PATENT DOCUMENT

Publication Number: US-10301046-B2
Application Number: US-201615204255-A
Country: US
Kind Code: B2

Title: Packaging with lay-flat flaps

Abstract:
A package for an item is disclosed. The package includes an outer box and a first insert panel. The outer box includes a base panel and a first flap extending from the base panel. The first flap is configured to open and close the package. The first insert panel is disposed within the outer box. The first insert panel has a first end attached to the first flap and a second end disposed over the base panel. The first insert panel is configured to support an item within the package. The first insert panel is configured to move relative to the base panel when the first flap is opened. The first insert panel is configured to keep the first flap in an open position by friction between the first insert panel and the base panel.

Claims:
What is claimed is: 
     
       1. A package comprising:
 an outer box having a base panel and a first flap extending from the base panel, the first flap configured to open and close the package; 
 a second flap extending from the base panel opposite the first flap, the second flap configured to open and close the package; 
 a first insert panel disposed within the outer box, the first insert panel having a first end attached to the first flap and a second end disposed over the base panel, the first insert panel configured to support an item within the package; and 
 a second insert panel disposed within the outer box, the second insert panel having a first end attached to the second flap and a second end disposed over the base panel, the second insert panel configured to support an item within the package, 
 wherein the second end of the first insert panel is configured to slide relative to the base panel when the first flap is opened, 
 wherein the first insert panel is configured to keep the first flap in an open position by friction between the first insert panel and the base panel, 
 wherein the second insert panel is configured to move relative to the base panel when the second flap is opened, 
 wherein the second insert panel is configured to keep the second flap in an open position by friction between the second insert panel and the base panel, and 
 wherein the motion of the second insert panel when the second flap is opened is in an opposite direction as motion of the first insert panel when the first flap is opened. 
 
     
     
       2. The package of  claim 1 , wherein the outer box has two side cushioning cells, and wherein the first insert panel is disposed between the two side cushioning cells. 
     
     
       3. The package of  claim 2 , wherein the two side cushioning cells each define a slot near the base panel,
 wherein the second end of the first insert panel comprises a tab disposed within the slot of each of the two side cushioning cells, and 
 wherein the slot guides the motion of the first insert panel. 
 
     
     
       4. The package of  claim 2 , wherein the two side cushioning cells comprise a rectangular prism. 
     
     
       5. The package of  claim 2 , wherein the two side cushioning cells comprise a honeycomb material. 
     
     
       6. The package of  claim 1 , wherein the first end of the first insert panel is attached to the first flap via an adhesive. 
     
     
       7. The package of  claim 1 , further comprising a cushioning cell disposed on a side portion of the first flap adjacent to the first insert panel. 
     
     
       8. The package of  claim 1 , wherein the first flap comprises a side portion forming a side of the outer box and a top portion forming a top of the outer box. 
     
     
       9. The package of  claim 8 , wherein the first end of the first insert panel is attached to the first flap at the side portion. 
     
     
       10. The package of  claim 1 , wherein the material of the package causes the first flap to be naturally biased toward a closed position, and
 wherein the friction between the first insert panel and the base panel contributes to overcoming the bias to keep the first flap in the open position. 
 
     
     
       11. The package of  claim 1 , wherein the first insert panel remains parallel to the base panel and slides on the base panel while the second end of the first insert panel slides relative to the base panel when the first flap is opened. 
     
     
       12. A package comprising:
 an outer box having a base panel; and 
 two insert panels disposed on the base panel at a bottom of the package and attached to the outer box, 
 wherein the two insert panels move relative to the base panel when the package transitions between a first position wherein the package is closed and a second position wherein the package is open, 
 wherein there is a larger gap between the two insert panels in the second position than in the first position, 
 wherein the two insert panels comprise tabs, 
 wherein the outer box defines slots that receive the tabs in the first position and the second position, and 
 wherein the tabs move within the slots when the two insert panels move between the first position and the second position. 
 
     
     
       13. The package of  claim 12 , wherein there is no gap between the two insert panels in the first position. 
     
     
       14. The package of  claim 12 , further comprising an item disposed within the outer box. 
     
     
       15. The package of  claim 14 , wherein the item is disposed across the gap, and wherein a weight of the item keeps the two insert panels from moving relative to each other in the absence of applied outside force, thereby keeping the package from moving between closed and open. 
     
     
       16. The package of  claim 12 , wherein the two insert panels each comprise a width that is equal to a width of an interior of the package. 
     
     
       17. The package of  claim 12 , wherein the movement of the two insert panels relative to the base panel comprises the two insert panels sliding relative to the base panel. 
     
     
       18. A package comprising:
 an outer box having a base panel; 
 two insert panels disposed over the base panel and attached to the outer box; and 
 an item disposed within the outer box, 
 wherein the two insert panels move relative to the base panel when the package transitions between a first position wherein the package is closed and a second position wherein the package is open, 
 wherein there is a larger gap between the two insert panels in the second position than in the first position, and 
 wherein the item is disposed across the gap, and wherein a weight of the item keeps the two insert panels from moving relative to each other in the absence of applied outside force, thereby keeping the package from moving between closed and open. 
 
     
     
       19. The package of  claim 18 , wherein the two insert panels are parallel to and in contact with the base panel in both the first position and the second position. 
     
     
       20. The package of  claim 18 , wherein the movement of the two insert panels relative to the base panel comprises the two insert panels sliding relative to the base panel.

Description:
FIELD 
     The described embodiments relate generally to packaging and specifically to packaging that has flaps that stay open after opening the packaging. 
     BACKGROUND 
     Packaging may be used, for example, to store, transport, protect and/or present products to consumers. 
     SUMMARY 
     The present disclosure details systems, apparatuses, and methods related to packaging that has flaps that stay open after opening the packaging. A package may include an outer box having a base panel and a first flap extending from the base panel and a first insert panel disposed within the outer box. The first flap may be configured to open and close the package. The first insert panel may have a first end attached to the first flap and a second end disposed over the base panel. The first insert panel may be configured to support an item within the package. The first insert panel may be configured to move relative to the base panel when the first flap is opened. The first insert panel may be configured to keep the first flap in an open position by friction between the first insert panel and the base panel. 
     In some embodiments, the package also includes a second flap extending from the base panel opposite the first flap and a second insert panel disposed within the outer box. In some embodiments, the second flap is configured to open and close the package. In some embodiments, the second insert panel has a first end attached to the second flap and a second end disposed over the base panel. In some embodiments, the second insert panel is configured to support an item within the package. In some embodiments, the second insert panel is configured to move relative to the base panel when the second flap is opened. In some embodiments, the second insert panel is configured to keep the second flap in an open position by friction between the second insert panel and the base panel. In some embodiments, the motion of the second insert panel when the second flap is opened is in an opposite direction as the motion of the first insert panel when the first panel is opened. 
     In some embodiments, the outer box has two side cushioning cells. In some embodiments, the first insert panel is disposed between the two side cushioning cells. In some embodiments, the two side cushioning cells each define a slot near the base panel. In some embodiments, the second end of the first insert panel comprises a tab disposed within the slot of each of the two side cushioning cells. In some embodiments, the slot guides the motion of the first insert panel and the second insert panel. In some embodiments, the two side cushioning cells comprise a rectangular prism. In some embodiments, the two side cushioning cells comprise a honeycomb material. 
     In some embodiments, the first end of the first insert panel is attached to the first flap via an adhesive. In some embodiments, the package also includes a cushioning cell disposed on a side portion of the first flap adjacent to the first insert panel. In some embodiments, the first flap comprises a side portion forming a side of the outer box and a top portion forming a top of the outer box. In some embodiments, the first end of the first insert panel is attached to the first flap at the side portion. In some embodiments, the material of the package causes the first flap to be naturally biased toward a closed position. In some embodiments, the friction between the first insert panel and the base panel contributes to overcoming the bias to keep the first flap in the open position. 
     In some embodiments, a package includes an outer box having a base panel and two insert panels disposed over the base panel and attached to the outer box. In some embodiments, the two insert panels move relative to the base panel when the package transitions between a first position wherein the package is closed and a second position wherein the package is open. In some embodiments, there is a larger gap between the two insert panels in the second position than in the first position. 
     In some embodiments, there is no gap between the two insert panels in the first position. In some embodiments, the package also includes an item disposed within the package. In some embodiments, the item is disposed across the gap. In some embodiments, a weight of the item keeps the two insert panels from moving relative to each other in the absence of applied outside force, thereby keeping the package from moving between closed and open. 
     In some embodiments, the two insert panels each comprise a width that is equal to a width of an interior of the package. In some embodiments, the two insert panels comprise tabs. In some embodiments, the outer box defines slots that receive the tabs. In some embodiments, the tabs move within the slots when the two insert panels move between the first position and the second position. 
     In some embodiments, a method of packaging a product includes placing an item across a gap between two movable panels of a package. In some embodiments, each of the panels forms a linkage with a flap of the package. In some embodiments, the flaps of the package are open. In some embodiments, the method includes reducing the gap by moving the panels toward each other by closing the flaps of the package. In some embodiments, the weight of the item contributes to maintaining the flaps in a closed position, by contributing to a frictional force between the movable panels and a base panel. 
     In some embodiments, the method includes increasing the gap by moving the panels away from each other by opening the flaps of the package. In some embodiments, the weight of the item contributes to maintaining the flaps in an open position, by contributing to a frictional force between the movable panels and the base panel. 
     In some embodiments, the method includes attaching the two movable panels to the flaps of the package via an adhesive to form the linkage. 
    
    
     
       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 view of a package in a closed configuration according to some embodiments. 
         FIG. 2  shows a package in an open configuration according to some embodiments. 
         FIG. 3  shows a package in an open configuration according to some embodiments. 
         FIG. 4  shows a top view of a package in an open configuration according to some embodiments. 
         FIG. 5  shows a layout of a portion of a package according to some embodiments. 
         FIG. 6  shows a layout of a portion of a package according to some embodiments. 
         FIG. 7  shows a layout of a portion of a package according to some embodiments. 
         FIG. 8  shows a portion of a partially-assembled package according to some embodiments. 
         FIG. 9  shows a portion of a partially-assembled package according to some embodiments. 
         FIG. 10  shows a portion of a partially-assembled package according to some embodiments. 
         FIG. 11  shows an interior portion of a package according to some embodiments. 
         FIG. 12  shows an interior portion of a package according to some embodiments. 
         FIG. 13  shows a portion of a partially-assembled package according to some embodiments. 
         FIG. 14  shows a portion of a partially-assembled package according to some embodiments. 
         FIG. 15  shows a package in a closed configuration according to some embodiments. 
         FIG. 16  shows a package in a closed configuration according to some embodiments. 
         FIG. 17  shows an item in a package according to some embodiments. 
     
    
    
     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 claims. 
     Packaging may be used, for example, to store, transport, protect and/or present products to consumers. Because the consumer is primarily concerned with the product (i.e., an item within the package), it is desirable to have packaging that adequately protects the product but does not interfere with the presentation of the product. Furthermore, because the packaging will likely be discarded, it is desirable to provide packaging made of environmentally friendly materials. In this regard, environmentally friendly materials, such as cardboard, result in packaging flaps that have the tendency to stay in the closed position, thus interfering with the product within the package. Accordingly, improvements in packaging are desirable. 
     The following disclosure relates generally to packaging, and more specifically, to packaging that does not interfere with the presentation of the product within the packaging. In some embodiments of the present invention, the packaging may be used for any product. In some embodiments, the packaging is used for heavy products, but lighter products may also be packaged according to the features disclosed herein. The packaging disclosed herein may be used in a variety of package sizes. 
     In some embodiments, a package includes an outer box and one or more inserts. The outer box may form the majority of the package, including a base and one or more flaps that open and close to open and close the package. An insert may be attached to the outer box such that the insert moves relative to the outer box when the flaps open and close. 
     For example, an insert may be attached at one end to a portion of the flap with the other end resting over the base of the outer box. When the flap opens, the insert moves partially away from its position over the base when the package is closed. Because the movement of the flap is tied to the movement of the insert, the weight of the product within the package may keep the flap open, thus reducing the interference of the flap with the view of the package. In some embodiments, the weight of the package is enough to hold the flap open via the insert, but not so great that an individual cannot easily close the flap when desired. In this regard, the flap may be considered a lay-flat flap, even if the flap does not lay entirely flat. 
     In some embodiments, two flaps are used with two inserts. The two flaps may be disposed on opposite sides. The two inserts move away from each other when the package is opened via the two flaps. The weight of the product within the package may keep both flaps open via the two inserts. 
     In some embodiments, the outer box and/or the inserts provide cushioning cells on the sides of the package. The cushioning cells may assist in protecting the package and also facilitate movement of the inserts and closure of the package, among other things. For example, a cushioning cell of the outer box may include slots to receive a portion of the inserts. The slots may define the possible movement of the inserts. A cushioning cell of the outer box may also include slots to receive a portion of the flaps when the package is closed. 
     These and other embodiments are discussed below with reference to the 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. 
     A package  10 , as shown, for example, in  FIGS. 1-4 , may be used to store, transport, protect, and/or present a product or other item  12 . In  FIG. 1 , package  10  is shown in a closed configuration. In  FIGS. 2-4 , package  10  is shown in an open configuration. In some embodiments, package  10  includes an outer box  20  and one or more inserts  60 . In some embodiments, two inserts  60  may be used. 
     Outer box  20  may form the majority of package  10 . In some embodiments, outer box  20  includes a base  22 , one or more flaps  30 , and one or more cushioning cells  50 . Base  22  may form the bottom of package  10 . As shown in  FIG. 4 , a majority of base  22  may be covered by inserts  60  with a gap  66  between inserts  60 . In some embodiments, flaps  30  extend continuously from base  22 . In some embodiments, two flaps  30  extend continuously from base  22  on opposite sides. 
     As shown, in  FIGS. 2 and 3 , the opening and closing of flaps  30  control the movement of inserts  60  and the gap  66  between inserts  60  due to a linkage between flaps  30  and inserts  60 . Package  10  in  FIG. 3  is open farther than package  10  in  FIG. 2  (i.e., flaps  30  are farther from the closed configuration). As a result, inserts  60  are farther apart from each other, thus increasing the width of gap  66 . In some embodiments, the width of gap  66  is zero when package  10  is closed. In some embodiments, item  12  may affect the movement of inserts  60  and flaps  30 . For example, item  12  may be placed in package  10  across gap  66  between inserts  60 . In some embodiments, the weight of item  12  contributes to maintaining the flaps in a closed position or an open position by contributing to a frictional force between the movable panels and a base panel. 
     In some embodiments, flaps  30  comprise a side portion  32  and a top portion  34 . Side portion  32  may form a side of package  10 . Top portion  34  may form a top of package  10  when package  10  is in a closed position (see  FIG. 1 ). In some embodiments, flaps  30  comprise a tab  36 . For example, as shown in  FIG. 4 , each flap  30  comprises two tabs  36  that may assist in closing package  10 , as discussed in more detail below. In some embodiments, each flap  30  may be differently. For example, one flap  30  may only extend to the middle of package  10  in the closed configuration, while the other flap  30  may extend beyond the middle of package  10  in the closed configuration. This allows for flaps  30  to overlap in the closed configuration. Because flaps  30  may be of different length, tabs  36  on one flap  30  may be located in a different portion of flap  30  than tabs  36  on the other flap  30 , as shown, for example, in  FIG. 4 . 
     In some embodiments, outer box  20  may comprise cushioning cells  50  disposed on those sides of base  22  that do not extend continuously into flaps  30 . In some embodiments, cushioning cell  50  forms a side of package  10 . In some embodiments, cushioning cell  50  protects item  12  from damage (e.g., if package  10  is dropped). In some embodiments, cushioning cell  50  includes a material  55  disposed within a cavity  54  of cushioning cell  50 . In some embodiments, material  55  comprises a honeycomb material, as shown, for example, in  FIG. 9 . In some embodiments, material  55  contributes to the cushioning effect of cushioning cell  50 . 
     In some embodiments, cushioning cell  50  comprises slots  56 . In some embodiments, slots  56  are disposed at a top portion of cushioning cell  50 . For example, slots  56  may be disposed at an outer top portion of cushioning cell  50 , as shown in  FIG. 4 . In some embodiments, slots  56  are configured to receive tabs  36  to assist in closing package  10 . Slots  56  may be disposed anywhere along the length of cushioning cell  50 . In some embodiments, slots  56  are disposed in the middle along the length of cushioning cell  50 . In some embodiments, slots  56  are shaped and sized to receive two tabs  36  (i.e., one from each flap  30 ). Tabs  36  may be positioned along flaps  30  such that when package  10  is in a closed position, tabs  36  will align with slots  56 . 
     In some embodiments, cushioning cell  50  further comprises slots  58 . In some embodiments, slots  58  are disposed at a bottom portion of cushioning cell  50  adjacent to base  22 . In some embodiments, slots  58  are configured to interact with a portion of inserts  60 , as discussed in more detail below. 
     In some embodiments, outer box  20  comprises gussets  40 . For example gussets  40  may be disposed at each corner of package  10 . In some embodiments, gussets  40  fold in between adjacent cushioning cells  50 . In some embodiments, gussets  40  fold in between cushioning cell  50  and side portion  32 . In some embodiments, gussets  40  contribute to the look and feel of package  10 . For example, gusset  40  may be visible to a user when package  10  is closed instead of an interior, unfinished edge of the material that forms outer box  20 . In addition, gussets  40  may also contribute to protecting item  12  within package  10 . 
     In some embodiments, outer box  20  is formed from a single layout, as shown, for example, in  FIG. 5 . In some embodiments, the layout that forms outer box  20  comprises adhesive portions  59  that partially form cushioning cells  50 . The indication of an adhesive portion  59  in  FIG. 5  is not an indication that a particular side of the indicated portion is the side where adhesive is applied. Rather the indication of an adhesive portion  59  means that adhesive may be applied on either side of adhesive portion  59  or both sides of adhesive portion  59 . 
     In some embodiments, adhesive portions  59  are provided with a double-sided adhesive. For example, adhesive portions  59  may be provided with a double-sided adhesive that sticks to that portion of the layout. The opposite side of the double-sided adhesive may include a covering (e.g., paper) that may be peeled off to expose the adhesive. The double-sided adhesive may then stick to another portion of the layout as cushioning cells  50  are formed. In some embodiments, adhesive portions  59  are merely marked as such for a manufacturer to apply adhesive when forming package  10 . The process of forming package  10 , and outer box  20  specifically, out of the layout is discussed in more detail below. 
     Inserts  60  may form an interior portion of package  10 . In some embodiments, inserts  60  are configured to attach to outer box  20 . In some embodiments, inserts  60  are functionally coupled with flaps  30 . For example, in some embodiments, inserts  60  each include a cushioning cell  50 . Thus, while outer box  20  provides cushioning cells  50  disposed on those sides of base  22  that do not extend continuously into flaps  30 , inserts  60  may provide cushioning cells  50  disposed adjacent to side portions  32  of flaps  30 . In some embodiments, cushioning cells  50  of inserts  60  are attached to side portions  32 . For example, an adhesive may be used to attach cushioning cells of inserts  60  to side portions  32 . 
     Thus, in some embodiments, each side of package  10  has a cushioning cell  50 . In some embodiments, cushioning cells  50  frame item  12  as package  10  is opened. In some embodiments, after package  10  is opened, cushioning cells  50  of inserts  60  are spaced from item  12 , thus providing room for a user to lift item  12  out of package  10 . 
     Cushioning cells  50  of inserts  60  are similar to the cushioning cells  50  of outer box  20  described above. For example, cushioning cells of inserts  60  may form a side of package  10  and may protect item  12  from damage (e.g., if package  10  is dropped). Further, cushioning cells  50  of inserts  60  may include a material  55  disposed within a cavity  54  of cushioning cell  50 , such as a honeycomb material, as shown, for example, in  FIG. 9 . Such a material  55  may contribute to the cushioning effect of cushioning cell  50 . Cushioning cells  50  of inserts  60  may differ from cushioning cells  50  of outer box  20  in that cushioning cells  50  of inserts  60  do not have slots  56  or slots  58 . 
     In some embodiments, inserts  60  comprise one or more tabs  64  disposed on an opposite end from cushioning cell  50  of insert  60 , as shown, for example, in  FIG. 6 . In some embodiments, tabs  64  extend into slots  58  when package  10  is made. In some embodiments, the length of slots  58  sets a boundary on how much insert  60  can move relative to outer box  20 . For example, insert  60  can only move until tab  64  abuts an end of slot  58 . Because insert  60  is attached to flaps  30  (e.g., at side portions  32 ), insert  60  moves and tab  64  slides within slot  58  when flaps  30  are opened and closed. Thus, the movement of flaps  30  and inserts  60  are tied to one another due to the mechanical link between flaps  30  and inserts  60  (i.e., portion of insert  60  adhered to portion of flap  30 ). 
     In some embodiments, tabs  64  contribute to inserts  60  moving relative to outer box  20 . For example, tabs  64  may prevent inserts  60  from warping because tabs  64  are disposed within slots  58 . This configuration may help the sliding motion of insert  60  remain consistent over time. In some embodiments, a coating may be applied to tabs  64  that contribute to a smoother sliding motion. 
     In some embodiments, two inserts  60  are used as interior portions of package  10 , as shown, for example, in  FIG. 4 . Each insert  60 , in some embodiments, is a mirror image of the other. In some embodiments, inserts  60  comprise a supporting portion  62 . Supporting portions  62  may cover a majority of base  22  of outer box  20 . Thus, item  12  rests on supporting portions  62 . In some embodiments, the two inserts  60  may form a gap  66  between each supporting portion  62 . Gap  66  may have a larger width when package  10  is in an open configuration than when package  10  is in a closed configuration. 
     In some embodiments, each insert  60  is formed from a single layout, as shown, for example, in  FIG. 6 . In some embodiments, the layout that forms each insert  60  comprises adhesive portions  59  that partially form cushioning cells  50 . The indication of an adhesive portion  59  in  FIG. 6  is not an indication that a particular side of the indicated portion is the side where adhesive is applied. Rather the indication of an adhesive portion  59  means that adhesive may be applied on either side of adhesive portion  59  or both sides of adhesive portion  59 . 
     In some embodiments, adhesive portions  59  are provided with a double-sided adhesive. For example, adhesive portions  59  may be provided with a double-sided adhesive that sticks to that portion of the layout. The opposite side of the double-sided adhesive may include a covering (e.g., paper) that may be peeled off to expose the adhesive. The double-sided adhesive may then stick to another portion of the layout as cushioning cells  50  are formed. In some embodiments, adhesive portions  59  are merely marked as such for a manufacturer to apply adhesive when forming package  10 . The process of forming package  10 , and inserts  60  specifically, out of the layout is discussed in more detail below. 
     In some embodiments, package  10  may be formed from three layouts. In some embodiments, package  10  may be formed from only two layouts. More layouts may be used in some embodiments. To make package  10 , for example, each layout may be cut from a sheet having multiple layouts. In some embodiments, each layout may be die cut. In some embodiments, layouts are made of a corrugated material, such as cardboard (e.g., E-flute corrugated cardboard). In some embodiments, the layouts have a white finish over the corrugated material. In some embodiments, the edges of the layouts may be pre-crushed to reduce the amount of corrugate visible to a user in package  10 . Pre-crushing the edges of tabs  64  may contribute to a smoother sliding motion of inserts  60 . In some embodiments, the layouts include markings or indents where the layout should be folded to form package  10 . For example, the layout may be pre-scored and pre-folded before assembly. 
     With this configuration of package  10 , flaps  30  are lay-flat flaps even though the material, such as cardboard, of flaps  30  tends to return to the closed position. Specifically, the weight of item  12  within package  10  may overcome the tendency of flaps  30  to close and thus interfere with the view of item  12 . In some embodiments, the weight of item  12  is between 5 and 15 pounds. For example, the weight of item  12  is 12 pounds. 
     In some embodiments, cushioning cells  50  may be formed from each of the layouts. For example, the layout for outer box  20  may form two cushioning cells  50  and the layouts for inserts  60  may each form one cushioning cell  50 . As shown in  FIGS. 7 and 8 , for example, cushioning cell  50  may be formed by folding side portions  52  over into a rectangular prism. A side portion  52  may be formed into a rectangular prism on each side of cushioning cell (see  FIG. 8 ). In some embodiments, the portion of the layout next to side portion  52  (i.e., an end of outer box  20  or insert  60 ) may then be folded over to form cushioning cell  50 , as shown, for example, in  FIGS. 8 and 9 . Before folding the cushioning cell  50  over for the last time, a material  55  may be inserted into cushioning cell, as shown in  FIG. 9 . The last adhesive portion  59  will adhere to base  22  for cushioning cells  50  of outer box  20  and to supporting portion  62  for cushioning cells  50  of inserts  60 . Prior to closing cushioning cells  50  on outer box  20 , inserts  60  are placed in the proper position over base  22  so that tabs  64  are aligned with slots  58 , as shown, for example, in  FIG. 10 . When both cushioning cells  50  of outer box  20  have been closed, tabs  64  will be within slots  58 , as shown, for example, in  FIG. 11 . 
     In some embodiments, gusset  40  may be folded inwards to facilitate opening and closing of flaps  30 , as shown, for example, in  FIG. 12 . Each of the gussets  40  may be folded in this manner. In some embodiments, cushioning cell  50  of insert  60  may then be aligned with a boundary between base  22  and side portion  32 , as shown, for example, in  FIG. 13 . In some embodiments, this alignment also aligns the cushioning cell  50  of insert  60  with cushioning cells  50  of outer box  20  (see  FIG. 13 ). Cushioning cell  50  of insert  60  may then be attached to side portion  32 , as shown, for example, in  FIG. 14 . In some embodiments, cushioning cell  50  is attached to side portion  32  with an adhesive (e.g., double-sided adhesive). Each of the inserts  60  may be attached to outer box  20  in this manner. 
     While the manufacture of package  10  has been described in a particular order, the process may be done in a different order. Once all inserts  60  have been attached to outer box  20 , package  10  is ready to be used. In some embodiments, after package  10  is complete, item  12  may be placed within package  10  and flaps  30  may be folded over item  12  to close package  12 . 
     In some embodiments, package  10  is closed as shown, for example, in  FIG. 15 . In some embodiments, one of the flaps  30  is first closed. Tabs  36  on each side of flap  30  are inserted into slots  56 . In some embodiments, the other flap  30  may then be closed and the tabs  36  on each side of flap  30  inserted into slots  56 . In some embodiments, flaps  30  overlap with each other, as discussed above. This may help protect item  12  by keeping dust and other debris out of package  10 . 
     In some embodiments, an adhesive  14  is included over each of the flaps  30  to keep package  10  closed, as shown, for example, in  FIG. 16 . In some embodiments adhesive  14  comprises two adhesive portions, one for each flap  30 . In some embodiments adhesive  14  comprises two adhesive portions separated by a non-adhesive portion. In some embodiments, adhesive  14  includes a ripcord in the non-adhesive portion. When a user is ready to open package  10 , the user may pull on the ripcord to detach flaps  30  from each other. Flaps  30  may then be opened to expose the interior of package  10 . 
     As shown, for example, in  FIG. 17 , an item  12  may be included in package  10 . In some embodiments, the weight of item  12  assists in the functioning of package  10 . For example, the weight of item  12  on top of supporting portion  62  may keep inserts  60  from moving. Thus, when the user opens package  10 , flaps  30  pull inserts  60  apart from each other, increasing the width of gap  66 . The weight of item  12  keeps inserts  60  in this position. As a result, flaps  30  remain open and substantially lay flat. Accordingly, package  10  remains open and flaps  30  do not interfere with the view of item  12 . While the weight of item  12  keeps package  10  open, the weight is not so great that the user cannot easily open flaps  30  or close flaps  30  to return inserts  60  to the closed configuration. 
     The foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. These exemplary embodiments are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. All specific details described are not required in order to practice the described embodiments. 
     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, and that by applying knowledge within the skill of the art, one may readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. 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. For example, in some embodiments, only one flap  30  and one insert  60  may be used. In addition, insert  60  may be attached to flap  30  at a different location of flap  30  (i.e., not at side portion  32 ). In some embodiments, insert  60  may not include cushioning cells  50 . Other variations are also within the scope of this disclosure. 
     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 inventor(s), and thus, are not intended to limit the present invention and the claims. 
     The present invention has been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. 
     The phraseology or terminology used herein is for the purpose of description and not limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan. 
     The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined in accordance with the claims and their equivalents.

Metadata:
Filing Date: 20160707
Publication Date: 20190528
Grant Date: 20190528
Priority Date: 20160707
Inventors: MUNDT, MATTHEW
ANDRE, BARTLEY K.
Assignee: APPLE INC
CPC Classifications: [{"code": "B65B5/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65B7/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D5/6676", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/6629", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/6676", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/6629", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/6629", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65B7/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D5/6676", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65B5/04", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 60892521