <NUM>. As shown in <FIG>, the platform wrapper <NUM> may have foldable side portions which are folded over the corresponding side portions <NUM> of top platform element <NUM> and may be secured thereto.

As shown in <FIG>, the product tray element may include multiple product tray elements which are folded and assembled together to form a single open cavity <NUM> conforming to the shape of the product <NUM> to be packaged. A plurality of flat product tray elements <NUM> may be provided with different shapes and dimensions adapted to form respective open cavities conforming to products having different shapes and sizes.

A flat product pad <NUM> made from a cardboard material may be provided as well. The flat product pad <NUM> is folded to form a box shape and the folded product pad <NUM> is secured to the lower platform element <NUM> (<FIG>).

A package according to an aspect of the invention includes a board platform <NUM> having a top platform element <NUM> made from a cardboard material and a bottom platform element <NUM> made from a cardboard material. Each of the top platform element <NUM> and the bottom platform element <NUM> have a plurality of respective side portions <NUM>. The top platform element <NUM> has one or more cutout portions <NUM> conforming to one or more shapes of a product or products <NUM> to be packaged.

The package further includes one or more product tray elements <NUM> made from a cardboard material. The product tray element <NUM> is shaped and dimensioned to form an open cavity <NUM> conforming to the shape of the product <NUM> to be packaged. The product tray element <NUM> may include multiple pieces which are folded and/or assembled together to form the open cavity <NUM> or well. The product tray element or elements <NUM> are secured to one or both of the top platform element <NUM> and the bottom platform element <NUM> and are disposed between the top platform element <NUM> and the bottom platform element <NUM>.

The package further includes a platform wrapper <NUM> conforming to the shape and dimensions of the top platform element <NUM> and covering the exterior surface of the top platform element <NUM> which may include the side portions thereof. The package further includes a product tray wrapper <NUM> conforming to the dimensions of an interior side wall <NUM> of the open cavity <NUM> formed by the product tray element <NUM> and covering the interior side wall <NUM> of the open cavity <NUM>. The platform wrapper and the product tray wrapper are preferably made of a paper material.

Claim 1:
A method for manufacturing a package, the method comprising the steps of:
providing a board platform (<NUM>), the board platform (<NUM>)comprising a flat top platform element (<NUM>) made from a cardboard material and a separate flat bottom platform element (<NUM>) made from a cardboard material, each of the flat top platform element (<NUM>) and the separate flat bottom platform element (<NUM>) having a plurality of respective side portions (<NUM>), wherein the flat top platform element (<NUM>) has a cutout portion (<NUM>) conforming to a shape of a product to be packaged;
providing a flat product tray element (<NUM>) made from a cardboard material, wherein the flat product tray element (<NUM>) is shaped and dimensioned such that when folded, the product tray element (<NUM>) forms an open cavity (<NUM>) conforming to the shape of the product to be packaged;
providing a wrapper (<NUM>) made from a paper material, the wrapper (<NUM>) comprising a platform wrapper (<NUM>) conforming to the shape and dimensions of the flat top platform element (<NUM>) and a product tray wrapper (<NUM>) conforming to the dimensions of an interior side wall (<NUM>) of the open cavity (<NUM>) formed by the product tray element (<NUM>);
folding the flat product tray element (<NUM>) to form the open cavity (<NUM>) conforming to the shape of the product to be packaged;
folding the plurality of respective side portions (<NUM>) of the flat top platform element (<NUM>) and the separate flat bottom platform element (<NUM>) to form respective box shapes;
securing the folded product tray element (<NUM>) forming the open cavity (<NUM>) to at least one of the top platform element (<NUM>) and the bottom platform element (<NUM>);
assembling the top platform element (<NUM>) and the bottom platform element (<NUM>) and enclosing the folded product tray element (<NUM>) forming the open cavity (<NUM>) between the top platform element (<NUM>) and the bottom platform element (<NUM>);
wrapping the interior side wall (<NUM>) of the open cavity (<NUM>) formed by the product tray element (<NUM>) with the product tray wrapper (<NUM>); and
wrapping the exterior surfaces of the top platform element (<NUM>) with the platform wrapper (<NUM>).