PATENT DOCUMENT

Publication Number: US-9975692-B2
Application Number: US-201615236032-A
Country: US
Kind Code: B2

Title: Earphone packaging

Abstract:
A package for an electronic device is disclosed. The package includes a first layer of compressed natural fibers defining an aperture and a second layer of compressed natural fibers disposed adjacent to the first layer of compressed natural fibers. The aperture is configured to receive a portion of the electronic device. The second layer of compressed natural fibers has a flap partially covering the aperture defined by the first layer of compressed natural fibers. The first and second layers of compressed natural fibers are bonded to each other by high-frequency welding.

Claims:
What is claimed is: 
     
       1. A package for an electronic device, the package comprising:
 a first layer of compressed natural fibers defining an aperture, the aperture configured to receive a portion of the electronic device; and 
 a second layer of compressed natural fibers disposed adjacent to the first layer of compressed natural fibers, the second layer of compressed natural fibers having a flap partially covering the aperture defined by the first layer of compressed natural fibers, 
 wherein the first and second layers of compressed natural fibers are bonded to each other by high-frequency welding. 
 
     
     
       2. The package of  claim 1 , wherein the first layer is paper and wherein the second layer is paper. 
     
     
       3. The package of  claim 1 , wherein the second layer of compressed natural fibers comprises two flaps partially covering the aperture defined by the first layer of compressed natural fibers. 
     
     
       4. The package of  claim 1 , further comprising:
 a third layer of compressed natural fibers disposed adjacent to the first layer of compressed natural fibers on an opposite side from the second layer of compressed natural fibers, 
 wherein the first layer of compressed natural fibers defines a second aperture, 
 wherein the third layer of compressed natural fibers comprises a flap partially covering the second aperture defined by the first layer, and 
 wherein the third layer of compressed natural fibers completely covers the aperture defined by the first layer of compressed natural fibers. 
 
     
     
       5. The package of  claim 4 , wherein the third layer of compressed natural fibers is bonded to the second layer of compressed natural fibers by high-frequency welding. 
     
     
       6. The package of  claim 4 , wherein the first, second, and third layers of compressed natural fibers are configured to constrain the portion of the electronic device in three dimensions. 
     
     
       7. The package of  claim 1 , wherein each layer of compressed natural fibers comprises a coating of polypropylene laminate. 
     
     
       8. The package of  claim 1 , wherein the first layer of compressed natural fibers forms an exterior portion of the package. 
     
     
       9. A packaged product comprising:
 the package of  claim 1 ; and 
 a product, wherein the product includes a product body and a cable connected to the product body, 
 wherein a portion of the product body is disposed above the first layer, 
 wherein a portion of the product body is disposed below the first layer, and 
 wherein the cable is not visible from above the first layer. 
 
     
     
       10. The packaged product of  claim 9 , wherein a perimeter of the aperture of the first layer is smaller than a perimeter of the product body. 
     
     
       11. The packaged product of  claim 9 , wherein the flap is biased to press the product body against a perimeter of the aperture. 
     
     
       12. A package for earphones, the package comprising:
 a compressed natural fiber earphone support portion comprising a first compressed natural fiber layer and a second compressed natural fiber layer, the first and second compressed natural fiber layers defining two holes configured to secure the earphones; 
 a compressed natural fiber cable support portion attached to the compressed natural fiber earphone support portion, wherein the cable support portion and the second compressed natural fiber layer are monolithic; and 
 a compressed natural fiber cable guide portion attached to the cable support portion and comprising projections, each projection having tabs on each end disposed at an angle to form an annular guide for a coiled cable of the earphones. 
 
     
     
       13. The package of  claim 12 , further comprising a connector support portion attached to the cable support portion, the connector support portion comprising an aperture configured to receive a connector of the earphones. 
     
     
       14. The package of  claim 13 , further comprising an accessory support portion attached to the connector support portion, wherein the connector support portion comprises an additional aperture configured to receive an accessory. 
     
     
       15. The package of  claim 12 , wherein the cable guide portion comprises a passageway that surrounds the cable of the earphones, and wherein the passageway is configured to break away when a user opens the package, allowing the cable to be removed from the package. 
     
     
       16. The package of  claim 12 , further comprising:
 a side portion that is monolithic with the compressed natural fiber cable support portion and the second compressed natural fiber layer, wherein the side portion forms a side of the package; and 
 two tabs that extend from the cable support portion and each form a side of the package, 
 wherein the two tabs and the side portion are not visible from above the first compressed natural fiber layer when the package is closed. 
 
     
     
       17. The package of  claim 12 , wherein the second compressed natural fiber layer comprises flaps partially covering the two holes to secure the earphones. 
     
     
       18. The package of  claim 12 , wherein a grammage of the first compressed natural fiber layer is greater than a grammage of the second compressed natural fiber layer. 
     
     
       19. Packaged earphones, comprising:
 the package of  claim 12 ; and 
 the earphones, wherein the earphones are secured within the two holes and wherein the cable of the earphones extends from the earphones in a direction parallel to the first and second compressed natural fiber layers, and wherein the cable is not visible from above the first and second compressed natural fiber layers. 
 
     
     
       20. The packaged earphones of  claim 19 , wherein the compressed natural fiber earphone support portion is disposed over the compressed natural fiber cable support portion with a majority of the cable disposed between the compressed natural fiber earphone support portion and the cable support portion.

Description:
FIELD 
     The described embodiments relate generally to packaging and specifically to earphone packaging. 
     BACKGROUND 
     Earphone packaging may be used, for example, to store, transport, protect and/or present earphones to consumers. 
     SUMMARY 
     The present disclosure details systems, apparatuses, and methods related to a package for an electronic device, such as earphone packaging. A package for an electronic device may include a first layer of compressed natural fibers defining an aperture and a second layer of compressed natural fibers disposed adjacent to the first layer of compressed natural fibers. In some embodiments, the aperture receives a portion of the electronic device. In some embodiments, the second layer of compressed natural fibers has a flap partially covering the aperture of the first layer of compressed natural fibers. The first and second layers of compressed natural fibers may be bonded to each other by high-frequency welding. For example, the first and second layers of compressed natural fibers may include a coating or film, such as a polypropylene laminate. The polypropylene laminate of the first and second layers may be high-frequency welded together, thus bonding the first and second layers of compressed natural fibers to each other. 
     In some embodiments, the first layer is paper. In some embodiments, the second layer is paper. In some embodiments, the second layer includes two flaps partially covering the aperture defined by the first layer of compressed natural fibers. In some embodiments, the package also includes a third layer of compressed natural fibers disposed adjacent to the first layer on an opposite side from the second layer. In some embodiments, the first layer defines a second aperture. In some embodiments, the third layer includes a flap partially covering the second aperture defined by the first layer. In some embodiments, the third layer completely covers the aperture defined by the first layer. In some embodiments, the third layer is bonded to the second layer by high-frequency welding. In some embodiments, the first, second, and third layers constrain the electronic device in three dimensions. 
     In some embodiments, each layer of compressed natural fibers includes a coating of polypropylene laminate. The first layer may form an exterior of the package. 
     In some embodiments, a packaged product includes the packaging described above and a product. The product may include a product body and a cable connected to the product body. In some embodiments, a portion of the product body is above the first layer. In some embodiments, a portion of the product body is below the first layer. The cable may not be visible from above the first layer. 
     In some embodiments, a perimeter of the aperture of the first layer is smaller than a perimeter of the product body. The flap may be biased to press the product body against the perimeter of the aperture. 
     In some embodiments, a package includes a compressed natural fiber earphone support, a compressed natural fiber cable support, and a compressed natural fiber cable guide. The compressed natural fiber earphone support may include a first compressed natural fiber layer and a second compressed natural fiber layer. In some embodiments, the first and second compressed natural fiber layers define two holes configured to secure the earphones. In some embodiments, the compressed natural fiber cable support is attached to the compressed natural fiber earphone support. In some embodiments, the cable support and the second compressed natural fiber layer are monolithic. In some embodiments, the compressed natural fiber cable guide is attached to the cable support and includes projections. Each projection may have tabs on each end arranged at an angle to form an annular guide for a coiled cable of the earphones. 
     In some embodiments, the package includes a connector support attached to the cable support. The connector support may include an aperture to receive a connector of the earphones. In some embodiments, the package includes an accessory support attached to the connector support. The accessory support may include an additional aperture to receive an accessory. 
     In some embodiments, the cable guide includes a passageway that surrounds the cable of the earphones. The passageway may break away when a user opens the package, allowing the cable to be removed from the package. 
     In some embodiments, the package includes a side portion that is monolithic with the compressed natural fiber cable support and the second compressed natural fiber layer, and the side portion may form a side of the package. In some embodiments, the package includes two tabs that extend from the cable support, and each may form a side of the package. In some embodiments, the two tabs and the side portion are not visible from above the first compressed natural fiber layer when the package is closed. 
     In some embodiments, the second compressed natural fiber layer includes flaps partially covering the two holes to secure the earphones. In some embodiments, a grammage of the first compressed natural fiber layer is greater than a grammage of the second compressed natural fiber layer. 
     In some embodiments, packaged earphones include the package described above and the earphones. In some embodiments, the earphones are secured within the two holes. In some embodiments, the cable of the earphones extends from the earphones in a direction parallel to the first and second compressed natural fiber layers. In some embodiments, the cable is not visible from above the first and second compressed natural fiber layers. In some embodiments, the compressed natural fiber earphone support is disposed over the compressed natural fiber cable support with a majority of the cable disposed between the compressed natural fiber earphone support and the cable support. 
    
    
     
       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 an earphone package according to some embodiments. 
         FIG. 2  shows a side view of an earphone package according to some embodiments. 
         FIG. 3  shows a partial cross-sectional view taken along line  3 - 3  of  FIG. 1 . 
         FIG. 4  shows a partial cross-sectional view taken along line  4 - 4  of  FIG. 1 . 
         FIG. 5  shows an interior view of an earphone package in an open configuration according to some embodiments. 
         FIG. 6  shows an exterior view of an earphone package in an open configuration according to some embodiments. 
         FIG. 7  shows an interior view of an earphone package in an open configuration according to some embodiments. 
         FIG. 8  shows an exploded view of an earphone package according to some embodiments. 
         FIG. 9  shows a portion of an earphone package according to some embodiments. 
         FIG. 10  shows a portion of an earphone package according to some embodiments. 
         FIG. 11  shows a portion of an earphone package according to some embodiments. 
         FIG. 12  shows a portion of an earphone package according to some embodiments. 
         FIG. 13  shows a portion of an earphone 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. 
     This disclosure relates generally to packaging, and more specifically, to earphone packaging. While earphone packaging is specifically discussed, the principles discussed herein are also applicable to packaging for other products. In some embodiments of the present invention, the packaging may be used for any product, particularly for small, lightweight products. 
     Packaging may be used, for example, to store, transport, protect and/or present products, such as earphones or other electronic devices, to consumers. In some embodiments, earphone packaging may be designed to accomplish several goals. For example, the packaging may protect the earphones (e.g., by securing the earphones in place) while presenting the earphones to consumers, including making the earphones easily accessible for consumers to remove the earphones from the packaging. The use of adhesives may, for example, secure earphones in place, but adhesives may make it more difficult for consumers to remove the earphones from the packaging. Thus, in some embodiments the packaging described herein secures earphones in place while also making earphones easily accessible by using mechanisms and techniques that minimize the use of adhesive. At the same time, because the packaging may be discarded, in some embodiments the packaging is made with a minimal amount of material, and the material is environmentally friendly (e.g., recyclable, for example in a conventional paper recycling stream without requiring deconstruction of the packaging and separation of its component parts). 
     In some embodiments, packaging may be formed of layers of compressed natural fibers (e.g., paper or cardboard, formed of, for example, cellulose, bagasse, or bamboo fibers). The layers of compressed natural fibers may be attached to one another to form the packaging. In some embodiments, the layers of compressed natural fibers are attached by high-frequency welding. In some embodiments, the layers of compressed natural fibers may be attached to one another by adhesive. 
     In some embodiments, an upper surface layer of the packaging defines one or more apertures that receive part of a product. For example, the upper surface layer may include two apertures, one for each earphone in a pair. The apertures may conform to the outline of the earphones, but be slightly smaller than the earphones, so that the earphones can rest against the perimeter of the aperture from underneath without going through the apertures. This can help present the earphones as “floating” within the packaging on the upper surface, especially without any other anchoring or affixing mechanism viewable from above the upper surface. Additional apertures, either in the same layer or a different layer, may be included to receive, for example, a headphone jack, adapter, or other type of electrical connector (e.g., a USB device, an adapter, a power plug, etc.). 
     In some embodiments, a layer of compressed natural fibers adjacent to an aperture includes one or more flaps partially covering the apertures in the adjacent layer. The flap may be biased towards the aperture so that when a product is placed between the flap and the aperture the product is secured in place between the flap and the perimeter of the aperture. In some embodiments, two flaps together secure the product in place. In this way, the flaps can secure the product in place from below the upper visible surface, allowing the product to be showcased from the opposite side of the aperture without the flaps themselves being visible. Furthermore, the flaps may allow easy access to the product for removal from the packaging. For example, the product may be removed by pulling the product between the flaps. 
     In some embodiments, because the particular part of the product is larger than the aperture, the flaps and a perimeter of the aperture form a space for storing the particular part of the product. In some embodiments, a portion of the product extends beyond this space (i.e., above the layer that has the aperture). This portion of the product may be displayed to consumers, thus showcasing the product. 
     In some embodiments, the packaging stores the remainder of the product, such as the cables of the earphones, below the upper layer to be primarily out of sight from the consumer&#39;s view. For example, one or more layers of compressed natural fibers may provide a guide to wrap the cables in an annular (e.g., circular) pattern within the packaging. In some embodiments, one or more layers of compressed natural fibers may have tabs to close the packaging. 
     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. 
     Packaging  100 , as shown, for example, in  FIGS. 1 and 2 , may be used to store, transport, protect, and/or present a product  10  or other item, such as, for example, earphones (sometimes referred to as in-ear headphones or ear pods). In some embodiments, portions of product  10  may be disposed within an interior of packaging  100  and other portions of product  10  may be disposed outside of the interior of (e.g., above) packaging  100 . This may allow a particular part of product  10  to be displayed or presented to consumers while hiding the remainder of product  10  from view. 
     For example, as shown in  FIGS. 1 and 2 , product  10  may include a product body  12  and a cable  14  connected to product body  12 . In some embodiments, product  10  includes two product bodies  12  (e.g., two earphones). In some embodiments, a portion of product body  12  is disposed above an upper layer  400  of packaging  100 . In some embodiments, a portion of product body  12  is disposed within packaging  100 . In some embodiments, cable  14  is not visible from above packaging  100  (see  FIG. 1 ). In some embodiments, cable  14  may be visible from a side view of packaging  100  (see  FIG. 2 ). 
     In some embodiments, packaging  100  is configured to support product  10  in the manner described above (i.e., presenting product body  12  while hiding cable  14 ) so that product  10  stays in place in the absence of applied force, but is also easily and quickly removable from packaging  100 . In some embodiments, packaging  100  comprises a plurality of layers of compressed natural fibers, such as paper, to accomplish this. 
     In some embodiments, various layers of packaging  100  include apertures (e.g., apertures  220 ,  320 ,  420 ,  520 ,  525 ,  530 ,  620 , and  630 ) to receive portions of product  10  (see, e.g.,  FIG. 8 ). In some embodiments, various layers of packaging  100  include flaps (e.g., flaps  222 ,  322 ,  622 , and  632 ) to at least partially cover the apertures and thereby secure the portions of product  10  in place. In some embodiments, the dimensions of the flaps are sized appropriately to secure the particular portion of product  10  in place. For example, in some embodiments, the flaps may extend across an entire aperture. In some embodiments, the flaps may extend along at least half of the length of the exposed portion of product  10 . In some embodiments, the portions of product  10  may be pulled between the flaps to remove product  10  from packaging  100 . In some embodiments, various layers of packaging  100  include tabs (e.g., tabs  230  and sections  238 ) to guide portions of product  10 , such as cable  14 , within packaging  100 . In some embodiments, various layers of packaging  100  may include tabs (e.g., tabs  330 ,  360 , and  540 ) to form sidewalls  306  of packaging  100  (i.e., sides of packaging  100  that appear similar in shape and location to sidewall  305  when packaging  100  is closed). 
     In some embodiments, apertures (e.g., apertures  320  and  420 ) and flaps (e.g., flaps  322 ) create a space to contain product body  12 , as shown, for example, in  FIGS. 3 and 4 .  FIGS. 3 and 4  are schematic representations of partial cross-sections through portions of an aperture and product at locations without flaps ( FIG. 3 ) and with flaps ( FIG. 4 ). In some embodiments, a portion of product body  12  extends above product body section  410 , which may form part of upper layer  400  of packaging  100 , as described below. In some embodiments, a portion of product body  12  extends below product body section  310 , which may form part of a layer  300  below upper layer  400 . Because the edges of product body section  410  and  310  (i.e., the perimeters of apertures  420  and  320 ) are not perfectly aligned (see  FIG. 3 ), product body  12  is less likely to rotate from the desired position of product body  12  for presentation to consumers, as it is partially cradled against the offset between layers. In some embodiments, as shown, for example, in  FIG. 4 , flaps  322  are biased toward apertures  420 . Thus, in some embodiments, flaps  322  are biased to press product body  12  against the perimeter of aperture  420 . 
     In some embodiments, the perimeter of aperture  420  is smaller than a perimeter of product body  12 , or the distance between opposing sides of the aperture is smaller than the width of a corresponding portion of product body  12  (as shown, for example, in  FIG. 4 ). Thus, product body  12  may not fit through aperture  420  unless product body  12  is forced through, layer  400  is flexed, or some other manipulation of packaging  100  allows product body  12  to pass through aperture  420 . In the absence of applied force, product body  12  is secured in place in packaging  100  with only a portion of product body  12  being displayed to consumers (see  FIG. 1 ). In some embodiments, although flaps  322  are biased to press product body  12  toward the perimeter of aperture  420 , product body  12  may be easily removed from packaging  100  by applying force to overcome the bias and pull product body  12  between flaps  322 . 
     In some embodiments, product body section  310  and product body section  410  together secure product body  12  in packaging  100 . In some embodiments, apertures  320  and  420  may imitate the shape of product body  12 . For example, while both apertures  320  and apertures  420  may follow the same contour of the shape of product body  12 , they may overlap portions of product body  12  to different degrees such that the shape of aperture  320  may slightly differ from the shape of aperture  420 . In some embodiments, as shown, for example, in  FIG. 5 , the perimeter of aperture  320  does not match up with the perimeter of aperture  420 . Thus, a portion of product body section  410  may protrude to partially cover aperture  320 . Similarly, in some embodiments, as shown, for example, in  FIG. 6 , the perimeter of aperture  420  does not match up with the perimeter of aperture  320 . Thus, a portion of product body section  310  may protrude to partially cover aperture  420 . In some embodiments, the difference in perimeters of apertures  320  and aperture  420  contributes to securing product body  12  in place. For example, product body  12  may rest on the portion of product body section  310  that protrudes to partially cover aperture  420 , which may assist in preventing rotation of product body  12  or preventing product body  12  from slipping out of place. As an additional example, the portion of product body section  410  that protrudes to partially cover aperture  320  may also assist in preventing rotation of product body  12  or preventing product body  12  from slipping out of place. 
     In some embodiments, aperture  320  and/or aperture  420  may constrain product body  12  in an X and Y direction while flaps  322  may constrain product body  12  in a Z direction (e.g., by being biased to press product body  12  against the perimeter of aperture  320  and/or aperture  420 . In some embodiments, cable  14  extends from product body  12  in a direction parallel to product body section  310  and product body section  410 . In some embodiments, cable  14  abuts the bottom of product body section  310  where cable  14  extends from product body  12 . 
     In some embodiments, additional apertures and flaps may be used in other layers to house other portions of product  10 , such as connector  18 , as shown, for example, in  FIG. 7 . In some embodiments, additional apertures and flaps may be used to house additional accessories. For example, in some embodiments, as shown in  FIG. 8 , packaging  100  comprises layer  200 , layer  300 , layer  400 , layer  500 , and layer  600 . Each of these layers may include one or more apertures and/or one or more flaps, as described in more detail below. In some embodiments, more or fewer layers may be used. The number of layers may depend on the type of product  10  within packaging  100  or the number of accessories included in packaging  100 . 
     In some embodiments, layer  200 , as shown, for example, in  FIG. 9 , operates as a cable guide portion of packaging  100 . In some embodiments, layer  200  comprises a center section  210 . In some embodiments, center section  210  defines an aperture  220 . In some embodiments, one or more flaps  222  (e.g., two flaps  222 ) extend from center section  210  over aperture  220 . In some embodiments, tabs  230  extend from opposite ends of center section  210 . Tabs  230  may be folded to create the cable guide portion of packaging  100 . 
     For example, tabs  230  may include sections  232 ,  234 ,  236 , and  238 . In some embodiments, sections  232 ,  234 , and  236  may be folded (e.g., at right angles to each other) to form a passageway  239  for retaining cable  14  coiled within packaging  100  (see  FIG. 7 ). In some embodiments, section  232  is folded at a 90 degree angle to center section  210  to form an inner sidewall of the passageway  239 . In some embodiments, section  234  is folded at a 90 degree angle to section  232  to form a top of the passageway  239 . In some embodiments, section  236  is folded at a 90 degree angle to section  234  to form an outer sidewall of the passageway  239 . Thus, cable  14  may be coiled within packaging  100 , and passageway  239  may be created by folding sections  232 ,  234 , and  236 , as described above, around cable  14  such that cable  14  passes between sidewall sections  232  and  236  and underneath top section  234  (see  FIG. 7 ). 
     In some embodiments, sections  238  are folded towards the center of layer  200  to act as tabs against which cable  14  coils within packaging  100  (see  FIG. 7 ). The diameter at which cable  14  coils within packaging  100  may depend on the degree to which sections  238  are folded relative to section  232 , thereby providing flexibility in the coil diameter of cable  14 , which can help to ensure that components of product  10  along the coil are arranged in an appropriate location while allowing consistent coiling of turn of coiled cable  14 . For example, a controller  16  positioned along a part of cable  14  may not have the same flexibility as cable  14 , so it is intended that controller  16  will be arranged along one of the straight sidewalls  306  of packaging  100  rather than at a corner where cable  14  bends. Since sections  238  can bend to accommodate differing coil diameters, the appropriate diameter may be used so that controller  16  ends up in the desired position around a perimeter of packaging  100 . Other components of product  10  along cable  14  can be positioned similarly, such as a connector  18 , which may be positioned in a center of packaging  100  (e.g., within aperture  220  and underneath flap  222 ) based on the angle between sections  232  and sections  238  when sections  238  are folded towards the center of layer  200 . 
     In some embodiments, the angle between sections  232  and sections  238  is between 10 and 60 degrees. In some embodiments, the angle between sections  232  and sections  238  is between 30 and 50 degrees. In some embodiments, the angle between sections  232  and sections  238  is about 45 degrees. In some embodiments, the diameter at which cable  14  coils within packaging  100  may be between 30 and 50 millimeters. In some embodiments, the diameter at which cable  14  coils within packaging  100  may be about 40 millimeters. Other angles and diameters may be utilized depending on the characteristics of product  10 . For example, the length of cable  14  or the distance between components thereof may affect the desired angle between sections  232  and sections  238  and the desired diameter at which cable  14  coils within packaging  100 . 
     In some embodiments layer  300 , as shown, for example, in  FIG. 10 , operates as a product body support portion and as a cable support portion. In some embodiments, layer  300  comprises a product body section  310  and a cable section  340 . In some embodiments, product body section  310  and cable section  340  are connected via sidewall  305 . In some embodiments, product body section  310 , cable section  340  and sidewall  305  are monolithic. In some embodiments, product body section  310 , cable section  340 , and sidewall  305  fold relative to each other so that product body section  310  is parallel with cable section  340  and separated from cable section  340  by a distance equal to the height of sidewall  305 . For example, product body section  310  may form part of a top portion of packaging  100 , cable section  340  may form part of a bottom portion of packaging  100 , and sidewall  305  may form part of a side portion of packaging  100 . 
     In some embodiments, product body section  310  defines an aperture  320 . In some embodiments, product body section  310  defines two apertures  320 . In some embodiments, apertures  320  are configured to receive product body  12 . In some embodiments, the shape of apertures  320  imitate the shape of product body  12  (i.e., are shaped to follow a contour of a perimeter of product body  12 ). In some embodiments, one or more flaps  322  extend from product body section  310  over each aperture  320 . For example, two flaps  322  may extend over each aperture  320 . In some embodiments, a tab  330  extends from product body section  310  on a side opposite from sidewall  305 . In some embodiments, tab  330  forms a portion of a sidewall  306  opposite sidewall  305 . For example, as shown cross-hatched in  FIG. 8 , an adhesive  370  may be disposed on one side of tab  330  to attach to a section  542  from layer  500  to form a sidewall  306  opposite sidewall  305 . 
     In some embodiments, cable section  340  defines aperture  350 , which may provide a space to accommodate parts of product  10  (e.g., parts that are disposed within other apertures secured by flaps as described above). In some embodiments, aperture  350  is similar in shape to center section  210  of layer  200 . In some embodiments, cable  14  coils within packaging  100  and rests on cable section  340 . In some embodiments, cable section  340  forms a bottom portion of passageway  239 . In some embodiments, tabs  360  extend from opposite ends of cable section  340 . Tabs  360  may be folded to create sidewalls  306  of packaging  100 . 
     For example, tabs  360  may include sections  362  and  364 . In some embodiments, section  362  is folded at a 90 degree angle to cable section  340  to form a sidewall  306  of packaging  100 . In some embodiments, section  364  may fold over the top of section  234 . In some embodiments, section  364  may be disposed between section  234  and product body section  310 . 
     In some embodiments, an adhesive  370  may be disposed on section  362 , as shown cross-hatched in  FIG. 8 . For example, section  362  may be adhered to section  236  of layer  200 . This arrangement may hold the passageway  239  formed by sections  232 ,  234 , and  236  in place. In some embodiments, adhesive  370  may be double-sided adhesive. In some embodiments, adhesive  370  is a differential adhesive, with one side of adhesive  370  having greater tack than the other side, which may help a consumer open packaging  100  when desired without tearing up portions of the packaging along with the adhesive, since the adhesive will have a natural tendency to stay together on the side with the higher tack. Because adhesive  370  may attach to section  362  and section  236 , when packaging  100  is opened by separating sections  362  and  236 , the passageway  239  surrounding cable  14  is also opened, allowing cable  14  to be easily removed from packaging  100 . For example, after passageway  239  is opened, tabs  230  may be easily folded back to allow consumers to remove cable  14  from its position within packaging  100 . 
     In some embodiments, cable section  340  comprises an indent  342  on a side of cable section  340 . For example, indent  342  may be disposed on the side of cable section  340  opposite from sidewall  305 . In some embodiments, indent  342  provides a space for an additional side wall formed by another layer (such as layer  500 ). In some embodiments, indent  342  allows a side wall to close packaging  100  without protruding beyond the perimeter of product body section  410  (see  FIG. 1 ). 
     In some embodiments layer  400 , as shown, for example, in  FIG. 11 , operates as a second layer of a product body support portion. In some embodiments, layer  400  comprises a product body section  410 . In some embodiments, product body section  410  defines an aperture  420 . In some embodiments, product body section  410  defines two apertures  420 . In some embodiments, apertures  420  are configured to receive product body  12 . In some embodiments, the shape of apertures  320  imitate the shape of product body  12  (i.e., are shaped to follow a contour of a perimeter of product body  12 ). Apertures  420  may be generally the same shape as apertures  320 , but slightly offset to different degrees around their peripheries, as described above (see, e.g.,  FIGS. 3 and 4 ). In some embodiments, product body section  410  forms a top layer of packaging  100 . 
     In some embodiments layer  500 , as shown, for example, in  FIG. 12 , operates as a connector support portion. In some embodiments, layer  500  is disposed below layer  300 . In some embodiments, layer  500  comprises a connector section  510 . In some embodiments, embodiments, connector section  510  defines aperture  520 . In some embodiments, aperture  520  is sized to receive connector  18  (e.g., headphone jack, adaptor, or other electrical connector) of product  10 . In some embodiments, aperture  520  and flaps  222  operate in a similar manner as aperture  420  and flaps  322  to secure connector  18 . For example, aperture  520  may constrain connector  18  in an X and Y direction while flaps  222  may constrain connector  18  in a Z direction (e.g., by being biased to press connector  18  against the perimeter of aperture  520 ). 
     In some embodiments, a tab  540  extends from connector section  510 . Tab  540  may comprise section  542  and section  544 . In some embodiments, section  542  may form a sidewall  306  of packaging  100  (e.g., by attaching to tab  330  via adhesive  370 ). In some embodiments, section  544  may fold over the top of product body section  410 , as shown, for example, in  FIG. 1 . 
     In some embodiments, connector section  510  only defines one aperture (e.g., aperture  520 ). In some embodiments, connector section  510  defines one or more additional apertures, such as aperture  525  and aperture  530 . In some embodiments, aperture  525  and aperture  530  are configured to receive a portion of an accessory for product  10 , such as an adaptor. In some embodiments, aperture  525  and aperture  530  are configured to receive different portions of the same accessory. In some embodiments, aperture  525  may receive a portion of a different accessory than an accessory received by aperture  530 . 
     In some embodiments, layer  600 , as shown, for example, in  FIG. 13 , may operate as an accessory support portion. For example, layer  600  may be disposed below connector section  510  to house an accessory. In some embodiments, layer  600  comprises an accessory section  610 . In some embodiments, accessory section  610  completely covers aperture  520 , and thus, may help constrain connector  18  in a Z direction. 
     In some embodiments, accessory section  610  may define one or more apertures, such as apertures  620  and  630 . In some embodiments, one or more flaps  622  (e.g., two flaps  622 ) extend from accessory section  610  over aperture  620 . In some embodiments, aperture  525  and flaps  622  operate in a similar manner as aperture  420  and flaps  322  to secure a portion of an accessory. For example, aperture  525  may constrain a portion of the accessory in an X and Y direction while flaps  622  may constrain the portion of the accessory in a Z direction (e.g., by being biased to press the portion of the accessory against the perimeter of aperture  525 ). 
     In some embodiments, one or more flaps  632  (e.g., two flaps  632 ) extend from accessory section  610  over aperture  630 . In some embodiments, aperture  530  and flaps  632  operate in a similar manner as aperture  420  and flaps  322  to secure a portion of an accessory. For example, aperture  530  may constrain a portion of the accessory in an X and Y direction while flaps  632  may constrain the portion of the accessory in a Z direction (e.g., by being biased to press the portion of the accessory against the perimeter of aperture  530 ). 
     In some embodiments, center section  210  of layer  200  completely covers apertures  620  and  630 , and thus, may help constrain portions of the accessory in a Z direction. In some embodiments, layer  600  may not be included in packaging  100 , with layer  500  being the bottom layer. In some embodiments, this may leave a portion of connector  18  exposed. 
     As discussed above, packaging  100  is formed from a plurality of layers of compressed natural fibers, such as paper. In some embodiments, each layer comprises paper of the same grammage (grammage being a measure of mass per unit of area). In some embodiments, some layers may comprise different grammages. For example, in some embodiments, all layers have the same grammage (e.g., a grammage of  300 ) except for layer  400 . In some embodiments, layer  400  comprises paper having a greater grammage than layers  200 ,  300 ,  500 , and  600  (e.g., layer  400  may have a grammage greater than 120% of the grammage of layers  200 ,  300 ,  500 , and  600 , such as, for example, a grammage of  380 ). In some embodiments, the greater grammage of layer  400  may contribute to securing product body  12  in place and may provide reinforcing structure for packaging  100  so that packaging  100  can maintain its shape through the packaging, shipping, and handling processes while using lower grammage material for the other layers, thereby reducing waste and weight of packaging  100  overall. For example, the greater grammage of layer  400  may provide greater stiffness, thus contributing to the prevention of rotation of product body  12  and the prevention of flexing of packaging  100 . 
     In some embodiments, each layer of packaging  100  may be formed from a sheet of compressed natural fibers. In some embodiments, each layer of packaging is formed only of compressed natural fibers. In some embodiments the entirety of packaging  100  is formed of compressed natural fiber layers and adhesives. In some embodiments the entirety of packaging  100  is formed of compressed natural fiber layers, adhesives, and polypropylene laminate. 
     In some embodiments, each layer is die-cut from a sheet of compressed natural fibers. In some embodiments, layers that have similar outer perimeters (e.g., a portion of layer  300  and layer  400 ) may be die-cut together. In some embodiments, portions of the layers that will be folded are scored (e.g., compressed to provide a crease or cut less-than-completely through the layer, with or without removing material with the cut such as with a v-shaped miter cut) to help each fold be accurate. For example, in some embodiments, flaps  222 ,  322 ,  622 , and  632  are scored at a location to contribute to biasing flaps  222 ,  322 ,  622 , and  632  to press against the portion of product  10  that is being held in place, while also allowing insertion of product  10  during assembly of packaging  100  without damaging flaps  222 ,  322 ,  622 , and  632 . 
     In some embodiments, the process of die-cutting and the process of scoring are done simultaneously. In some embodiments, the layers of packaging  100  are die-cut in a downward direction. In some embodiments, the layers of packaging  100  are die-cut in an upward direction. In some embodiments, different layers are die-cut in different directions. For example, in some embodiments, layer  200  may be die-cut in a downward direction and layers  300 ,  500 , and  600  are die-cut in an upward direction. 
     In some embodiments, the process of die-cutting may contribute to allowing the majority of packaging  100  to be hidden from a consumer&#39;s view from above the top layer (e.g., layer  400 ). For example, the die-cut pattern of tab  540 , tab  330 , tabs  360 , and sidewall  305  may cut into a portion of cable section  340  and connector section  510 . Thus, when tab  540 , tab  330 , tabs  360 , and sidewall  305  are formed into the sidewalls  305  and  306  of packaging  100 , they may be disposed at least slightly underneath product body section  310  and hidden from view, rather than bulging out from underneath product body section  310 . 
     In some embodiments, one or more layers (e.g., layers  200 ,  300 ,  400 ,  500 , and  600 ) may be attached to one another to form packaging  100 , as shown, for example, in  FIGS. 5 and 6 . Various layers (e.g., layers  200 ,  300 ,  400 ,  500 , and  600 ) may be adhered together by, for example, tape (e.g., double-sided tape) or glue, or by high-frequency welding. High-frequency welding provides a strong bond and a clean edge, avoiding potential exposed tape or glue. In some embodiments, each layer comprises a coating to facilitate high-frequency welding. For example, each layer may comprise a coating of polypropylene laminate. In some embodiments, the polypropylene laminate of one layer (e.g., layers  200 ,  300 ,  400 ,  500 , or  600 ) may be high-frequency welded to the polypropylene laminate of an adjacent layer. By bonding the polypropylene laminate of one layer to the polypropylene laminate of an adjacent layer, adjacent layers may be adhered or bonded together. In some embodiments, layers  200 ,  300 ,  400 ,  500 , and  600  may be adhered together by high-frequency welding by applying heat and pressure in areas  700 , as shown cross-hatched in  FIGS. 9, 10, 12, and 13 . While the cross-hatching of high-frequency welded areas  700  is different than the cross-hatching of adhesives  370 , either of these areas could utilize adhesive or welding. In some embodiments, as shown, for example, in  FIGS. 10, 12, and 13 , an area  710  around the edges of connector section  510 , accessory section  610 , and product body section  310  are not high-frequency welded to adjacent layers. In some embodiments, this allows the creases formed by scoring to operate and may contribute to allowing the majority of packaging  100  to be hidden from a consumer&#39;s view from above the top layer (e.g., layer  400 ). 
     In some embodiments, as shown, for example, in  FIG. 7 , assembled packaging  100  may hold product  10  with product body  12  secured in product body sections  310  and  410  and cable  14 , together with controller  16  and connector  18 , secured in center section  210 , cable section  340 , and connector section  510 . 
     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, apertures and flaps may be of different shapes and sizes, or in different locations than shown in the figures. In addition, while earphones have been primarily shown in the figures, in some embodiments, other products may be packaged according to the principles disclosed herein. 
     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: 20160812
Publication Date: 20180522
Grant Date: 20180522
Priority Date: 20160812
Inventors: PINCUS, DEREK BOWMAN
TANG, Lorraine Y.
Assignee: APPLE INC
CPC Classifications: [{"code": "B65H2701/3919", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65H75/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D73/0078", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D65/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D85/671", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D77/2024", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D65/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D5/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D85/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D81/133", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D85/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D77/2024", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D85/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D65/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D85/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D81/133", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D73/0078", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65H75/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65H2701/3919", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D85/671", "inventive": true, "first": true, "tree": "[]"}, {"code": "B65D85/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D85/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D65/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "B65D65/38", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 60481299