Patent Document

BACKGROUND 
     The present disclosure relates generally to a packaging for balls. More particularly, the present disclosure relates generally to an open packaging for sporting balls. 
     Recently, there has been an effort to produce packaging that lessens the environmental impact. One way is to make the packaging of a recyclable, degradable, post-consumer and/or biodegradable material. An alternative and additional way is to minimize the amount of packaging material used by removing or reducing any unnecessary packaging. However, minimizing the amount of packaging material could impact the display and placement of the product in retailers. 
     The display and placement of the product on the shelves of retailers can help persuade a consumer to purchase a product. For example, the amount of shelf space allocated to the product and the location of the shelf space can influence the sales of the product. The more favorable shelf space generally is the shelf area that is more visible to a consumer, for example, the shelf space at eye level and/or a large allocation of shelf space. However, there is competition for favorable shelf space. Retailers generally have more products available to be displayed than they have shelf space. Also, retailers may want to have as much product as possible in a given area so that the risk of the unavailability of a product on the shelf is minimized. Retailers may also want to avoid having unnecessarily long periods where the product is unavailable on the shelf because the original displayed quantity of sold products has been sold. 
     Retailers typically maximize the shelf space available by the placement of the products on a shelf. Retailers generally display products on a shelf by stacking the additional products behind and/or on top of the first visible product on the shelf. A manufacturer can improve the chances of a more favorable shelf space placement of the product by using a packaging that requires more visible shelf space, such as horizontal space, to display the first visible product. 
     Additional considerations in the design of the packaging include shipping and handling. The packaging should provide protection against blemishes during shipping and handling. Also, the packaging should not be subject to movement or rolling when placed in a shipping box or displayed on a shelf. 
     One of the more difficult items to package and display are round or spherical objects, such as balls. Golf balls are mostly sold by the dozen in a solid rectangular or square outer box packaging. Many of the outer box packaging further includes four solid inner rectangular boxes called “sleeves” that each contain three golf balls. 
     Therefore, there exists a need in the art for packaging for balls that lessens the environmental impact by reducing the amount of packaging material, while maximizing the visibility of the packaging on a shelf. 
     SUMMARY 
     An open packaging includes features that minimize the amount of packaging material required to contain and that are configured to stabilize the balls while shipping and handling. These features are configured to maximize the amount of shelf space required for the packaging to be displayed on a retail shelf. 
     In one aspect, a packaging is provided for at least one ball. The packaging comprises a first wall and a second wall opposing the first wall, the first wall and the second wall each including at least one opening. The packaging also comprises at least one wall opening being between the first wall and the second wall. The opening is configured to expose a portion of the ball and restrain movement of the ball, and the wall opening is configured to expose a portion of the ball. 
     In another aspect, the first wall and the second wall each include three circular openings, the openings of the first wall and the second wall being identical. 
     In another aspect, the packaging is configured to contain three golf balls. 
     In another aspect, the first wall and the second wall each include four cylindrical openings, the openings of the first wall and the second wall being identical. 
     In another aspect, the packaging is configured to contain twelve balls. 
     In another aspect, the packaging is configured to receive at least one of a second packaging, each second packaging being configured to contain three balls. 
     In another aspect, a packaging is provided for at least two balls. The package comprises a first column and a second column adjacent to the first column in a first direction. The first column and the second column are each configured to contain a ball and having at least one opening configured to expose a portion of the ball and restrain movement of the ball. The first column is disposed at a first position and the second column is disposed at a second position with respect to a second direction that is perpendicular to the first direction, the first position being different than the second position. 
     In another aspect, the packaging further comprises a third column adjacent to the second column in the first direction and a fourth column adjacent to the third column in the first direction. The third column and the fourth column are each configured to contain the ball and each having the opening configured to expose a portion of the ball and restrain movement of the ball. The third column is disposed at the first position and the fourth column is disposed at the second position. 
     In another aspect, the packaging further comprises a third column and a fourth column adjacent to the third column in the first direction. The third column and the fourth column are each configured to contain the ball and having the opening configured to expose a portion of the ball and restrain movement of the ball. The third column is disposed at the second position and the fourth column is disposed at the first position. 
     In another aspect, a one-piece blank for forming a packaging for containing at least one ball is provided. The blank comprises a front panel that forms a front of a packaging; and a back panel that is identical to the front panel and that forms the back of the packaging. The front and back panels each include at least one opening to expose the ball. The blank also comprises a first side panel that is between the front panel and back panel and that is hingedly connected to the front panel and the back panel and a second side panel that is adjacent to and is hingedly connected to one of a front panel and a back panel. 
     Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. 
         FIG. 1  is a schematic perspective view of known packagings for golf balls; 
         FIG. 2  is a schematic front view of retailer shelves displaying the known packagings; 
         FIG. 3  is a schematic perspective view of an embodiment of a packaging sleeve; 
         FIG. 4  is a schematic perspective view of the sleeve of  FIG. 3  containing golf balls; 
         FIG. 5  is a schematic side view of the sleeve of  FIG. 3 ; 
         FIG. 6  is a schematic perspective view of an embodiment of a rectangular outer box; 
         FIG. 7  is a schematic perspective view of an embodiment of a rectangular outer box; 
         FIG. 8  is a schematic perspective view of the outer box of  FIG. 7  containing golf balls; 
         FIG. 9  is a schematic perspective view of the outer box of  FIG. 7  containing an embodiment of sleeves; 
         FIG. 10  is a schematic perspective view of an embodiment of a packaging sleeve; 
         FIG. 11  is a schematic perspective view of the sleeve of  FIG. 10  containing golf balls; 
         FIG. 12  is a schematic perspective view of an embodiment of a rectangular outer box; 
         FIG. 13  is a schematic perspective view of the outer box of  FIG. 12  containing golf balls; 
         FIG. 14  is a schematic perspective view of the outer box of  FIG. 12  containing an embodiment of sleeves; 
         FIG. 15  is a schematic perspective view of an embodiment of a packaging sleeve; 
         FIG. 16  is a schematic perspective view of the sleeve of  FIG. 15  containing golf balls; 
         FIG. 17  is a schematic perspective view of an embodiment of a rectangular outer box; 
         FIG. 18  is a schematic perspective view of the outer box of  FIG. 17  containing golf balls; 
         FIG. 19  is a schematic perspective view of the outer box of  FIG. 17  containing an embodiment of sleeves; 
         FIG. 20  is a schematic perspective view of an embodiment of a rectangular outer box; 
         FIG. 21  is a schematic perspective view of an embodiment of a packaging sleeve; 
         FIG. 22  is a schematic perspective view of an embodiment of a rectangular outer box; 
         FIG. 23  is a schematic perspective view of an embodiment of a staggered outer box; 
         FIG. 24  is a schematic perspective view of an embodiment of a staggered outer box; 
         FIG. 25  is a schematic perspective view of the outer box of  FIG. 24  containing golf balls; 
         FIG. 26  is a schematic perspective view of an embodiment of a staggered outer box; 
         FIG. 27  is a schematic perspective view of an embodiment of a staggered outer box; 
         FIG. 28  is a schematic perspective view of the outer box of  FIG. 27  containing golf balls; 
         FIG. 29  is a schematic perspective view of an embodiment of a staggered outer box; 
         FIG. 30  is a schematic front view of a blank from which an embodiment of a sleeve may be formed; and 
         FIG. 31  is an embodiment of a process for forming a sleeve containing balls from a blank. 
     
    
    
     DETAILED DESCRIPTION 
     Golf balls are typically sold in a package of twelve balls. A package of twelve balls typically includes four sleeves  100  of three golf balls. Such a sleeve  100  is shown in  FIG. 1 . Sleeve  100  is generally provided in a rectangular box.  FIG. 1  also shows two known solid outer boxes  110  and  120  that are configured to contain four sleeves  100 . Square outer box  110  contains two adjacent rows of two sleeves  100 . Rectangular outer box  120  contains four sleeves  100  side-by-side. Sleeves  100  and outer boxes  110  and  120  also require packaging material for all sides. Sleeves  100  and outer boxes  110  and  120  are typically made of a paper product, such as cardboard with a resin layer, recyclable material, recycled material and/or post-consumer material. 
       FIG. 2  shows a typical example of a retail shelf display of outer boxes  110  and  120 . In  FIG. 2 , each individual outer box  110  and  120  corresponds to a different product. Rectangular outer box  120  has a larger diameter than square outer box  110  and thus requires more shelf space than square outer box  110 . Retailers place the extra products behind the first visible product. Retailers thus generally allocate more visible space to rectangular outer box  120  than square outer box  110 . Accordingly, rectangular outer box  120  has a more favorable shelf placement than square outer box  110 . 
     The present embodiments relate to an open packaging for a round object. The round object may be any type of round object. For example, the round object may be tennis balls, table tennis balls and any other type of athletic ball. The discussion herein is generally limited to a discussion of an open packaging for a golf ball, but the round object should not be considered to be so limited. 
     The embodiments of the opening packaging described herein are designed to reduce the amount of packaging material, and, in some embodiments, reducing the packaging material without necessarily reducing the amount of shelf space for displaying the packaging. Instead, many of the embodiments of the open packaging are designed to enhance the visibility of the product by encouraging favorable retail shelf placement. As shown in the figures, the amount of packaging material may be reduced by adding openings in the opposing walls. These openings provide additional support and containment for the ball. These openings also further reduce the amount of packaging material by reducing the packaging material needed to contain a golf ball. Because the openings expose portions of the ball, the packaging may have a configuration in which the depth is less than the diameter of a golf ball. Also, due to the additional support of these openings, opposing walls may be removed and thus further reducing the amount of packaging material needed to manufacture the packaging according to the embodiments. 
     In some embodiments, referring to  FIGS. 3-5 , sleeve  300  is configured to contain three golf balls. In other embodiments, sleeve  300  may be configured to contain any number of golf balls. 
     Sleeve  300  may be made of any material known in the art. The material may be any known paper product, including recycled, recyclable and/or post-consumer material. In some embodiments, the shape of sleeve  300  may be selected to correspond to size of the golf balls. Also, the height, the width and the depth of sleeve  300  may be selected based on the dimensions of the golf ball and number of the golf balls. For example, the height of the sleeve may be selected to correspond to the total height of golf balls. In  FIGS. 3-5 , sleeve  300  has a height that corresponds to three golf balls. 
     In some embodiments, sleeve  300  may have a rectangular shape. Sleeve  300  may have four walls and two open sides. As shown in  FIGS. 3-5 , sleeve  300  has four walls: first wall  310 , second wall  320 , third wall  330  and fourth wall  340 . First wall  310  and second wall  320  extend in the width direction (labeled W) and are parallel to one another. Third wall  330  and fourth wall  340  extend in the height direction (labeled H) and are parallel to one another. Sleeve  300  does not have any walls on two opposing sides and has open opposing sides in the depth direction (labeled D). The two opposing open sides are not limited to the depth direction between first wall  310  and second wall  320 . In other embodiments, sleeve  300  may have two open opposing sides in the width direction and have opposing walls in the depth and height directions. 
     In some embodiments, sleeve  300  may have openings in two opposing walls in the height direction. In other embodiments, sleeve  300  may have openings in one wall or on all walls. 
     The openings may be configured to expose a portion of the golf ball. The openings may also be configured to contact and engage the surface of the golf ball so as to inhibit or prevent movement of the ball relative to sleeve  300 . The openings may generally maintain the original position of the golf ball, which is the position in which the golf ball was placed when originally packed. In some embodiments, the openings may be smaller than the diameter of an individual golf ball. In other embodiments, the openings may be smaller than the total diameter of several golf balls. 
     The openings may also be of any shape, such as circular, cylindrical, polygonal, or other geometrical shapes, and of any number. In some embodiments, there may be an opening in each opposing wall for each ball. In other embodiments, there may be one opening on each opposing wall that extends across all of the golf balls. The openings in opposing walls may also be symmetric. The openings, alternatively, may be asymmetric. For example, a sleeve may have an opening for each ball on one wall and have one opening extending across all of the golf balls on an opposing wall. 
     The open opposing walls and the openings may reduce the amount of packaging material required to contain a golf ball. Because the packaging does not need to totally cover and encompass the ball to contain a golf ball, the openings in the walls reduce the amount of packaging needed in the length direction to contain a golf ball. In other words, the length of any one wall in a package made according to embodiments of the present invention may be shorter than the length of a corresponding wall in a conventional package because the opening allows a portion of the golf ball to protrude through the wall. Also, because the openings expose portions of the ball, the openings may reduce the amount of packaging material needed in the depth direction to contain the ball. The depth of the packaging may be less than a diameter of a golf ball. 
     As shown in  FIGS. 3-5 , third wall  330  and fourth wall  340  each have three openings configured to retain a golf ball in position. Third wall  330  has first opening  332 , second opening  334 , and third opening  336 . Fourth wall  340  has first opening  342 , second opening  344 , and third opening  346 . The openings are circular and are the same size. The openings in third wall  330  and fourth wall  340  are also respectively symmetric. The openings in third wall  330  and fourth wall  340  may have any configuration and may be asymmetric. 
     As shown in  FIGS. 4 and 5 , sleeve  300  is configured to receive three balls  400  that are positioned adjacently in the height direction of the sleeve  300 . The openings in third side  330  and fourth side  340  have a shape that is configured to inhibit movement of golf ball  400 . The openings in third side  330  and fourth side  340  and open opposing side walls expose a portion of golf balls  400 . The openings are circular and have a smaller diameter than the diameter of golf balls  400 . 
     The sleeve may be sold individually or multiple sleeves may be packaged together. In some embodiments, four sleeves may be packaged together. Multiple sleeves may be packaged for example, in plastic wrap or an outer box. 
     An outer box may be formed of any known material. The material may be any known paper product, including recycled, recyclable and/or post-consumer material. In some embodiments, the outer box may be formed of the same material as the sleeves. An outer box may also contain balls without using a sleeve. In some embodiments, the outer box may be configured to organize the balls in groups of three balls. In other embodiments, the outer box may be configured to organize the balls so that they can be individually separated from the outer box. 
     In some embodiments, referring to  FIG. 6 , four sleeves may be packaged in a rectangular outer box  600 . Outer box  600  may be configured to receive any number of sleeves. As shown in  FIG. 6 , rectangular box  600  is configured to receive four sleeves  610 ,  620 ,  630 , and  640  in the width direction. Outer box  600  may be configured to receive the sleeves in the height direction. 
     Outer box  600  may have any type of closure or sealing device. In  FIG. 6 , outer box  600  has flip-top lid  650  that is attached to the outer box main body. In other embodiments, outer box  600  may have a lid that is not attached to the outer box main body and that is removable. 
     In other embodiments, referring to  FIGS. 7-9 , a plurality of golf balls or sleeves may be packaged in an open rectangular outer box  700 . Outer box  700  is configured to contain twelve balls. In other embodiments, outer box  700  may be configured to contain any number of golf balls. For example, outer box  700  may be configured to contain three golf balls like sleeve  300 . 
     Outer box  700  also has openings. Similar to sleeve  300 , these openings reduce the amount of packaging material used and are configured to restrict movement of the golf balls. The openings in the walls reduce the amount of packaging needed in the length direction to contain a golf ball. Also, because the openings expose portions of the ball, the openings may reduce the amount of packaging material needed in the depth direction to contain the ball. The depth of the packaging may be less than a diameter of a golf ball. 
     In one embodiment, outer box  700  has a rectangular shape with four walls and two open sides. As shown in  FIGS. 7-9 , outer box  700  has four walls: first wall  710 , second wall  720 , third wall  730 , and fourth wall  740 . First wall  710  and second wall  720  extend in the width direction and are parallel to one another. Third wall  730  and fourth wall  740  extend in the height direction and are parallel to one another. Outer box  700  may not have any walls on two opposing sides and has open opposing sides in the depth direction. The two opposing open sides are not limited to the depth direction between first wall  710  and second wall  720 . In other embodiments, outer box  700  may have two open opposing sides in the width direction and have opposing walls in the depth and height directions. 
     Third wall  730  and fourth wall  740  may each have openings configured to retain a golf ball in position. Third wall  730  and fourth wall  740  each have four openings. Third wall  730  has first opening  732 , second opening  734 , third opening  736 , and fourth opening  738 . Fourth wall  740  has first opening  742 , second opening  744 , third opening  746 , and fourth opening  748 . The openings in third wall  730  and fourth wall  740  have a cylindrical shape and are also symmetric. In other embodiments, like the openings of outer box  300 , as discussed above, the openings may be of any number, shape, and of different sizes. The openings in third wall  730  and fourth wall  740  may have any configuration and may be asymmetric. 
     Outer box  700  may have a separation device that is configured to separate the outer box into individual sleeves and/or boxes. The separation device may be any type of mechanical, chemical, or magnetic structure capable of joining together portions of outer box  700  when desired and also separating the portions when desired. In some embodiments, the separation device may be a tape or ribbon that when pulled cuts the material of outer box  700  into sleeves. In other embodiments, the separation device may include magnets. In some embodiments, the separation device may be perforations. As shown in  FIGS. 7-9 , outer box  700  may have perforations  750 ,  760 , and  770  on all walls between the openings. In some embodiments, the perforations may be configured to separate outer box  700  into four sleeves having the same size and shape. In other embodiments, outer box  700  may be configured to separate into any number of sleeves and boxes. Outer box  700  may also be configured to separate into sleeves and boxes having a different size and shape. The perforations may also be on any number of walls. For example, outer box  700  may only have perforations on third wall  730  and fourth wall  740 . 
     Referring to  FIGS. 8 and 9 , outer box  700  may be configured to contain a plurality of balls that may or may not be contained within another box or sleeve. In some embodiments, outer box  700  is configured to directly contain twelve balls. As shown in  FIG. 8 , outer box  700  is configured to contain four columns of balls, each column having three balls  800 . Each of the columns may be aligned with the openings, respectively. The cylindrical openings in third wall  730  and fourth wall  740  have a shape that is configured to inhibit movement of golf balls  800 . The openings in third wall  730  and fourth wall  740  and open opposing side walls expose a portion of golf balls  800 . In some embodiments, each of the openings has a height smaller than the height of three golf balls  800 . In other embodiments, the openings may have other shapes and sizes. The openings may also have a different orientation. For example, the openings may extend along the width direction, instead of the height direction. 
     In other embodiments, rectangular outer box  700  may also be configured to contain multiple sleeves of golf balls. Outer box  700  may be configured to contain any number of sleeves of any number of balls. As shown in  FIG. 9 , outer box  700  may be configured to contain four sleeves  910 ,  920 ,  930 , and  940  of three balls  800 . The four sleeves may each be similar to sleeve  300  shown in  FIGS. 3-5 . Outer box  700  may also be configured to receive and contain the sleeves in a different orientation by changing the configuration of the openings and sleeves, respectively. 
     Sleeves may also have another configuration.  FIGS. 10 and 11  show another embodiment of a sleeve that is configured to contain more than one golf ball. This configuration may result in a further reduction of packaging material. This configuration does not require a top wall and bottom wall. Also, the openings in the walls may further reduce the amount of packaging needed in the length direction to contain a golf ball. Also, because the openings expose portions of the ball, the openings may reduce the amount of packaging material needed in the depth direction to contain the ball. The depth of the packaging may be less than a diameter of a golf ball. 
     Sleeve  1000  is configured to contain three golf balls. In other embodiments, sleeve  1000  may be configured to contain any number of golf balls. 
     Sleeve  1000  has two walls and two open sides. As shown in  FIGS. 10 and 11 , sleeve  1000  has two walls: first wall  1010  and second wall  1020 . First wall  1010  and second wall  1020  extend in the height direction and converge at seams  1030  and  1040 . Sleeve  1000  does not have any walls on two opposing sides and has open opposing sides in the height direction. The two opposing open sides are not limited to the depth direction between first wall  1010  and second wall  1020 . In other embodiments, sleeve  1000  may have walls that converge at seams of the walls in the depth direction and have two open opposing sides in the width direction. 
     First wall  1010  and second wall  1020  each have openings configured to retain a golf ball in position. As shown in  FIGS. 10 and 11 , first wall  1010  and second wall  1020  each have three openings. First wall  1010  has first opening  1012 , second opening  1014 , and third opening  1016 . Second wall  1020  has first opening  1022 , second opening  1024 , and third opening  1026 . These openings, like the openings of sleeve  300 , are configured to receive three golf balls  1100 . These openings are similar to the openings of sleeve  300  and the configurations of these openings, including alternative configurations, are described above. 
     Referring to  FIGS. 12-14 , in some embodiments, an outer box may have a similar configuration to sleeve  1000 . Like outer box  700 , outer box  1200  is configured to contain twelve balls. In other embodiments, outer box  1200  may be configured to contain any number of golf balls. 
     Outer box  1200  has two walls and two open sides. As shown in  FIGS. 12-14 , outer box  1200  has two walls, first wall  1210  and second wall  1220 , that converge at seams  1280  and  1290  at the top and bottom. Outer box  1200  does not have any walls on two opposing sides and has open opposing sides in the depth direction. The two opposing open sides are not limited to the depth between the first wall  1210  and second wall  1220 . In other embodiments, outer box  1200  may have walls that converge at the seams that extend along the height direction and have two open opposing sides in the width direction. This configuration may further reduce the amount of packaging material used as compared to the configuration shown in  FIGS. 10 and 11 . The larger openings may further reduce the amount of packaging material used. 
     First wall  1210  and second wall  1220  each have openings configured to retain a golf ball in position. First wall  1210  and second wall  1220  each have four openings. First wall  1210  has first opening  1212 , second opening  1214 , third opening  1216 , and fourth opening  1218 . Second wall  1220  has first opening  1222 , second opening  1224 , third opening  1226 , and fourth opening  1228 . These openings are similar to the openings of outer box  700  and the configurations of these openings, including alternative configurations, are described above. 
     Outer box  1200 , like outer box  700 , may also have a separation device that is configured to separate outer box  1200  into sleeves. The separation device may be perforations  1250 ,  1260 , and  1270 . As shown in  FIGS. 12-14 , outer box  1200  may have perforations  1250 ,  1260 , and  1270  on all walls between the openings. The perforations may have any configuration. 
     Referring to  FIGS. 13 and 14 , like outer box  700 , outer box  1200  may be configured to contain a plurality of balls that may or may not be contained within another box or sleeve. In some embodiments, outer box  1200  is configured to directly contain twelve balls. As shown in  FIG. 13 , outer box  1200  is configured to contain four columns of balls, each column having three balls  1300 . 
     As shown in  FIG. 14 , outer box  1200  may be configured to contain four sleeves  1410 ,  1420 ,  1430 , and  1440  of three balls  1400 . The four sleeves may each be similar to sleeve  1000  shown in  FIGS. 10 and 11 . The sleeves may also have a different configuration. 
     The sleeves and outer box may also have a different configuration. Referring to  FIGS. 15 and 16 , sleeve  1500  has three walls and two open sides. As shown in  FIGS. 15 and 16 , sleeve  1500  has three walls: first wall  1520 , second wall  1530 , and third wall  1540 . First wall  1520  extends between second wall  1530  and third wall  1540 . Second wall  1530  and third wall  1540  extend in the height direction and converge at seam  1510 . Sleeve  1500  does not have any walls on two opposing sides and has open opposing sides in the depth direction. The two opposing open sides are not limited to the depth and height directions between second wall  1530  and third wall  1540 . In other embodiments, sleeve  1500  may have walls along the height and depth direction of the sleeve that converge at seams at the sides of the walls in the depth direction and have two open opposing sides in the width direction. 
     Like sleeve  300 , second wall  1530  and third wall  1540  each have openings configured to retain a golf ball in position. As shown in  FIGS. 15 and 16 , second wall  1530  and third wall  1540  each have three openings. Second wall  1530  has first opening  1532 , second opening  1534 , and third opening  1536 . Third wall  1540  has first opening  1542 , second opening  1544 , and third opening  1546 . These openings are similar to the openings of sleeve  300  and the configurations of these openings, including alternative configurations, are described above. 
     This configuration may reduce the amount of packaging material used to contain the golf balls. This configuration does not require a top wall. Also, the openings in the walls may further reduce the amount of packaging needed in the length direction to contain a golf ball. Also, because the openings expose portions of the ball, the openings may reduce the amount of packaging material needed in the depth direction to contain the ball. The depth of the packaging may be less than a diameter of a golf ball. 
     Referring to  17 - 19 , an outer box may have the same wall structure as sleeve  1500 . Like sleeve  1500 , outer box  1700  has three walls and two open sides. As shown in  FIGS. 17-19 , outer box  1700  has three walls: first wall  1720 , second wall  1730 , and third wall  1740 . First wall  1720  extends between second wall  1730  and third wall  1740 . Second wall  1730  and third wall  1740  converge at the top of outer box  1700  at seam  1710  along the width direction. Outer box  1700  does not have any walls on two opposing sides and has open opposing sides in the height direction. 
     Second wall  1730  and third wall  1740  each have openings configured to retain a golf ball in position. Second wall  1730  and third wall  1740  each have four openings. Second wall  1730  has first opening  1732 , second opening  1734 , third opening  1736 , and fourth opening  1738 . Third wall  1740  has first opening  1742 , second opening  1744 , third opening  1746  and fourth opening  1748 . These openings are similar to the openings of outer box  1200  and the configurations of these openings, including alternative configurations, are described above. 
     Outer box  1700  may also have a separation device that is configured to separate outer box  1700  into sleeves and/or boxes. As shown in  FIGS. 17-19 , like outer box  1200 , outer box  1700  may have perforations  1750 ,  1760 , and  1770  on all walls between the openings. 
     Referring to  FIGS. 18 and 19 , outer box  1700  may be configured to contain a plurality of balls that may or may not be contained within another box or sleeve. In some embodiments, outer box  1700  is configured to directly contain twelve balls. As shown in  FIG. 18 , outer box  1700  is configured to contain four columns of balls, each column having three balls  1800 . Each of the columns may be aligned with the openings, respectively. The cylindrical openings in second wall  1730  and third wall  1740  have a shape that is configured to contact a surface of golf balls  1300  to inhibit movement. 
     In other embodiments, outer box  1700  may also be configured to contain multiple sleeves of golf balls. Outer box  1700  may be configured to contain any number of sleeves of any number of balls. As shown in  FIG. 19 , outer box  1700  may be configured to contain four sleeves  1910 ,  1920 ,  1930  and  1940  of three balls  1900 . The four sleeves may each be similar to sleeve  1500  shown in  FIGS. 15 and 16 . The sleeves may also have a different configuration. Outer box  1700  may also be configured to receive the sleeves in the height direction by changing the orientation of the openings. 
     Referring to  FIGS. 20-23 , in other embodiments, the sleeve and/or outer box may include a separation device that is capable of separating an individual ball from the sleeve and inner box, respectively. The separation device may be configured so that a user can select the number of golf balls to be separated from the sleeve or outer box. The separation device may be perforations. 
     As shown in  FIG. 20 , outer box  2000  has two walls and two open sides. Outer box  2000  has two walls: first wall  2010  and second wall  2020 . First wall  2010  and second wall  2020  that converge at the top and bottom at seams  2090  and  2092 , respectively, in the height direction. In the embodiment shown in  FIG. 20 , outer box  2000  does not have any walls on two opposing sides and has open opposing sides in the depth direction. The two opposing open sides are not limited to the depth direction between first wall  2010  and second wall  2020 . In other embodiments, outer box  2000  may have walls that converge at the sides in the depth direction and have two open opposing sides in the width direction. Outer box  2000  may also have a third wall that extends between first wall  2010  and second wall  2020 . 
     The walls of outer box  2000  each have openings configured to retain a golf ball in position. Each opening corresponds to a position of a golf ball. The number of openings may be varied according to the specified number of golf balls for packaging. Outer box  2000  is configured to contain twelve golf balls. 
     First wall  2010  and second wall  2020  each have twelve openings. The openings may be of any configuration. In some embodiments, the openings may be configured to be in four columns and three rows. The configuration of the openings may be based on the desired width or height of the outer box and number of golf balls. 
     As shown in  FIG. 20 , second wall  2020  has first opening  2022 , second opening  2024 , third opening  2026 , fourth opening  2032 , fifth opening  2034 , sixth opening  2036 , seventh opening  2042 , eighth opening  2044 , ninth opening  2046 , tenth opening  2052 , eleventh opening  2054  and twelfth opening  2056 . In some embodiments, the openings are circular and are the same size. These openings are similar to the openings of sleeve  300  and the configurations of these openings, including alternative configurations, are described above. 
     In some embodiments, outer box  2000  may also have a separation device that is configured to separate outer box  2000  into individual balls, sleeves and/or boxes. The separation device may be perforations  2060  and  2062  that divide golf balls  2080  into three rows and perforations  2070 ,  2072 , and  2074  that divide golf balls  2080  into four columns. As shown in  FIG. 20 , outer box  2000  may have the perforations on all the walls and between every opening so as to be capable of dividing outer box  2000  by individual golf ball  2080 . In some embodiments, the perforations may only be between certain openings. The perforations may be configured only to separate outer box  2000  into four sleeves of three golf balls  2080  having the same size and shape. In other embodiments, outer box  2000  may be configured to separate into any number of sleeves and boxes. Outer box  2000  may also be configured to separate into sleeves and boxes having a different size and shape. 
     In other embodiments, referring to  FIGS. 21 and 22 , the sleeve and outer box may be configured to provide further containment of the golf balls. Further containment may be provided by configuring the sleeve and outer box to have an additional contact surface. 
       FIG. 21  shows sleeve  2100  that is configured to form a supportive pocket around golf ball. Like sleeve  1000 , sleeve  2100  has two walls and two open sides. Sleeve  2100  has two walls: first wall  2110  and second wall  2120 . First wall  2110  and second wall  2120  extend in the height direction and converge at seams  2130  and  2140 . First wall  2110  and second wall  2120  also converge at intervening seams  2150  and  2160 . These intervening sleeves may create a containment and protective pocket for a golf ball. Sleeve  2100  does not have any walls on two opposing sides and has open opposing sides in the depth direction. Sleeve  2100  may also be configured to change the orientation of the seams and open opposing sides like sleeve  1000 . 
     First wall  2110  and second wall  2120  each have openings configured to retain a golf ball in position. As shown in  FIG. 21 , first wall  2110  and second wall  2120  each have three openings. Second wall  2120  has first opening  2122 , second opening  2124 , and third opening  2126 . First wall  2110  has openings similar to the openings of second wall  2120  (that are not shown). Each of these openings, like the openings of sleeve  300 , is configured to receive three golf balls  2170 . These openings are similar to the openings of sleeve  300  and the configurations of these openings, including alternative configurations, are described above. 
     One or all of the intervening seams may be a separation device. Referring to  FIG. 21 , seams  2150  and  2160  may be perforations. 
     Referring to  FIG. 22 , an outer box may have a similar configuration as sleeve  2100 . Outer box  2200  may have four columns of sleeves like sleeves  2100 . Outer box  2200  has two walls, first wall  2210  and second wall  2220 , and open opposing sides. First wall  2210  and second wall  2220  converge at the top and bottom at seams  2290  and  2092 , respectively, in the width direction. Outer box  2200  does not have any walls on two opposing sides and has open opposing sides in the depth direction. 
     Outer box  2200  further includes intervening seams  2260  and  2262  between first wall  2210  and second wall  2220 . These seams, like seams  2150  and  2160 , may create a containment and protective pocket for a ball. 
     Like, outer box  2000 , outer box  2200  has openings that each corresponds to a position of a golf ball. Second wall  2220  has first opening  2222 , second opening  2224 , third opening  2226 , fourth opening  2232 , fifth opening  2234 , sixth opening  2236 , seventh opening  2242 , eighth opening  2244 , ninth opening  2246 , tenth opening  2252 , eleventh opening  2254 , and twelfth opening  2256 . The openings of first wall  2210  are identical to the openings of second wall  2220  and are not shown. These openings are similar to the openings of outer box  2000  and the configurations of these openings, including alternative configurations, are described above. 
     In some embodiments, outer box  2200  may also have a separation device that is configured to separate outer box  2200  into individual balls, sleeves and/or boxes. The intervening seams  2260  and  2262  may be perforations. Also, outer box  2200  may also include perforations  2270 ,  2272 , and  2274  that divide golf balls  2280  into four columns. As shown in  FIG. 22 , outer box  2200  may have perforations on all the walls and between every opening so as to be capable of dividing outer box  2200  by individual golf ball  2280 . Like outer box  2000 , outer box  2200  may be configured to separate into any number of sleeves and boxes. 
     In some embodiments like those discussed above, outer boxes may be configured to have identical four columns of golf balls. In other embodiments, outer boxes may be configured to have staggered columns of golf balls. The columns may be staggered by varying the heights of the columns of golf balls. In some embodiments, referring to  FIGS. 23-29 , outer boxes may have a first column and a third column that are at a first height and a second column and a fourth column that are at a second height different from the first height. In other embodiments, the columns of golf balls may be of any height configuration. The columns may be of all different heights. The outer boxes may also have a different configuration by varying the number of columns and the number of golf balls. 
     Multiple outer boxes that have staggered columns may be used organized to prevent further movement while shipping. The multiple outer boxes may be packed within a shipping box in a staggered configuration within the shipping box by associating the balls of different columns with one another. For example, the first column of a first staggered outer box may be adjacent to the second column of a second staggered outer box. 
     In some embodiments, referring to  FIGS. 23-28 , an outer box may have a staggered configuration by staggering directly adjacent columns only in the height direction. The columns may also have the same depth. In other embodiments, referring to  FIGS. 29 and 30 , an outer box may have a staggered configuration of two rows of two columns. 
       FIG. 23  illustrates an embodiment of an outer box having a staggered configuration. Outer box  2300  is configured to contain twelve balls. Outer box  2300  has four columns of balls: first column  2330 , second column  2340 , third column  2350 , and fourth column  2360 . Each column is configured to contain three balls. Each column has a net height that corresponds to three golf balls. First column  2330  and third column  2350  are at a first height, and second column  2340  and fourth column  2360  are at a second height. The first height starts and ends higher than the second height. 
     Each column may have a flat top and bottom. The flat top and bottom is configured to enable stacking and positioning of the outer box on a shelf and within a shipping box without movement from its original position. The columns of outer box  2300  may also include angled corners. The angled corners may be disposed on the side of the column that is exposed. In  FIG. 23 , first column  2330  has first angled corner  2331 , second angled corner  2333 , and third angled corner  2335 ; second column  2340  has first angled corner  2341  and second angled corner  2343 ; third column  2350  has first angled corner  2351  and second angled corner  2353 ; and fourth column  2360  has first angled corner  2361 , second angled corner  2363 , and third angled corner  2365 . The angled corners in first wall  2310  (not shown) and second wall  2320  are symmetric. The angled corners may assist in the alignment of the golf balls within each column. The angled corners may also further reduce the packaging material. 
     Each column also has three openings. First column  2330  has first opening  2332 , second opening  2334 , and third opening  2336 ; second column  2340  has first opening  2342 , second opening  2344 , and third opening  2346 ; third column  2350  has first opening  2352 , second opening  2354 , and third opening  2356 ; and fourth column  2360  has first opening  2362 , second opening  2364 , and third opening  2366 . The columns have these openings in first wall  2310  (not shown) and second wall  2320 . The openings of first wall  2310  and second wall  2320  are symmetric. These openings are similar to the openings of outer box  2000  and the configurations of these openings, including alternative configurations, are described above. 
     Outer box  2300  may have any type of closure or sealing device. In  FIG. 23 , outer box  2300  has flip-top lid  2312  that is attached to the outer box main body. In other embodiments, outer box  2300  may have a lid that is not attached to the outer box main body and that is removable. 
     In some embodiments, outer box  2300  may also have a separation device that is configured to separate outer box  2300  into individual balls, sleeves and/or boxes. The separation device may be perforations. Outer box  2300  may include perforations  2370 ,  2372 , and  2374  that are between each column and divide golf balls  2280  into four columns. Outer box  2300  may be configured to separate into any number of sleeves and boxes. 
     In some embodiments, outer box  2300  may have walls on every side. In other embodiments, referring to  FIGS. 24 and 25 , outer box  2400  may have open side walls. As shown in  FIG. 25 , outer box  2400  is configured to contain twelve golf balls  2500 . 
     Outer box  2400 , like outer box  2300 , has four columns of balls: first column  2430 , second column  2440 , third column  2450 , and fourth column  2460 . Each column is configured to contain three balls. Each column may have a flat top and bottom. The flat top and bottom is configured to enable stacking and positioning of the outer box on a shelf and within a shipping box without movement from its original position. 
     The columns of outer box  2400  may also include angled corners. The angled corners may be disposed on the side of the column that is exposed. First column  2430  has first angled corner  2431 , second angled corner  2433 , and third angled corner  2435 ; second column  2440  has first angled corner  2441  and second angled corner  2443 ; third column  2450  has first angled corner  2451  and second angled corner  2453 ; and fourth column  2460  has first angled corner  2461 , second angled corner  2463 , and third angled corner  2465 . The angled corners in first wall  2410  (not shown) and second wall  2420  are symmetric. The angled corners may assist in the alignment of the golf balls within each column. The angled corners may also further reduce the packaging material. 
     Each column also has three openings. First column  2430  has first opening  2432 , second opening  2434 , and third opening  2436 ; second column  2440  has first opening  2442 , second opening  2444 , and third opening  2446 ; third column  2450  has first opening  2452 , second opening  2454 , and third opening  2456 ; and fourth column  2460  has first opening  2462 , second opening  2464 , and third opening  2466 . The columns have these openings in first wall  2410  (not labeled) and second wall  2420 . The openings of first wall  2410  and second wall  2420  are symmetric. These openings are similar to the openings of outer box  2000  and the configurations of these openings, including alternative configurations, are described above. 
     Outer box  2400  does not have any side walls extending in the depth direction and has open opposing sides. The side walls are not necessary because the openings maintain the position of the ball within the box. 
     In some embodiments, outer box  2400  may also have a separation device that is configured to separate outer box  2400  into individual balls, sleeves and/or boxes. The separation device may be perforations. Outer box  2400  may include perforations  2470 ,  2472 , and  2474  that are between each column and divide golf balls  2480  into four columns. Outer box  2400  may be configured to separate into any number of sleeves and boxes. 
     Outer box may also be configured to have straight edges. Referring to  FIGS. 26-28 , each column may have straight edges. 
       FIG. 26  illustrates an embodiment of a staggered outer box with straight edges. Outer box  2600  is configured to contain twelve balls. Outer box  2600  has four columns of balls: first column  2630 , second column  2640 , third column  2650 , and fourth column  2660 . Like outer box  2400 , each column is configured to contain three balls and has a net height that corresponds to three golf balls. First column  2630  and third column  2650  are at a first height, and second column  2640  and fourth column  2660  are at a second height that is higher than the first height. 
     Each column has a flat top and bottom and also has three openings. First column  2630  has first opening  2632 , second opening  2634 , and third opening  2636 ; second column  2640  has first opening  2642 , second opening  2644 , and third opening  2646 ; third column  2650  has first opening  2652 , second opening  2654 , and third opening  2656 ; and fourth column  2660  has first opening  2662 , second opening  2664 , and third opening  2666 . The columns have these openings in first wall  2610  (not shown) and second wall  2620 . The openings of first wall  2610  and second wall  2620  are symmetric. These openings are similar to the openings of outer box  2000  and the configurations of these openings, including alternative configurations, are described above. 
     Outer box  2600  may have any type of closure or sealing device. Outer box  2600  may have a flip-top lid that is attached to the outer box main body. or a lid that is not attached to the outer box main body and that is removable. 
     In some embodiments, outer box  2600  may also have a separation device that is configured to separate outer box  2600  into individual balls, sleeves and/or boxes. Outer box  2600  may include perforations  2670 ,  2672 , and  2674  that are between each column and divide golf balls  2680  into four columns. Outer box  2600  may be configured to separate into any number of sleeves and boxes. 
     In some embodiments, outer box  2600  may have walls on every side. In other embodiments, referring to  FIGS. 27 and 28 , outer box  2700  may have open side walls. As shown in  FIG. 28 , outer box  2700  is configured to contain twelve golf balls  2800 . 
     Outer box  2700 , like outer box  2600 , has four columns of balls: first column  2730 , second column  2740 , third column  2750 , and fourth column  2760 . Each column is configured to contain three balls and has three openings. First column  2730  has first opening  2732 , second opening  2734 , and third opening  2736 ; second column  2740  has first opening  2742 , second opening  2744 , and third opening  2746 ; third column  2750  has first opening  2752 , second opening  2754 , and third opening  2756 ; and fourth column  2760  has first opening  2762 , second opening  2764 , and third opening  2766 . The columns have these openings in first wall  2710  (not labeled) and second wall  2720 . The openings are symmetric on first wall  2710  and second wall  2720 . These openings are similar to the openings of outer box  2000  and the configurations of these openings, including alternative configurations, are described above. 
     Outer box  2700  does not have walls on the top and bottom sides extending in the width direction and has open opposing sides in the depth direction. These walls are not necessary because the openings maintain the position of the ball within the box. 
     In some embodiments, outer box  2700  may also have a separation device that is configured to separate outer box  2700  into individual balls, sleeves and/or boxes. The separation device may be perforations. Outer box  2700  may include perforations  2770 ,  2772 , and  2774  that are between each column and divide golf balls  2780  into four columns. Outer box  2700  may be configured to separate into any number of sleeves and boxes. 
     Referring to  FIG. 29 , outer box  2900  may have staggered columns in the height direction that are configured to have two columns and two rows of columns. Outer box  2900  may have straight edges and corners. In other embodiments, outer box  2900  may have angled edges and corners that correspond to the circular angle of the golf ball. 
     Outer box  2900  is configured to contain twelve balls. Outer box  2900  has four columns of balls: first column  2930 , second column  2940 , third column  2950 , and fourth column  2960 . Like outer box  2400 , each column is configured to contain three balls and has a net height that corresponds to three golf balls. First column  2930  and fourth column  2960  are at a first height, and second column  2940  and third column  2950  are at a second height that is higher than the first height. First column  2930  is symmetric with fourth column  2960  and second column  2940  is symmetric with third column  2950 . 
     Each column may a flat top and bottom. Also, in some embodiments, each column may have three openings in each exposed surface for a total of six openings. In other embodiments, the openings may vary for each column and may be different for each column. 
     As shown in  FIG. 29 , first column  2930  has first opening  2932 , second opening  2934 , and third opening  2936 ; second column  2940  has first opening  2941 , second opening  2942 , third opening  2943 , fourth opening  2944 , fifth opening  2945 , and sixth opening  2946 ; and fourth column  2960  has first opening  2962 , second opening  2964 , and third opening  2966 . The openings of third column  2950 , which are not shown, are symmetric to the openings of second column  2940 . 
     Outer box  2900  may have any type of closure or sealing device. Outer box  2900  may have a flip-top lid that is attached to the outer box main body. or a lid that is not attached to the outer box main body and that is removable. 
     In some embodiments, outer box  2900  may also have a separation device that is configured to separate outer box  2900  into individual balls, sleeves and/or boxes. Outer box  2900  may also include perforations configured to separate into any number of sleeves and boxes. 
     In some embodiments, outer box  2900  may have walls on every side. In other embodiments, outer box  2900  may have open side walls. 
     The sleeves and outer boxes may be configured from blanks. Blanks may have the wall panels in any configuration. In one embodiment shown in  FIG. 30 , sleeve  300  may have been formed from blank  3000 . Panels  3010 ,  3020 ,  3030 , and  3040  are hingedly connected together along fold lines  3050 ,  3060 , and  3070 . Sleeve  300  may be formed by folding the panels. For example, panel  3010  may be folded at fold line  3050  while panel  3030  may be folded at fold line  3060  and panel  3040  may be folded at fold line  3070  so that panel  3040  converges with panel  3010 . Panel  3010  may be attached to panel  3040  by a fastener. The fastener may be any known adhesive, like glue or tape, or mechanical means, such as staples. 
       FIG. 31  illustrates a process for forming a sleeve containing golf balls from a blank. In step  3102 , a blank from which the sleeve is configured may be formed. To form a sleeve according to any embodiment discussed above, a blank may be cut to a predetermined configuration. For example, for sleeve  300 , the blank may be cut into the configuration shown in  FIG. 30 . 
     After the blank is formed, in step  3104 , the blank may be folded along the fold lines. The blank may be folded along the fold lines so that it can be filled by golf balls. In some embodiments, the blank may not be folded along all of the fold lines. For example, for sleeve  300 , panel  3030  may be folded at fold line  3060  and panel  3040  may be folded at fold line  3070  so that panel  3040  is parallel with panel  3020 . 
     In step  3106 , the blank may then be filled with the balls. The amount of balls depends on the configuration of the blank. In some embodiments, the blank may be filled with three golf balls. In other embodiments, the blank may be formed with twelve golf balls. 
     After the blank is filled with the balls, at step  3108 , the blank may be sealed to form the sleeve. The blank may be edge-sealed with an adhesive, like glue or tape, or mechanical means, such as staples. In some embodiments, the blank may need to be further folded before the blank is sealed. For example, with respect to blank  3000 , panel  3010  may be folded at fold line  3050  so that it converges with panel  3040 . After which, blank  3000  may be sealed with an adhesive to form a sleeve. 
     The process may not include all of the steps discussed above. For example, it may be not necessary to form the blanks. The sleeves may be formed from preconfigured blanks. Also, the steps in the process discussed above may be performed in any order. The steps need not be performed in the order shown in the figure or in the order described above. The order of steps in the process may be altered in some embodiments. 
     Although not shown, the sleeves and outer boxes may include graphics that compel the retailer to provide a larger amount of shelf space for the outer box. For example, referring to  FIG. 29 , outer box  2900  may include graphics along the surfaces of columns  2930 ,  2940 , and  2960  that requires the outer box to be displayed in the diamond position with column  2940  in the front and middle so that the graphic can be properly understood. This position would require shelf space that is almost equivalent to three golf balls. This would be larger than the known square inner box shown in  FIG. 2  and thus would require more visible retail space. 
     While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Technology Category: 7