PATENT DOCUMENT

Publication Number: US-11827431-B2
Application Number: US-202117160499-A
Country: US
Kind Code: B2

Title: Packaging with simultaneously foldable base and tray

Abstract:
Packaging may include a base box comprising cardboard, e.g., cardboard corrugate. Disposed within the base box may be a tray for receiving a product, which also may comprise cardboard. By constructing a base box and tray that both fold flat without destructive means, this type of configuration retains a high-end reception of the end product and product packaging, while encouraging proper recycling once the customer decides to dispose of the packaging.

Claims:
What is claimed is: 
     
       1. Packaging, comprising:
 a base box comprising:
 a base panel; and 
 four side panels, each extending vertically from the base panel, and each foldable outward from the base panel; and 
 foldable wings to couple adjacent ends of the four side panels, respectively, wherein each wing is foldably attached to one of a pair of adjacent ends of the four side panels and is received within a pocket of the other of the pair of adjacent ends of the four side panels; 
 
 a foldable tray received in the base box, wherein folding one of the side panels outward causes the foldable tray to lower toward the base panel of the base box; and 
 a lid comprising:
 four lid side panels, each extending vertically from a lid top panel, and each foldable outward from the lid top panel; and 
 foldable wings to couple adjacent ends of the four lid side panels, respectively, wherein each wing is foldably attached to one of a pair of adjacent ends of the four lid side panels and is received within a pocket of the other of the pair of adjacent ends of the four lid side panels, wherein when the lid is coupled to the base box, the pockets of the base box are perpendicular to the pockets of the lid. 
 
 
     
     
       2. The packaging of  claim 1 , wherein each of the base box and the foldable tray is formed from cardboard. 
     
     
       3. The packaging of  claim 1 , wherein the base box is configured to fold flat outwardly in a first direction, and the foldable tray is configured to fold flat outwardly in a second direction, wherein the second direction is perpendicular to the first direction. 
     
     
       4. Packaging, comprising:
 a base box transitionable between an assembled state and a flattened state comprising:
 a base panel; 
 four side panels, each extending vertically from the base panel at respective folds when the box is in an assembled state, and each foldable outward from the base panel to configure the base box to a flattened state; and 
 
 a tray configured to be received in the base box and transitionable between an assembled state and a flattened state, the tray comprising:
 a tray cover; and 
 a tray support disposed beneath the tray cover and slidably connected to the tray cover, wherein the tray support structurally supports the tray cover in an assembled state and positions the tray cover above the base panel, wherein the tray support is foldable to a flattened state when the base box is in a flattened state, 
 
 wherein in the assembled configuration a first side panel of the four side panels and a second side panel of the four side panels extend perpendicularly from the base panel and the tray cover is spaced apart from the base panel, and 
 wherein when the first side panel and the second side panel are rotated outwardly about their folds, the tray cover and a portion of the tray support slide relative to each other and lower toward the base panel, to transition the base box into the flattened state. 
 
     
     
       5. The packaging of  claim 4 , wherein the tray support further comprises:
 first and second side panels configured to be fixed to an inner periphery of the base box; 
 first and second upper support panels extending from the first and second side panels, respectively, and providing a product support area when the packaging is in an assembled state, 
 wherein as an inner periphery of the base box folds outwardly to a flattened state the first and second side panels allow the first and second upper support panels to lower towards the base panel of the base box, thereby flattening the tray. 
 
     
     
       6. The packaging of  claim 5 , wherein the tray cover is fixed to the first upper support panel, such that as the first upper support panel lowers towards the base panel of the base box, the tray cover also lowers towards the base panel of the base box, and wherein the tray cover extends from a first of the four side panels to a second of the side panels opposite the first side panel when in an assembled state. 
     
     
       7. The packaging of  claim 6 , wherein the tray cover is translationally coupled to the second upper support panel, such that as the second upper support panel lowers towards the base panel of the base box, the tray cover also lowers towards the base panel of the base box and translates along the upper surface of the second upper support panel. 
     
     
       8. The packaging of  claim 5 , wherein the second upper support panel comprises a slot to receive a guide, wherein the guide is fixed to the lower surface of the tray cover. 
     
     
       9. The packaging of  claim 8 , wherein as the second upper support panel moves when folding the tray flat, the guide is free to translate within the slot, thereby also translating the tray cover along the slot. 
     
     
       10. The packaging of  claim 4 , wherein the base box, tray cover, and tray support are made from cardboard. 
     
     
       11. The packaging of  claim 4 , wherein the base box further comprises:
 wing guides; and 
 a lower box cover folded around the base panel and side panels, the lower box cover including wings to be received in a pocket between a portion of the lower box cover and a side panel of the base box, guided by the wing guides, such that the base box is secured in an assembled state. 
 
     
     
       12. The packaging of  claim 11 , wherein each of the wings includes a mechanical lock configured to releasably attach to the base box. 
     
     
       13. The packaging of  claim 11 , further comprising a lid, the lid comprising:
 a lid top panel; 
 four side panels, each extending vertically from the lid top panel at respective folds when the lid is in an assembled state, and each foldable outward from the lid top panel to configure the lid to a flattened state; and 
 a lid cover folded around the lid top panel and side panels, the lid cover including wings to be received in a pocket between a portion of the lid top cover and a side panel of the lid, such that the lid is secured in an assembled state, and 
 wherein the wings of the lid extend into the panels offset 90 degrees from the panels that the wings of the base box extend into, in an assembled state. 
 
     
     
       14. A foldable tray for packaging and configured to be coupled within a base box, comprising:
 a tray cover formed of a first cardboard material; and 
 a tray support disposed beneath the tray cover and formed of a second cardboard material different from the first cardboard material, comprising:
 first and second side panels configured to be fixed to an inner periphery of a base box; 
 first and second upper support panels extending from the first and second side panels and towards the center of the tray support; 
 center support panels extending from the opposing ends of the first and second upper support panels towards a bottom surface of an interior of the base box; and 
 a ground panel connecting the center support panels and coupled to the bottom surface of an interior of the base box, 
 wherein in an assembled state the foldable tray supports a product, 
 wherein the first and second side panels allow the first and second upper support panels to lower towards the ground panel, thereby flattening the tray in response to an outward force on the first and second side panels, 
 wherein the tray cover is fixed to the first upper support panel, and 
 wherein the tray cover is translationally coupled to the second upper support panel. 
 
 
     
     
       15. The foldable tray of  claim 14 , wherein in an assembled state the center support panels are angled toward each other relative to the ground panel, such that in a folded state the tray folds flat relative to the base box. 
     
     
       16. The foldable tray of  claim 14 , wherein the base box includes wings that fold inward and secure the side panels of the base box in the assembled state, and wherein the first side panel of the tray is fixed to an inner surface of a first side panel of the base box, such that as the first side panel of the base box rotates outward to the flattened state, the first side panel of the tray support rotates toward the base panel of the base box, thereby flattening a first side of the tray. 
     
     
       17. The foldable tray of  claim 14 , further comprising a lid, the lid comprising:
 a lid top panel; 
 four side panels, each extending vertically from the lid top panel at respective folds when the lid is in an assembled state, and each foldable outward from the lid top panel to configure the lid to a flattened state; and 
 foldable wings to couple adjacent ends of the four side panels, respectively, wherein each wing is foldably attached to one of a pair of adjacent ends of the four side panels and is received within a pocket of the other of the pair of adjacent ends of the four side panels, wherein in an assembled state, the wings secure the lid in a direction opposing the translational direction of the tray cover. 
 
     
     
       18. A foldable tray for packaging and configured to be coupled within a base box, comprising:
 a tray cover formed of a cardboard material; and 
 a tray support disposed beneath the tray cover, comprising:
 first and second side panels configured to be fixed to an inner periphery of a base box; 
 first and second upper support panels extending from the first and second side panels and towards the center of the tray support; 
 center support panels extending from the opposing ends of the first and second upper support panels towards a bottom surface of an interior of the base box; and 
 a ground panel connecting the center support panels and coupled to the bottom surface of an interior of the base box, 
 wherein the first and second side panels allow the first and second upper support panels to lower towards the ground panel, thereby flattening the tray in response to an outward force on the first and second side panels, 
 wherein the tray cover is fixed to the first upper support panel, and 
 wherein the tray cover is translationally coupled to the second upper support panel.

Description:
FIELD 
     The described embodiments relate generally to packaging. More particularly, the present embodiments relate to packaging having foldable components including a foldable base and tray that may simultaneously be collapsed and flattened for recycling. 
     BACKGROUND 
     The described embodiments relate generally to packaging. More particularly, the present embodiments relate to packaging using folded recyclable components including a simultaneously foldable base and tray for easier recycling. Product packaging is an integral part of a customer&#39;s experience. It introduces the customer to their product, and can affect the customer&#39;s feelings toward the product and the company that created it. This is especially true for companies that wish to move toward a single stream recycling solution for their packaging. In general, some current higher end packaging (e.g., for electronic devices) may include plastic materials. While these materials and packaging designs provide adequate coverage, they are not environmentally friendly and use nonrenewable resources for their raw material. 
     In contrast, some more environmentally friendly materials such as molded fiber based trays that are integrated in a lower base box may be structurally configured such that no deformation of the packaging is easily achievable without damaging the packaging such that it may not be intuitive to a customer to recycle the packaging. 
     What is needed is a recyclable packaging paradigm that can maintain packaging integrity prior to being received by an end user, but easily and intuitively fold and collapse each of its components such that they are easily recyclable. 
     SUMMARY 
     Packaging may include a base box including: a base panel and four side panels, each extending vertically from the base panel. Each may be foldable outward from the base panel. The packaging may include a foldable tray received in the base box, and folding one of the side panels outward causes the foldable tray to lower toward the base panel of the base box. In some embodiments, the base box includes foldable wings to couple adjacent ends of the four side panels, respectively. Each wing is foldably attached to one of a pair of adjacent ends of the four side panels and is received within a pocket of the other of the pair of adjacent ends of the four side panels. 
     The packaging includes a lid in some embodiments. The lid may include four lid side panels, each extending vertically from a lid top panel, and each foldable outward from the lid top panel. In some embodiments, the lid includes foldable wings to couple adjacent ends of the four lid side panels, respectively, and each wing may be foldably attached to one of a pair of adjacent ends of the four lid side panels and is received within a pocket of the other of the pair of adjacent ends of the four lid side panels. In some embodiments, when the lid is coupled to the base, the pockets of the base are perpendicular to the pockets of the lid. 
     In some embodiments, each of the base box and the foldable tray is formed from cardboard. 
     In some embodiments, the base box is configured to fold flat outwardly in a first direction, and the foldable tray is configured to fold flat outwardly in a second direction, wherein the first direction is perpendicular to the first direction. 
     Some embodiments are directed to packaging that includes a base box transitionable between an assembled state and a flattened state. The base box may include a base panel and four side panels, each extending vertically from the base panel at respective folds when the box is in an assembled state. Each side panel may be foldable outward from the base panel to configure the base box to a flattened state. 
     The packaging may include a tray configured to be received in the base box and transitionable between an assembled state and a flattened state. In some embodiments, the tray includes a tray cover and a tray support disposed beneath the tray cover and slidably connected to the tray cover. In some embodiments, the tray support structurally supports the tray cover in an assembled state and positions the tray cover above the base panel. The tray support is foldable to a flattened state when the base box is in a flattened state. The tray support may include first and second side panels configured to be fixed to an inner periphery of the base box, and include first and second upper support panels extending from the first and second side panels, respectively, and providing a product support area when the packaging is in an assembled state. As an inner periphery of the base box folds outwardly to a flattened state the first and second side panels allow the first and second upper support panels to lower towards the base panel of the base box, thereby flattening the tray. 
     In some embodiments, the tray cover is fixed to the first upper support panel, such that as the first upper support panel lowers towards the base panel of the base box, the tray cover also lowers towards the base panel of the base box. The tray cover extends from a first of the four side panels to a second of the side panels opposite the first side panel when in an assembled state. In some embodiments, the tray cover is translationally coupled to the second upper support panel, such that as the second upper support panel lowers towards the base panel of the base box, the tray cover also lowers towards the base panel of the base box and translates along the upper surface of the second upper support panel. The base box, tray cover, and tray support are made from cardboard in some embodiments. 
     The second upper support panel may include a slot to receive a guide, and the guide may be fixed to the lower surface of the tray cover. As the second upper support panel moves when folding the tray flat, the guide is free to translate within the slot, thereby also translating the tray cover along the slot. The base box may further include wing guides. In some embodiments, the base box further includes a lower box cover folded around the base panel and side panels, the lower box cover including wings to be received in a pocket between a portion of the lower box cover and a side panel of the base box, guided by the wing guides, such that the base box is secured in an assembled state. Each of the wings may include a mechanical lock configured to releasably attach to the base box in some embodiments. 
     The packaging may include a lid. The lid may include a lid top panel and four side panels, each extending vertically from the lid top panel at respective folds when the lid is in an assembled state, and each foldable outward from the lid top panel to configure the lid to a flattened state. The lid may include a lid cover folded around the lid top panel and side panels, the lid cover including wings to be received in a pocket between a portion of the lid top cover and a side panel of the lid, such that the lid is secured in an assembled state. In some embodiments, the wings of the lid extend into the panels offset 90 degrees from the panels that the wings of the base box extend into, in an assembled state. 
     In some embodiments, in the assembled configuration a first side panel of the four side panels and a second side panel of the four side panels extend perpendicularly from the base panel and the tray cover is spaced apart from the base panel, and wherein when the first side panel and the second side panel are rotated outwardly about their folds, the tray cover and a portion of the tray support slide relative to each other and lower toward the base panel, to transition the base box into the flattened state. 
     Some embodiments are directed to a foldable tray for packaging and configured to be coupled within a base box. The foldable tray for packaging may include a tray cover formed of a first cardboard material, and a tray support disposed beneath the tray cover and formed of a second cardboard material different from the first cardboard material. The tray support may include first and second side panels configured to be fixed to an inner periphery of a base box, first and second upper support panels extending from the first and second side panels and towards the center of the tray support, center support panels extending from the opposing ends of the first and second upper support panels towards a bottom surface of an interior of the base box, and a ground panel connecting the center support panels and coupled to the bottom surface of an interior of the base box. In an assembled state the foldable tray supports a product. The first and second side panels allow the first and second upper support panels to lower towards the ground panel, thereby flattening the tray in response to an outward force on the first and second side panels. In some embodiments, the tray cover is fixed to the first upper support panel, and the tray cover is translationally coupled to the second upper support panel. 
     In some embodiments, in an assembled state the center support panels are angled toward each other relative to the ground panel, such that in a folded state the tray folds flat relative to the base box. The base box includes wings that fold inward and secure the side panels of the base box in the assembled state, and wherein the first side panel of the tray is fixed to an inner surface of a first side panel of the base box, such that as the first side panel of the base box rotates outward to the flattened state, the first side panel of the tray support rotates toward the base panel of the base box, thereby flattening a first side of the tray in some embodiments. 
     The foldable tray may include a lid. The lid may include a lid top panel, four side panels, each extending vertically from the lid top panel at respective folds when the lid is in an assembled state, and each foldable outward from the lid top panel to configure the lid to a flattened state, and foldable wings. In some embodiments, the wings couple adjacent ends of the four side panels, respectively, and each wing is foldably attached to one of a pair of adjacent ends of the four side panels and is received within a pocket of the other of the pair of adjacent ends of the four side panels. In some embodiments, in an assembled state, the wings secure the lid in a direction opposing the translational direction of the tray cover. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG.  1    shows a top isometric view of packaging with tray and base box in an embodiment, in a first, assembled configuration. 
         FIG.  2    shows a top isometric view of the packaging shown in  FIG.  1    in a second, outwardly folded configuration. 
         FIG.  3    shows a top isometric view of the packaging shown in  FIG.  1    in a third, outwardly folded configuration. 
         FIG.  4    shows a top isometric view of the packaging shown in  FIG.  1    in a fourth, outwardly folded configuration. 
         FIG.  5    shows a schematic cross section view of a tray and base box in a first configuration. 
         FIG.  6    shows a schematic cross section view of the tray and base box of  FIG.  5    in a second configuration. 
         FIG.  7    shows a schematic cross section view of the tray and base box of  FIG.  5    in a third configuration. 
         FIG.  8    shows an exploded view of a packaging with tray and base box in an embodiment. 
         FIG.  9    shows a partial assembled view of tray and guide in an embodiment. 
         FIG.  10    shows a side view of the guide shown in  FIG.  9   . 
         FIG.  11    shows a top view of the guide shown in  FIG.  9   . 
         FIG.  12    shows a partial assembled view of a base box having a wing and wing guide in an embodiment. 
         FIG.  13    shows an assembled state of packaging in an embodiment. 
         FIG.  14    shows a flattened state of the packaging shown in  FIG.  13   . 
         FIG.  15    shows an exploded view of a foldable lid in an embodiment. 
         FIG.  16    shows a partial assembled view of a base box having a mechanical lock in an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     As described above, the packaging described herein provides a packaging solution utilizing environmentally friendly materials, specifically cardboard (or other cellulose-based material). A base box and tray are disclosed that together, are configured to fold flat once a customer is finished using the packaging, thereby easing recyclability. Elements are described that achieve a structurally sound package, while allowing an end user to easily break-down the package for recycling. 
     Some embodiments include packaging including a base box comprising cardboard, e.g., paperboard or cardboard corrugate. Disposed within the base box may be a support tray for receiving a product, which also may comprise cardboard. By constructing a base box and support tray that both fold flat without destructive means, this type of configuration retains a high-end reception of the end product and product packaging, while encouraging proper recycling once the customer decides to dispose of the packaging. 
     In some embodiments, each panel of the base box or tray or both may be formed from a continuous sheet (e.g., a cardboard blank). The respective elements may be formed of the same material or different materials (e.g., different cellulose-based material). For example, the tray may have a cover formed from paperboard, hiding a tray support component made of corrugate. A finished package may include other components such as a lid, which also may fold flat and may be formed similarly to the base box. The lower box may wholly envelop the tray support structure in a finished configuration, such that the tray support structure is not visible to a customer. 
     Advantageously, this improves upon prior systems having, for example, plastic tray insert components. And in terms of intuitive breakdown and recycling without destroying the packaging, this improves upon prior systems that make use of molded fiber components that are not easily made to lie flat. 
     Companies may be sensitive to the cost of packaging and may wish to promote packaging that is eco-friendly. Certain packaging materials are higher cost due to their processing, and while engineers may be able to design single-component packaging, the cost may be prohibitive for certain materials. Optimization of packaging in material usage may help keep costs low, and if done well may not interfere with, and may promote, a positive user experience. Packaging made out of recyclable and/or biodegradable materials, such as paper or other cellulose-based products can reduce environmental impact, especially when it is intuitive for a customer to properly recycle. Packaging that is interesting in character and well-executed may boost a product&#39;s or a brand&#39;s reputation, thereby attracting new customers and retaining previous customers. 
     In utilizing eco-friendly materials such as cardboard structures, some designs may be less likely to be properly recycled, in part due to the difficulty in breaking down the box/tray components to lie flat and be placed in recycling. Packaging described herein improves on past designs, and provides eco-friendly components that are intuitive to break down and lie flat without requiring destruction (e.g., tearing, ripping, crushing) in order for the packaging to easily be recycled. Packaging described in this document achieves these and other beneficial characteristics by balancing structural robustness, eco-friendly materials, and aesthetic elements. 
     To keep the product protected and secure during transport, handling, or storage, the base boxes and trays disclosed herein may include recesses or features to hold various components, documents, or products. Each of these recesses or features may include components or designs that allow those recesses or features to also lie flat when the packaging is ready for recycling. A lid may cover the product when the packaging is closed, and may be similarly foldable to lie flat when ready for recycling. A product contained by the packaging may be, for example, an electronic device such as, for example, a desktop, monitor, laptop, tablet computer, or smartphone, or it may be a non-electronic device. 
     In some embodiments, the packaging may be retail packaging (i.e., finished packaging for containing and conveying a product to a user such as may be used in a retail setting, not shipping packaging for containing a packaged product during shipment) that one may expect to find on the shelf in a retail store, and which one may open after purchase to directly access their product. 
     These and other embodiments are discussed below with reference to the accompanying figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIGS.  1 - 4    show isometric views of packaging  1  in four different configurations, the first in  FIG.  1    being when packaging  1  is assembled and able to receive a product in product area  221 , which may optionally include recess  222  to receive a portion of the product or an accessory, such as product documentation, cords, headphones, etc. Each recess  222  may be configured to also fold to a flattened state when the packaging is ready for recycling. In some embodiments, protrusions may be provided, e.g., as part of a tray structure, and those protrusions may also be configured to fold to a flattened state when the packaging is ready for recycling. As shown in the figures, packaging  1  includes a base box  10  that receives tray  20 , presenting as an integrated base for packaging  1 . Base box  10  includes side panels  102  that extend vertically from bottom panel  100  (e.g., a base panel) in an assembled state. Side panels  104  similarly extend from bottom panel  100 , thus forming a base box to receive tray  20 . As shown, in total there are generally four side panels, although additional geometries are contemplated. Tray cover  220  is received within the side panels  102  and  104 , and covers the additional components of tray  20 , presenting as an integrated tray. 
     As shown in  FIG.  2   , base box  10  may be pulled at side panels  102  or panels  104 , such that the respective pairs of panels begin to rotate away from the opening of base box  10 . As the panels fold away, tray cover  220  slides in one direction revealing track  208  and upper support panel  204  of tray support  200 . As the panels further fold away as shown in  FIG.  3   , product support area  206  is revealed, which adds structural support under tray cover  220  in the finished configuration of  FIG.  1   . Wings  116  of base box  10  become more visible, and the box further begins to flatten. Turning to  FIG.  4   , the base box  10  and tray  20  are fully flattened, and thus ready for recycling. Wings  116  may slip out of the slots  117  formed in base box as described herein, or may be retained if it is desired to reverse the folding steps to reconstruct the packaging  1 . Put another way, each side panel may be foldable outward from the base panel  100 . Folding one of the side panels outward causes the tray  20  to lower toward the base panel  104  of the base box  10 . The wings  116  couple adjacent ends of the four side panels, respectively. Each wing  116  is foldably attached to one of a pair of adjacent ends of the four side panels and is received within a pocket of the other of the pair of adjacent ends of the four side panels (further described herein). 
       FIGS.  5 - 7    show a schematic cross section of components of base box  10  and components of tray  20  in three configurations, showing the internal structure that allows for the flattening of the tray. As further described below, support tray  200  provides additional structural support for tray  20  during use. Support tray  200  includes side panels  202  and  202 ′, which may be adhered at an inner periphery of base box  10  (e.g., inner surfaces of panels  102 , respectively). As shown, each of side panels  202 / 202 ′ extend upward to a fold, whereby upper support panels  204 / 204 ′ extend towards the center of support tray  200 . Together, upper support panels  204 / 204 ′ form a plane that tray cover  220  may be aligned on top of, and together form a product support area  206  that provides structural support for the product when packaging  1  is in an assembled state. In practice, tray cover  220  may be connected to the top surface of one of the upper support panels, e.g., support panel  204 ′. Because of the split configuration of the upper support panels  204 / 204 ′, the tray is allowed to split and fold flat (as shown in the sequence of  FIGS.  5 - 7   ), while maintaining a solid, unbroken appearance of tray cover  220  in an assembled configuration. 
     Towards the ends of upper support panels  204 / 204 ′ opposite side panels  202  and  202 ′, center support panels  212  and  212 ′ extend downward to ground panel  214  which is coupled to the interior of base box  10  at bottom panel  100 . Ground panel  214  may be adhered to the bottom panel  100  in some embodiments.  FIG.  5    shows center support panels  212  and  212 ′ extending upward and toward one another from ground panel  214 . By fixing an initial angle towards the center of the support tray  200 , sufficient distance is provided such that support tray  200  may fold fully flat in the flattened state (as shown in the flattened configuration of  FIG.  7   ). This initial angle also provides structural support to the product support surface, in that a downward force (e.g., weight of product) would only tend to make the center support panels  212  and  212 ′ move toward each other, maintaining their position and stability. If support panels  212  and  212 ′ were angled away from each other a downward force might tend to make them move away from each other, toward premature collapse of the box. 
     Turning to  FIG.  8   , an exploded view of packaging  1  is shown, showing the components of tray  20  and base box  10 . Tray cover  220  is shown and is configured to hide support tray  200 . Product support area  221  may be inset within tray cover  220 , or integrated within tray cover  220 . In some embodiments, product support area  221  may be configured as a document pocket. Tray cover  220  may include panels  224  extending downward and further hiding edges of hidden components of tray  20  in use. 
     As described above, now referencing  FIG.  8   , support tray  200  is shown below tray cover  220 , and provides additional structural support for tray  20  during use. Support tray  200  is connected to tray cover  220  on a first side of tray  20 , e.g., at support panel  204 ′. On a second side of tray  20 , e.g., the side of support panel  204 , support tray  200  is connected to guides  210 . Guides  210  in turn slide along slots  208  of support panel  204 , e.g., when support tray  200  is folding outwardly away from its center, such that tray cover  220  maintains a planar orientation and translates relative to support panel  204  parallel to the axes of guides  210 , when packaging  1  is being folded flat. Support shims  205  and  205 ′ may be fixed to the bottom surface of support panels  204  and  204 ′, respectively, and provide additional planar structural support to product support area  206 . As shown, support shim  205  may include slots that match slots  208 , so as to allow easy translation of guides  210  within slots  208 . As shown in  FIG.  8   , support tray  200  may be formed from a continuous sheet (e.g., a cardboard blank). In some embodiments, support tray  200  may be formed from additional individual components, e.g., split support components. 
     Base box  10  may include bottom panel  100 , with side panels  102  and panels  104  extending outward and foldable upward to provide for an interior cavity forming the opening of base box  10 . As shown, panels  100 ,  102 , and  104  may all be formed from a continuous sheet (e.g., a cardboard blank). Lower box cover  108  wraps around panels  100 ,  102 , and  104 , holding the assembled shape of base box  10 . In some embodiments, lower box cover  108  may be made of a higher end finished paperboard, such that a separate material for panels  100 ,  102 , and  104  may be hidden in use. In some embodiments, tray cover  220  may be made of a higher end finished paperboard, such as separate materials for the support tray  200 . As can be appreciated from  FIG.  8   , panels  113  and  112 , match to the outside surfaces of panels  102  and  104 , respectively, when lower box cover is folded up into an assembled configuration. Panels  114  and  115  in turn fold over and match to the inside surfaces of panels  102  and  104 , respectively. Wing guides  106  may be fixed to panels  104 , and are configured to accommodate and aid in guiding wings  116  to be folded into a pocket  116  between panel  112  on the lower box cover  108  and side panel  104 . In this configuration, with wings  116  received within pockets  117 , it is clear that base box  10  is in an assembled state, and can receive tray  20  within it. 
       FIG.  9    shows an enlarged view of a portion of support tray  200 , showing guides  210  having been inserted into slot  208 . Also shown on the right side of the figure are guides  210  shown from the side and top, respectively. As shown, in some embodiments, guides  210  include a dovetail shaped fold  211  that may fix guides  210  in their respective slots  208 . In assembly, this dovetail shaped fold  211  may be folded and angled through slot  208 , and thereafter the top surfaces of guides  210  may be fixed to tray cover  220 . As can be appreciated from the figures showing the flattening states of packaging  1 , guides  210  may be placed towards an end of the slots  208  closest to the side panel  202 , such that when they are attached to tray cover  220 , the tray cover is free to translate away from that end and towards side panel  202 ′ when the tray  20  is flattened. Each of guides  210  may be formed from a folded continuous sheet of recyclable material. Adhesive or non-adhesive based alternatives may be used to fix the top surfaces of guides  210  to tray cover  220 .  FIG.  10    shows a side view of guide  210 , and  FIG.  11    shows a top view of guide  210 . 
       FIG.  12    shows an enlarged view of a portion of base box  10  showing wing guide  106 , coupled to panel  104 . In some embodiments, wing guide  106  may be formed as a continuous sheet from panel  104 , i.e., folded in on itself. Wing  116  is shown in an assembled position, with the wing contour following the wing guide contour along the surface of panel  104 . As shown, panel  112  may fold up and create a pocket that encases wing  116  between panel  104  and panel  112  in an assembled state. The wing guides  106  may be formed as a panel, and may serve as a spacer to space panel  112  away from panel  104  to create the pocket  117 . In some embodiments, to effect this a wing guide  106  is at least as thick as its corresponding wing  116 . In some embodiments, a second wing  116 ′ may be included, and may be folded towards the inside of box base box  10 , such that fold line  119  corresponds to the corner of base box  10  shown in  FIG.  12   . 
       FIG.  13    shows an assembled state of packaging  1 , and  FIG.  14    shows a flattened state of packaging  1 . As shown in the flattened state, tray  20  and side panels  102  of base box  10  generally flatten out in a first direction (y), while side panels  104  of base box  10  flatten in a second direction (x) generally perpendicular to the first direction. This provides additional structural stability in the assembled position, such that the packaging  1  does not involuntarily collapse outward and flatten without an applied force designed to flatten it. As shown in  FIG.  13   , in an assembled state, packaging  1  maintains a unitary appearance and shows virtually no gaps and seams in the construction. And in  FIG.  14   , even in a flattened state, there is no destructive damage to the packaging  1 —simply it folds away tray  20  and base box  10  together. The folding away of the tray  20  and base box  10  may be simultaneous, such that side panels  202 / 202 ′ are attached to the side panels  102  of box  10 . In this way, the translational coupling between guides  210  and slots  208  allow base box  10  to flatten outwardly, while support tray  200  unfolds below tray cover  220 . In some embodiments, the base box is configured to fold flat outwardly in a first direction, and the tray is configured to fold flat outwardly in a second direction, wherein the second direction is perpendicular to the first direction. In some embodiments, the base box folds flat in both the first direction and the second direction. 
       FIG.  15    shows lid  30 , which may be included in packaging  1 , as a cover to base box  20 . Lid  30  may be formed similarly to base box  20 . Lid  30  may include top panel  300 , with side panels  302  and panels  304  extending outward and foldable downward to provide for an interior cavity forming the opening of lid  30 . In some embodiments, the lid includes foldable wings  310  to couple adjacent ends of the four lid side panels, respectively, and each wing  310  may be foldably attached to one of a pair of adjacent ends of the four lid side panels and is received within a pocket of the other of the pair of adjacent ends of the four lid side panels. In some embodiments, when the lid  30  is coupled to the base box  10 , the pockets of the base box  10  are perpendicular to the pockets of the lid  30 . For example, in a rectangular configuration (where the base and lid both have cooperating rectangular forms), wings may extend from panels forming the shorter sides of the base box, and wings may extend from panels forming the longer sides of the lid, or vice versa. In this way, additional structural support is provided in an assembled, closed configuration, in that the collapsing direction for the base box and lid are opposing and retain each other in an assembled state. Specifically, the lid panels that rotate outward first to remove the lid wings are the perpendicular to the base panels that rotate outward first to remove the base wings. As shown, panels  300 ,  302 , and  304  may all be formed from a continuous sheet (e.g., a cardboard blank). Upper lid cover  308  wraps around panels  300 ,  302 , and  304 , holding the assembled shape of lid  30 . As with lower box cover  108 , in some embodiments, lid cover  308  may be made of a higher end finished paperboard, such that a separate material for panels  300 ,  302 , and  304  may be hidden in use. As can be appreciated, panels  313  and  312  match to the outside surfaces of panels  302  and  304 , respectively, when the lid cover is folded into an assembled configuration. Panels  314  and  315  in turn fold over and match to the inside surfaces of panels  302  and  304 , respectively. Wing guides  306  may be fixed to panels  302  or  304 , and are configured to accommodate and aid in guiding wings  310  to be folded into a pocket between panel  312  on the lid cover  308  and side panel  304 . 
     Finally,  FIG.  16    shows an embodiment of base box  40 , having a similar configuration as base box  10 . Base box  40  may include bottom panel  400 , with side panels  402  and panels  404  extending outward and foldable upward to provide for an interior cavity forming the opening of base box  40 . In  FIG.  16   , it is shown that side panel  404  includes a retention element  420 , formed as an aperture. Wing  416  includes a corresponding protrusion  417  that together form a mechanical lock, such that in order to begin the flattening of base box  40 , a sufficient force to overcome such a lock must be applied. In this regard, a tactile or audible cue may be perceptible given a threshold force such that it indicates the function of the flattening state is intended to the end user. Additionally, these mechanical locks increase structural robustness, e.g., protecting against drop events or other shipping vibrations to maintain the packaging  1  in an aesthetic and structurally sound condition until the end consumer decides to dispose of the packaging  1 . Alternative constraints may be applied, such that the wings are fixed in a particular orientation but free to deflect in response to a sufficient applied force. 
     Because the each of the components may be composed of recyclable cardboard that is a biodegradable or compostable material, if the other materials used are also similarly biodegradable or compostable, if and when the customer opts to dispose of the packaging, the packaging may simply be recycled without requiring material separation (e.g., in a single-stream recycling program). Advantageously, this improves upon prior systems having, for example, expanded polystyrene, foams, plastic inserts, or plastic film retention systems, which do not afford an environmentally friendly solution. The flattening aspect further improves upon other packaging systems that are not easily prepared for recycling without destructive force. 
     Components of packaging  1 , such as base boxes  10 / 40 , tray  20 , and lid  30 , may be formed from one or more cardboard blanks. In some embodiments, the blank is formed of a single continuous substrate, such as, for example cellulose-based material like cardboard corrugate. Other cellulose-based materials are contemplated, such as paperboard, certain molded fiber components of sufficient construction, or grayboard. Tabs, flaps, and regions without adhesive of the blank are folded such that no adhesive is visible in finished packaging  1 . In some embodiments, adhesive may be omitted and the various flaps and tabs attached in another suitable manner (e.g., by mechanical interlock or press fit). 
     Each of the components and their constituent parts, and other variations described herein may include corresponding features described with reference to each of the other components and features described without limitation. 
     In some embodiments, any surface finishing may take place after the components are cut from the blank, or alternatively prior to the blank being cut into separate sheets for assembling to a final product. Additionally, some operations may be performed concurrently. All or some of the surfaces of the packaging may be coated, or laminated, which may increase structural strength properties such as rigidity and which may protect a product within the packaging, or avoid scratching. 
     Additionally, the packaging may be manufactured in a cost-effective and environmentally-friendly way. In some embodiments, the packaging components may be constructed of a single integrally-formed piece of material. The single integrally-formed piece of material may be a foldable material that is folded into a configuration that holds and secures a product, either alone or within a cavity of a packaging container. In some embodiments, the foldable material may be a single piece of material that is cut by a single operation (e.g., a single die-cutting operation). In some embodiments, the foldable material may be die cut from a stock material (e.g., a sheet of cardboard corrugate, or roll of material), or other fiber or cellulose based material. Single integrally-formed pieces of material that are cut by a single cutting operation may facilitate efficient and reproducible manufacturing. Moreover, such manufacturing may reduce waste by reducing waste material during manufacturing. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings 
     It is well understood that the use of personally identifiable information should follow privacy policies and practices that are generally recognized as meeting or exceeding industry or governmental requirements for maintaining the privacy of users. In particular, personally identifiable information data should be managed and handled so as to minimize risks of unintentional or unauthorized access or use, and the nature of authorized use should be clearly indicated to users.

Metadata:
Filing Date: 20210128
Publication Date: 20231128
Grant Date: 20231128
Priority Date: 20210128
Inventors: UYEDA, Mark T.
Assignee: APPLE INC
CPC Classifications: [{"code": "B65D5/5038", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D5/321", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/4266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D77/042", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D2577/041", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D5/321", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D5/5038", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D5/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02W30/80", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D5/4266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D2577/041", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D77/042", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/321", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 82495371