PATENT DOCUMENT

Publication Number: US-9738424-B2
Application Number: US-201414328974-A
Country: US
Kind Code: B2

Title: Molded fiber packaging

Abstract:
Packaging used to hold and ship consumer products may include components having complementary edges that are coupled together when the packaging is assembled. The packaging may also display a product in an aesthetically appealing way by holding the product in way that makes it appear as if the product is “floating.” The packaging may be made of recyclable and/or biodegradable material, such as molded fiber paper material that reduces the environmental impact of the packaging.

Claims:
What is claimed is: 
     
       1. Packaging for a product, the packaging comprising:
 a lid comprising an exterior shell and a lid insert; and 
 a pedestal comprising a frame, a base permanently affixed to the frame, and a pedestal insert disposed between the frame and the base and coupled to at least one of the frame or the base; 
 wherein the frame comprises a top wall and a perimeter side wall disposed below the top wall, 
 wherein the lid is configured to receive at least a portion of the perimeter side wall of the frame; and 
 wherein the frame is a single monolithic piece made of molded fiber paper. 
 
     
     
       2. The packaging of  claim 1 , wherein the frame includes a chamfered bottom edge and the base includes a chamfered side edge. 
     
     
       3. The packaging of  claim 2 , wherein the bottom edge of the frame and the side edge of the base are chamfered at complementary angles. 
     
     
       4. The packaging of  claim 1 , wherein the frame comprises
 a convex curved wall connecting the top wall and the perimeter side wall. 
 
     
     
       5. A packaged product comprising:
 the packaging of  claim 1 ; and 
 a product in contact with the top wall. 
 
     
     
       6. The packaged product of  claim 5 , wherein a perimeter of the top wall is no greater than a perimeter of the product. 
     
     
       7. The packaged product of  claim 5 , wherein a perimeter of the perimeter side wall is equal to a perimeter of the product. 
     
     
       8. The packaged product of  claim 5 , wherein the top wall has a vertical orthographic projection and the product has a vertical orthographic projection, and wherein the projection area of the vertical orthographic projection of the top wall is less than the projection area of the vertical orthographic projection of the product. 
     
     
       9. The packaged product of  claim 5 , wherein the frame comprises a curved wall connecting the top wall and the perimeter side wall, and wherein an outer perimeter of an orthographic projection of the curved wall in a direction perpendicular to the top wall is greater than or equal to a perimeter of an orthographic projection of the product in a direction perpendicular to the top wall. 
     
     
       10. The packaging of  claim 1 , wherein at least a portion of the lid insert is in contact with at least a portion of the perimeter side wall when the packaging is assembled. 
     
     
       11. The packaging of  claim 1 , wherein the top wall defines at least one recess for receiving an accessory. 
     
     
       12. The packaging of  claim 1 , wherein the top wall defines a plurality of indentations configured to locate the product on the top wall. 
     
     
       13. The packaging of  claim 1 , wherein the exterior shell, the lid insert, the frame, and the base are made of molded fiber paper. 
     
     
       14. The packaging of  claim 1 , wherein the pedestal insert is adhesively bonded to at least one of the base or the frame. 
     
     
       15. A packaged product comprising:
 the packaging of  claim 1 ; and 
 a product. 
 
     
     
       16. The packaged product of  claim 15 , wherein the lid insert and the frame form a cavity when the packaging is assembled, the size and shape of the cavity corresponding to the size and shape of the product. 
     
     
       17. A packaged product comprising:
 a product; and 
 packaging comprising:
 a lid comprising an exterior shell and a lid insert; and 
 a pedestal comprising a frame, a base attached to the frame, and a pedestal insert disposed between the frame and the base and coupled to at least one of the frame or the base; 
 
 wherein the lid is configured to receive at least a portion of the pedestal; and 
 wherein at least one of the exterior shell, the lid insert, the frame, or the base is made of molded fiber paper, and 
 wherein no portion of the pedestal surrounds a perimeter edge of the product. 
 
     
     
       18. A packaged product comprising:
 a product; 
 a pedestal for holding the product, the pedestal comprising:
 a frame, the frame comprising:
 a top wall; 
 a side wall disposed below the top wall; 
 a wall curved along its length from the top wall to the side wall; and 
 a base attached to the frame; and 
 
 a lid covering the product; 
 wherein the product is disposed on the top wall of the pedestal above the side wall and curved wall; and 
 wherein no portion of the side wall surrounds a perimeter edge of the product. 
 
 
     
     
       19. The packaged product of  claim 18 , further comprising a pedestal insert disposed between the frame and the base and coupled to at least one of the frame or the base. 
     
     
       20. The packaged product of  claim 19 , wherein the base and frame together define a cavity, and
 wherein the pedestal insert is disposed in the cavity. 
 
     
     
       21. The packaged product of  claim 20 , wherein the cavity is completely enclosed by the frame and the base. 
     
     
       22. The packaged product of  claim 18 , wherein a perimeter of the side wall is equal to a perimeter of the product. 
     
     
       23. The packaged product of  claim 18 , wherein the top wall of the frame has a vertical orthographic projection and the product has a vertical orthographic projection, and wherein the projection area of the vertical orthographic projection of the top wall of the frame is less than the projection area of the vertical orthographic projection of the product. 
     
     
       24. The packaged product of  claim 18 , wherein an outer perimeter of a vertical orthographic projection of the curved wall is greater than or equal to a perimeter of a vertical orthographic projection of the product. 
     
     
       25. The packaged product of  claim 18 , wherein the pedestal is made of molded fiber paper. 
     
     
       26. The packaged product of  claim 18 , wherein the side wall includes a chamfered bottom edge and the base includes a chamfered side edge. 
     
     
       27. The packaged product of  claim 26 , wherein the bottom edge of the side wall and the side edge of the base are chamfered at complementary angles. 
     
     
       28. The packaged product of  claim 26 , wherein the chamfered bottom edge of the side wall is coupled to the chamfered side edge of the base. 
     
     
       29. The packaged product of  claim 18 , wherein the frame is a single monolithic piece. 
     
     
       30. The packaged product of  claim 18 , wherein the top wall forms an uppermost portion of the pedestal.

Description:
FIELD 
     The described embodiments relate generally to packaging for a consumer product. More particularly, the embodiments relate to packaging that displays a product in an aesthetically appealing way. 
     BACKGROUND 
     Packaging for consumer products protects products from damage and facilitates brand recognition. Effective packaging can be an important marketing tool used to attract and retain customers. 
     SUMMARY 
     Packaging for consumer products protects products from damage and facilitates brand recognition. Packaging should provide adequate protection for a product during shipping and handling. Additionally, effective packaging can be an important marketing tool used to attract customers. Packaging should hold and display a product in an aesthetically appealing way that catches a consumer&#39;s attention. Effective packaging should catch a consumer&#39;s attention and focus that attention on the product rather than the packaging itself. 
     Environmental considerations may play a role in designing packaging. For example, packaging may be designed to be environmentally friendly. Packaging made out of recyclable and/or biodegradable materials can reduce environmental impact. Maintaining desired aesthetics and function of packaging in view of such environmental considerations can be a challenge. 
     The packaging according to embodiments described herein, or elements thereof, accomplish one or more of these and other objectives. 
     Some embodiments include packaging for a product including a lid having an exterior shell and a lid insert, a pedestal having a frame, a base attached to the frame, and a pedestal insert disposed between the frame and the base and coupled to (e.g., by adhesive bonding) at least one of the frame or the base. The lid being configured to receive at least a portion of the pedestal. At least one of the exterior shell, the lid insert, the frame, or the base may be made of molded fiber paper. The molded fiber paper may comprise 60% to 70% bamboo fibers and 30% to 40% bagasse fibers. 
     In some embodiments, the frame includes a chamfered bottom edge and the base includes a chamfered side edge. In some embodiments, the chamfered angle of the chamfered bottom edge of the frame is complementary to the chamfered angle of the chamfered side edge of the base. 
     In some embodiments, the frame includes a top wall, a side wall surrounding the top wall, and a convex curved wall connecting the top wall and the side wall. 
     In some embodiments, the packaging includes a packaged product in contact with the top wall. A perimeter of the side wall may be equal to or no greater than a perimeter of the product. The projection area of a vertical orthographic projection of the top wall (e.g., in a direction perpendicular to the top wall) may be less than the projection area of a vertical orthographic projection of the product. In some embodiments, a perimeter of a vertical orthographic projection of the top wall and curved wall is greater than or equal to a perimeter of a vertical orthographic projection of the product. 
     In some embodiments, at least a portion of the lid insert is in contact with at least a portion of the side wall when the packaging is assembled. 
     In some embodiments, the top wall defines at least one recess for receiving an accessory, and may define a plurality of indentations configured to locate the product on the top wall. In some embodiments, the packaging includes a packaged product, where the lid insert and the frame form a cavity when the packaging is assembled, the size and shape of the cavity corresponding to the size and shape of the product. In some embodiments, no portion of the pedestal surrounds a perimeter edge of the product. 
     In some embodiments, the frame and/or the base is a monolithic piece. 
     Some embodiments include a pedestal for holding a product, the pedestal including a frame and a base attached to the frame, the frame including a top wall, a side wall surrounding the top wall, and a convex curved wall connecting the top wall and the side wall. The top wall of the pedestal may be configured to hold the product and a perimeter of the side wall may be no greater than a perimeter of the product. In some embodiments, the base and frame together define a cavity and the pedestal insert is disposed in the cavity. In some embodiments, the cavity is completely enclosed by the frame and the base. 
     Some embodiments include a method of making molded fiber packaging including forming a pedestal. The pedestal may be formed using operations including: forming a molded fiber paper green body of a frame, the frame having a top wall surrounded by a side wall, the side wall having a bottom edge; forming a molded fiber paper green body of a base, the base comprising a side edge; drying the green body of the frame and the green body of the base; chamfering the bottom edge of the fame; chamfering the side edge of the base such that the chamfered side edge of the base is complimentary to the chamfered bottom edge of the frame; and assembling the frame and the base by adhering the frame to the base such that the chamfered bottom edge of the side wall is coupled to the chamfered side edge of the base. 
     In some embodiments, the method includes forming a lid. The lid may be formed using operations including: forming a molded fiber paper green body of an exterior shell; forming a molded fiber paper green body of a lid insert; drying the green body of the exterior shell and the green body of the lid insert; and adhering the exterior shell to the lid insert. 
     In some embodiments, the method includes assembling the lid and the pedestal by placing the lid over the pedestal. In some embodiments, the lid is configured to receive at least a portion of the pedestal. In some embodiments, the lid is configured to receive the entire pedestal. In some embodiments, at least a portion of the lid insert is in contact with at least a portion of the side wall when the packaging is assembled. 
     In some embodiments, the method includes forming a pedestal insert and adhering the pedestal insert to either the frame or the base before assembling the frame and the base. 
     In some embodiments, the base and frame together define a cavity, where the pedestal insert is disposed in the cavity and adheres to both the frame and the base when the frame and the base are assembled. 
     In some embodiments, the green body of the frame and the green body of the base are formed using a first set of molds. In some embodiments, the frame and the base are dried in a second set of molds while applying heat and pressure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, where like reference numerals designate like structural elements, and in which: 
         FIG. 1  shows an exploded view of packaging according to an embodiment. 
         FIG. 2  shows an exploded view of a packaging lid according to an embodiment. 
         FIG. 3  shows an exploded view of a packaging lid according to an embodiment. 
         FIG. 4  shows an assembled cross-sectional view of a packaging lid according to an embodiment. 
         FIG. 5  shows an exploded view of a packaging pedestal according to an embodiment. 
         FIG. 6  shows an exploded view of a packaging pedestal according to an embodiment. 
         FIG. 7  shows a cross-sectional view of a packaging pedestal according to an embodiment. 
         FIG. 8  shows cross-sectional view of a packaging pedestal and a product according to an embodiment. 
         FIG. 9  shows a packaging pedestal and a two-dimensional orthographic projection thereof according to an embodiment. 
         FIG. 10  shows a product and a two-dimensional orthographic projection thereof according to an embodiment. 
         FIG. 11  shows a comparison of the two-dimensional orthographic projection of  FIG. 9  and the two-dimensional orthographic projection of  FIG. 10 . 
         FIG. 12  shows a cross-sectional view of a product housed within packaging according to an embodiment. 
         FIG. 13  shows a flowchart for a method of making a packaging pedestal according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. 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. 
     References to “one embodiment,” “an embodiment,” “some embodiments,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. 
     The packaging described herein may be used to hold and ship items, such as, for example, consumer products. The packaging is structurally robust and protects the product during shipping and handling. The packaging may form an internal cavity shaped to conform to the shape of the product. Shaping the internal cavity in this way may prevent the product from moving during shipping and handling, thereby preventing damage to the product. The packaging may be made of lightweight material, which reduces shipping cost. Additionally, the packaging can include components having complementary edges that are coupled together when the packaging is assembled. Complementary edges aid in concealing seams between different components of the packaging, making at least a portion of the packaging look like a single monolithic piece when in fact it may be composed of various pieces. Complementary edges may also increase the structural integrity of the packaging. 
     The packaging described herein may also present and display the product in an aesthetically appealing way, promoting a continuity in user experience from packaged product to user device in an ordered and intuitive way during the unboxing process. In some embodiments, the packaging may include a pedestal configured to hold the product in a way that makes it appear as if the product is “floating” above the pedestal. A “floating” product catches a consumer&#39;s eye and focuses their attention on the product itself rather than the packaging. A “floating” product may also indicate to a consumer that a certain product is associated with a specific brand. In other words, the “floating” product may spark brand recognition that attracts consumers. 
     Furthermore, the packaging described herein may be made of recyclable and/or biodegradable material that reduces the environmental impact of the packaging. In some embodiments, at least one component of the packaging may be made from molded fiber paper. 
     These and other embodiments are discussed below with reference to  FIGS. 1-13 . 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. 
     Embodiments of the present invention include packaging  100  for protecting and displaying consumer products. As shown in  FIG. 1 , packaging  100  may include a lid  110  and a pedestal  150 . The lid may be composed of an exterior shell  120  and a lid insert  130 . In some embodiments, as shown in  FIGS. 2-4 , the exterior shell  120  and the lid insert  130  are separate monolithic pieces that are bonded together, using for example, an adhesive, tape, or welding. In some embodiments, exterior shell  120  and lid insert  130  may be a single integrally formed monolithic piece. Exterior shell  120  includes an exterior top surface  122 , an exterior side surface  124 , and a shell edge  126 . In some embodiments, exterior top surface  122  and/or exterior side surface  124  include indicia, including, for example, logos, brand names or colors, or product names. Exterior shell  120  also includes a lid cavity  128  having an interior side surface  127  and an interior top surface  129 , lid cavity  128  being configured to receive at least a portion of lid insert  130 . In some embodiments, lid cavity  128  may receive the entire lid insert  130 . 
     As shown in  FIGS. 2 and 3 , lid insert  130  includes a top surface  132 , a side surface  134 , and an insert edge  136 . Lid insert  130  also includes an insert cavity  138  having a side surface  135  and a top surface  139 . In some embodiments, top surface  139  may be shaped that so that it conforms to the exterior shape of a product  200 . In some embodiments, top surface  139  may include a flange or cavity  137  that conforms to the exterior shape of product  200  (see  FIG. 12 ). A top surface  139  that conforms to the exterior of a product  200  helps prevent the product  200  from moving or shifting during shipping and handling, thereby reducing potential damage to the product  200  and maintaining the product in the desired position for presentation upon opening the packaging. Insert cavity  138  may be configured to receive at least a portion of pedestal  150  when packaging  100  is assembled. In some embodiments, insert cavity  138  may be configured to receive the entire pedestal  150  along with product  200  (see  FIG. 12 ). In embodiments where exterior shell  120  and lid insert  130  are separate pieces, differently shaped lid inserts  130  may be interchanged during assembly to accommodate differently shaped products without having to alter the exterior shell  120 . 
       FIG. 4  shows exterior shell  120  and lid insert  130  assembled according to an embodiment. As shown in  FIG. 4 , exterior shell  120  may receive the entire lid insert  130  such that shell edge  126  aligns with insert edge  136 . When exterior shell  120  and lid insert  130  are assembled, side surface  134  of lid insert  130  may couple with (e.g., be in contact with) interior side surface  127  of exterior shell  120  and at least a portion of top surface  132  may couple with (e.g., be in contact with) interior top surface  129  of lid cavity  128 . Exterior shell  120  and lid insert  130  may be bonded together at the interface between side surface  134  of lid insert  130  and interior side surface  127  of exterior shell  120  and/or at the interface between top surface  132  of lid insert  130  and interior top surface  129  of exterior shell  120 . 
       FIGS. 5-7  show pedestal  150  according to an embodiment. Pedestal  150  may include a pedestal frame  160 , a pedestal insert  180 , and a base  190 . Pedestal frame  160 , pedestal insert  180 , and base  190  may be separate monolithic pieces that are bonded together, using for example, adhesive, tape, or welding. 
     Pedestal frame  160  may include a continuous outer surface  161  defined by a top wall  162 , a convex curved wall  164 , and a side wall  166 , side wall  166  including a bottom edge  168 . In some embodiments, frame  160  is a single monolithic piece. In other words, top wall  162 , convex curved wall  164 , and side wall  166  are formed as a single piece using, for example, casting, molding, and/or machining. In some embodiments, bottom edge  168  may be chamfered so as to couple with a side edge  196  of base  190  (described further below). 
     Top wall  162  may include at least one recess  172  for housing accessories, such as, for example, a power cord, a USB cord, or an instruction manual. Top wall  162  may also include at least one indentation  176  for locating product  200  in the correct intended position on top wall  162 . For example, top wall  162  may include four indentations  176  for receiving corresponding protrusions (e.g., “feet”) on the bottom of product  200 . Indentations  176  may ensure that product  200  is properly aligned in an aesthetically appealing intended location on top wall  162 . While  FIG. 4  shows four indentations  176 , any number of indentations  176  may be present on to wall  162 . In some embodiments, proper positioning of product  200  may be achieved through protrusions on top wall  162  to be received by indentations in product  200 . 
     As shown in  FIG. 5 , convex curved wall  164  surrounds top wall  162  and separates top wall  162  from side wall  166 . Side wall  166  surrounds top wall  162  and extends from convex curved wall  164  to bottom edge  168 . In some embodiments, side wall  166  is oriented in a direction perpendicular to top wall  162 . Convex curved wall  164  may have any radius of curvature. In some embodiments, the radius of curvature of convex curved wall  164  is between 1 mm and 10 mm. In some embodiments, the radius of curvature of convex curved wall  164  is between 7 mm and 10 mm. In some embodiments, the radius of curvature of convex curved wall  164  is between 8 mm and 9 mm. Convex curved wall  164  also includes rounded corners  170 . In some embodiments top wall  162  and side wall  166  each extend tangent to convex curved wall  164 . Wall  164  is shown having a convex curve for exemplary purposes. Wall  164  need not have a convex curve, but in some embodiments may instead have a different shape, such as, for example, a chamfer, one or more steps, or a concave curve. 
     As shown in  FIG. 6 , the underside of pedestal frame  160  may include a frame cavity  174  having a cavity surface  175 . Cavity surface  175  may have projections  177  corresponding to recesses  172  on top wall  162 . Frame cavity  174  may be sized and shaped to receive pedestal insert  180 . In some embodiments pedestal insert  180  may include a hollow interior  182  for receiving projections  177 . Pedestal insert  180  may also include a top wall  184 , a bottom wall  185 , an interior side wall  186 , and an exterior side wall  188  defining a hollow three-dimensional shape. Pedestal insert  180  may provide structural support for pedestal  150 . For example, pedestal insert may help prevent damage to product  200  should packaging  100  be dropped during shipping or handling by inhibiting flexure of frame  160 . In some embodiments, pedestal insert  180  is bonded to at least one of pedestal frame  160  or base  190 . 
     As shown in  FIGS. 5 and 6 , base  190  includes an upper surface  192 , a lower surface  194 , and side edge  196 . Side edge  196  may chamfered so as to couple with bottom edge  168  of pedestal frame  160 . When base  190  and frame  160  are assembled, as shown in  FIG. 7 , base  190  closes the bottom end of cavity  174 . In other words, frame  160  and base  190  define and completely enclose cavity  174 . In some embodiments, base  190  may be a single monolithic piece. 
       FIG. 7  shows an assembled view of pedestal  150  according to an embodiment. As shown in  FIG. 7 , bottom edge  168  includes a chamfer that complements a chamfer on side edge  196  of base  190 . The chamfer on bottom edge  168  and side edge  196  may have complementary angles (i.e., any angles as long as the sum of the chamfer angles on bottom edge  168  and side edge  196  equals 90°). In some embodiments bottom edge  168  may have a chamfer angle  163  of 45° and side edge  196  may have a chamfer angle  193  of 45°. In some embodiments, bottom edge  168  may have a chamfer angle  163  of 30° and side edge  196  may have a chamfer angle  193  of 60°. Chamfering edges  168  and  196  creates an aesthetically appealing, crisp, and robust edge for assembled pedestal  150 . Chamfered edges  168  and  196  aid in concealing seams between different components of pedestal  150  (e.g., seam  195 ) and make pedestal  150  look like a single solid piece. In some embodiments, edges  168  and  196  are not chamfered and/or are not coupled together when pedestal is assembled. In such embodiments, bottom edge  168  may couple with upper surface  192  or side edge  196  may couple with cavity surface  175 . 
     As shown in  FIG. 7 , pedestal insert  180  may contact upper surface  192  of base  190  and cavity surface  175  of pedestal frame  160 . Contact between the pedestal insert  180 , upper surface  192  and cavity surface  175  provides increased structural support for packaging  100 . In some embodiments, pedestal insert  180  may be bonded to at least one of upper surface  192  or cavity surface  175  using for example, adhesive, tape, or welding. 
       FIG. 8  shows pedestal  150  supporting product  200  according to an embodiment. Product  200  may be disposed on pedestal  150  such that it is supported by top wall  162 . The surface area of top wall  162  may be sized such that product  200  extends outward from top wall  162  and extends over convex curved wall  164 , thereby forming a gap  169  between convex curved wall  164  and product  200 . In other words, product  200  may sit proud above convex curved wall  164 , with no packaging around the sides or top of product  200  when lid  110  is removed. This makes the product look like it is “floating” on top of pedestal  150 . A “floating” product may be aesthetically appealing and servers to draw a consumer&#39;s attention to the product  200  rather than pedestal  150  used to hold product  200 , to promote an ordered and intuitive unboxing process. Features of the size and shape of top wall  162 , convex curved wall  164 , and side wall  166  used to create a “floating” product  200  is further described in reference to  FIGS. 9-11 . 
       FIG. 9  shows two-dimensional orthographic projections of top wall  162  and convex curved wall  164  in a vertical direction  10  (e.g., perpendicular to the major part of top wall  162 , or to upper surface  192  of base  190 ). Orthographic projection  300  is a two-dimensional orthographic projection of top wall  162  having a perimeter  302  and a projection area  304 . Orthographic projection  310  is a two-dimensional orthographic projection of top wall  162  and convex curved wall  164  together, and has a perimeter  312  and a projection area  314  (which includes projection area  304 ). Projection area  314  may encompass the vertical orthographic projection of side wall  166 . Since convex curved wall  164  surrounds top wall  162 , orthographic projection  310  encompasses orthographic projection  300  and surrounds orthographic projection  300  on all sides.  FIG. 10  shows a two-dimensional orthographic projection  320  of product  200  in vertical direction  10  when product  200  is positioned on top wall  162 , like in  FIG. 8 . Orthographic projection  320  has a perimeter  322  and a surface area  324 . 
       FIG. 11  shows the relative sizes of projection areas  304 ,  314 , and  324  according to an embodiment. Projection area  304  of orthographic projection  300  for top wall  162  has a length (l t ) and a width (w t ). Projection area  314  of orthographic projection  310  for top wall  162  and convex curved wall  164  together has a length (l e ) and a width (w e ). Projection area  324  of orthographic projection  320  for product  200  has a length (l p ) and a width (w p ). For embodiments designed to display a “floating” product, the relationship between these lengths and widths may be represented using one or both of the following inequalities: (1) l e &gt;l p &gt;l t ; and (2) w e &gt;w p &gt;w t . 
     If inequalities (1) or (2) are true, product  200  will extend over convex curved wall  164 , in at least one of the length or width directions. If both inequalities (1) and (2) are true, product  200  will extend over convex curved wall  164  in both of the length and width directions, thus creating gap  169  all the way around curved wall  164 , but will not extend past side wall  166 . In some embodiments, projection area  314  and perimeter  312  of orthographic projection  310  are greater than or equal to surface area  324  and perimeter  322  of orthographic projection  320 . Such a configuration allows lid  110  to fit over product  200  and contact side wall  166  when packaging is assembled. 
     In some embodiments, the length (l p ) and width (w p ) of orthographic projection  320  are less than the length (l e ) and width (w e ) of orthographic projection  310  (see  FIG. 11 ). In other words, perimeter  322  of orthographic projection  320  is no greater than perimeter  312  of orthographic projection  310 . In some embodiments, the length (l p ) and width (w p ) of orthographic projection  320  are equal to the length (l e ) and width (w e ) of orthographic projection  310 . In other words, perimeter  324  of orthographic projection  320  is equal to perimeter  312  of orthographic projection  310 . 
       FIG. 12  shows product  200  housed within assembled packaging  100  according to an embodiment. As shown in  FIG. 12 , lid  110  is placed over pedestal  150  such that pedestal  150  and product  200  are completely received by insert cavity  138 . Furthermore, interior side surface  135  of lid insert  130  is in contact with side wall  166 . The contact between side surface  135  and side wall  166  increases the robustness of packaging  100  and prevents unwanted movement or shifting of pedestal  150  and/or product  200  during shipping and handling. In such embodiments, the height of lid  110  may be such that shell edge  126  and insert edge  136  align with lower surface  194  of base  190 . Furthermore, in the embodiment shown in  FIG. 12 , cavity surface  139  of insert cavity  138  is sized and shaped to conform the exterior surface of product  200 . Insert cavity  138  includes flange  137  that extends inward from side surface  135  so as to contact product  200  when it is positioned on top wall  162 . The particular size and shape shown in the figures is exemplary—it may be modified to correspond to at least some portion of the exterior shape of a product intended to be packaged. 
     In some embodiments, at least one of the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , or base  190  is made of molded fiber paper. The molded fiber paper may be composed of 60 wt % to 70 wt % bamboo fibers and 30 wt % to 40 wt % bagasse fibers. Making at least one of the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , or base  190  out of molded fiber paper reduces the environmental impact of packaging  100  as compared to some other material choices, such as plastics, because the molded fiber paper is recyclable and biodegradable. In some embodiments, the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , and base  190  are all made of molded fiber paper. In some embodiments, the exterior shell  120 , lid insert  130 , frame  160 , and base  190  are made of molded fiber paper and pedestal insert  180  is made of a different material, such as cardboard. In some embodiments, the molded fiber paper can be made waterproof by coating it with a hydrophobic material such as wax. 
     In some embodiments, the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , or base  190  made of molded fiber paper may be manufactured using a two-stage molding process. For exemplary purposes, the process of making pedestal  150  will be described in detail with reference to  FIG. 13 , but it will be understood that exterior shell  120 , lid insert  130 , and/or pedestal insert  180  may be made using similar techniques. In some embodiments, the two-stage molding process for frame  160  may include the below-described operations: 
     A slurry of fiber paper including bamboo and bagasse may be created ( 1100 ), and a molded fiber paper green (i.e., uncured) body of a frame may be created by casting the slurry into a first mold ( 1105 ). In some embodiments, the slurry may include at least bamboo fibers, bagasse fibers, and water. The density of the dried molded fiber may be altered by altering the water content of the slurry. In some embodiments, the first mold may include a top mold and a bottom mold each having a cavity with surface features corresponding to the surface features of frame  160 . During operation, the slurry may be poured between the top mold and the bottom mold in order to form the green body of the frame. In some embodiments, the slurry may be compressed between the top mold and the bottom mold. 
     The molded fiber paper green body of the frame may be removed from the first mold and placed into a second mold ( 1110 ). 
     The molded fiber paper green body of the frame may be dried in the second mold using heat and pressure, thereby forming a finalized frame  160  ( 1115 ). Similar to the first mold, the second mold may have a top mold and bottom mold. However, the cavities of the second mold may have smother surface finishes and higher tolerances than the first mold. The smother surface finishes and higher tolerances of the second mold provide a smooth and aesthetically appealing outer surface for finalized frame  160 . 
     Bottom edge  168  of the frame  160  may be chamfered ( 1120 ). Bottom edge  168  may be chamfered using a cutting or machining tool or may be chamfered by hand. 
     A molded fiber paper green body of a base may be formed by casting the slurry into a third mold ( 1125 ). The third mold may include a top mold and a bottom mold each having a cavity with surface features corresponding to the surface features of base  190 . During operation, the slurry may be poured between the top mold and the bottom mold in order to form the green body of the base. In some embodiments, the slurry may be compressed between the top mold and the bottom mold. 
     The molded fiber paper green body of the base may be removed from the third mold and placed into a fourth mold ( 1130 ). 
     The molded fiber paper green body of the base may be dried in the fourth mold using heat and pressure, thereby forming finalized base  190  ( 1135 ). Similar to the third mold, the fourth mold may have a top mold and bottom mold. However, the cavities of the fourth mold may have a smother surface finishes and higher tolerances than the first mold. The smother surface finishes and higher tolerances of the fourth mold provide a smooth and aesthetically appealing outer surface for finalized base  190 . 
     In some embodiments, the third and fourth molds are sized so as to make a sheet of molded fiber paper that can be cut into multiple bases. For example, the molded fiber paper green body may be formed in a third mold and dried in a fourth mold each having a surface area approximately four times the size of the final base  190 . 
     Side edge  196  of base  190  may be chamfered such that chamfered side edge  196  is complementary to the chamfered bottom edge  168  of frame  160  ( 1140 ). Side edge  196  may be chamfered using a cutting or machining tool or may be chamfered by hand. 
     Pedestal insert  180  may be adhered to either frame  160  or base  190  ( 1150 ). 
     Frame  160  and base  190  may be assembled by adhering frame  160  to base  190  such that chamfered bottom edge  168  couples with chamfered side edge  196  ( 1155 ). Frame  160  may be adhered to base  190  using for example, adhesive and/or tape. For example, adhesive and/or tape may be applied to cavity surface  175  and/or upper surface  192  of base  190  such that the adhesive and/or tape contacts cavity surface  175  and upper surface  192  of base  190  when frame  160  and base  190  are assembled. Also for example, adhesive and/or tape may be applied to chamfered bottom edge  168  and/or chamfered side edge  196  such that the adhesive and/or tape contacts chamfered bottom edge  168  and chamfered side edge  196  when frame  160  and base  190  are assembled. 
     It should be understood that the order of the operations listed above is exemplary. The order of the operations may be rearranged and some operations may be omitted. For example, both the edges could be chamfered after both the frame  160  and the base  190  are finalized. Additionally, some operations may be performed concurrently. For example, frame  160  may be cast and dried at the same time as base  190  is cast and dried. In some embodiments, frame  160  and/or base  190  may be made using a single set of molds. For example, the method of making the pedestal  150  may include only a single set of molds, i.e., only the first mold and the third mold. In such embodiments, frame  160  may be cast and completely dried in the first mold and base  190  may be cast and completely dried in the third mold. In some embodiments, the method of making frame  160  and/or base  190  may include more than two sets of molds. Any number of molds may be used to perfect the surface finish, tolerances, mechanical characteristics, and/or chemical characteristics of frame  160  and/or base  190 . 
     In some embodiments, the thickness of top wall  162 , convex curved wall  164 , and side wall  166  of frame  160  is between 1.5 mm and 0.1 mm. In some embodiments, the thickness of top wall  162 , convex curved wall  164 , and side wall  166  of frame  160  is between 0.5 mm and 0.1 mm. In some embodiments, the thickness of top wall  162 , convex curved wall  164 , and side wall  166  of frame  160  is 0.2 mm+/−0.05 mm. In some embodiments, the thickness of the base is between 1.5 mm and 0.1 mm. In some embodiments, the thickness of base  190  is between 0.5 mm and 0.1 mm. In some embodiments, the thickness of the base is 0.2 mm+/−0.05 mm. 
     Exterior shell  120  and lid insert  130  may have the same or similar thickness as frame  160  and base  190 . Lid  110  may be formed by forming a molded fiber paper green body of an exterior shell, forming a molded fiber paper green body of a lid insert, drying the green body of the exterior shell and the green body of the lid insert, and adhering the exterior shell to the lid insert. 
     In some embodiments, at least one of the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , or base  190  is made of plastic. Suitable plastics include, for example, polyethylene, polypropylene, polyurethane, polystyrene, etc. In such, embodiments, the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , or base  190  may be formed using, for example, injection molding, thermoforming, and/or machining. In some embodiments, the exterior shell  120 , lid insert  130 , frame  160 , pedestal insert  180 , or base  190  are all made of plastic. 
     In some embodiments, pedestal  150  does not include a pedestal insert  180 . In some embodiments, pedestal insert  180  is formed as an integral part of either frame  160  or base  190 . For example, pedestal insert  180  may be formed on upper surface  192  of base  190 . In such an embodiment, interior side wall  186  and an exterior side wall  188  may extend from upper surface  192  to the portion of cavity surface  175  on top wall  162 . 
     In some embodiments, pedestal  150  may be a single monolithic piece. In other words, frame  160  and base  190  (with or without internal support features like pedestal insert  180 ) may be formed as a single piece using, for example, injection molding and/or machining. Additionally, pedestal  150  may not include cavity  174 , but instead may be made of a single block of material. 
     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 many of 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 the purposes of illustration and description. They are not intended 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. 
     The Detailed Description section is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventors, and thus, are not intended to limit the present invention and the appended claims in any way. 
     The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance. 
     The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Metadata:
Filing Date: 20140711
Publication Date: 20170822
Grant Date: 20170822
Priority Date: 20140711
Inventors: KORINEK MICHAEL
SILVANTO MIKAEL
Assignee: APPLE INC
CPC Classifications: [{"code": "Y02W90/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00537", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00527", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00231", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00361", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00268", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00194", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D5/528", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D81/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D43/0222", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D81/133", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02W90/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02W90/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00361", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00268", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00231", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00194", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D81/133", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D81/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D43/0222", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D5/528", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00537", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00527", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00537", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00527", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00361", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00268", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D2543/00194", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D43/0222", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 55067040