Method of Forming Assembled Package with First Ridge of First Tray Forming Part of Outer Surface of Assembled Package

This application is a continuation of U.S. patent application Ser. No. 18/360,392, filed on Jul. 27, 2023, which is a continuation in part of U.S. patent application Ser. No. 18/053,141, filed Nov. 7, 2022, the entire contents of each of which are hereby incorporated by reference.

Example embodiments generally relate to a package including one or more trays for a consumer product.

Packages can store and dispense consumer products that may be impacted by exposure to ambient air.

At least one example embodiment is directed toward a package.

In at least one example embodiment, the package includes an outer container including a first section and a second section; and a first tray within the outer container, the first tray defining a ridge along a periphery of the first tray, the ridge being held between a first peripheral edge of the first section and a second peripheral edge of the second section when the outer container is in a closed position and the first tray is being held within the outer container.

In at least one example embodiment, a first outer surface of the ridge is visible from outside of the package when the outer container is in the closed position and the first tray is being held within the outer container.

In at least one example embodiment, a first outer surface of the ridge is flush with a second outer surface of the first section and the second section when the outer container is in the closed position and the first tray is being held within the outer container.

In at least one example embodiment, a first outer surface of the ridge forms part of an overall outer surface of the package when the outer container is in the closed position and the first tray is being held within the outer container.

In at least one example embodiment, the ridge extends horizontally away from first sidewalls of the first tray.

In at least one example embodiment, each of the first section and the second section have second sidewalls extending from an end wall, the first section and the second section being identical to each other.

In at least one example embodiment, the first peripheral edge and the second peripheral edge are distal ends of the second sidewalls that are furthest from the end wall of each of the first section and the second section, respectively.

In at least one example embodiment, a first interior surface of the second sidewalls is inclined in an outwardly direction from the end wall to the first peripheral edge and the second peripheral edge of the first section and the second section, respectively.

In at least one example embodiment, the second sidewalls of each of the first section and the second section include a first pair of opposing sidewalls and a second pair of opposing sidewalls.

In at least one example embodiment, the second sidewalls have a horizontal cross-section that is substantially rectangular in shape.

In at least one example embodiment, the first section and the second section each define first interior and exterior corners between the end wall and the second sidewalls that are rounded, and the first section and the second section each define second interior and exterior corners between each of the first pair of opposing sidewalls and the second pair of opposing sidewalls that are rounded.

In at least one example embodiment, the first tray defines an impression of a first consumer product.

In at least one example embodiment, the first tray is selectively removable from the outer container.

In at least one example embodiment, the package further includes a second tray within the outer container, wherein a first lower portion of the first tray is at least partially connected to a first upper portion of the second tray.

In at least one example embodiment, the first tray and the second tray are selectively removable from the outer container.

In at least one example embodiment, a lower surface of the second tray contacts an end wall of the first section of the outer container when the second tray is being held within the outer container.

In at least one example embodiment, a first upper surface of the first tray forms at least a portion of a second upper surface of the package when the second section of the outer container is removed from the package and the first tray and the second tray are held within the first section.

In at least one example embodiment, a second upper portion of the ridge forms part of the second upper surface.

In at least one example embodiment, the first tray includes first sidewalls that extend vertically downward from the first upper surface, and the first lower portion includes at least part of a distal end of the first sidewalls.

In at least one example embodiment, the first tray includes first sidewalls that extend vertically downward from the first upper surface, the first sidewalls including first lower corners that are rounded at locations where the first sidewalls are joined, the first lower portion including a distal end of the first lower corners of the first sidewalls.

In at least one example embodiment, the first upper portion of the second tray defines first exterior corners that are rounded, the first lower corners being configured to grip the first exterior corners to connect the first tray to the second tray.

In at least one example embodiment, a first exterior surface of the first sidewalls and a second exterior surface of the second tray are conformed to a shape of a first interior surface of the first section.

In at least one example embodiment, the second exterior surface of the second tray, a third upper surface of the second tray, and second sidewalls of the first section define a ravine, the first sidewalls of the first tray being fitted into the ravine when the first tray and the second tray are connected together and are held in the first section.

In at least one example embodiment, the ravine is defined along an entire periphery of the second tray when the second tray is held in the first section.

In at least one example embodiment, the first tray defines at least one first impression of at least one first consumer product, and the second tray defines at least one second impression of at least one second consumer product.

In at least one example embodiment, the package further includes the at least one first consumer product contained within the at least one first impression; and the at least one second consumer product contained within the at least one second impression.

In at least one example embodiment, the at least one first consumer product isa heat-not-burn device, and the at least one second consumer product includes accessory items for the heat-not-burn device.

In at least one example embodiment, the package further includes consumer information material, wherein a third upper surface of the second tray defines a first inset surface, the consumer information material being held within the first inset surface.

In at least one example embodiment, at least one surface of the at least one first consumer product is viewable within the at least one first impression when the second section is removed from the package and the first tray is held within the first section.

In at least one example embodiment, the package further includes a band circumscribing at least a portion of the outer container, the band including at least one wide panel that is conformed to and in direct contact with at least one major surface of the first section, the second section or both the first section and the second section.

In at least one example embodiment, the band defines at least one tear strip that runs across a width of a portion of the band, the at least one tear strip being aligned with and running in front of a portion of the ridge.

Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.

Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives thereof. Like numbers refer to like elements throughout the description of the figures.

It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations or sub-combinations of one or more of the associated listed items.

It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, regions, layers and/or sections, these elements, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.

Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or groups thereof.

When the words “about” and “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value, unless otherwise explicitly defined.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of example embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

is an illustration of a perspective view of an outer container, in accordance with at least one example embodiment.is an illustration of a side view of the outer container, in accordance with at least one example embodiment.is an illustration of a front view of the outer container, in accordance with at least one example embodiment.is an illustration of a top view of the outer container, in accordance with at least one example embodiment.

In at least one example embodiment, the outer containerincludes a first sectionand a second section. In at least one example embodiment, the first sectionis a lower section of the outer containerand the second sectionis an upper section of the outer container. In at least one example embodiment, the first sectionand the second sectioncombine to form a “clam shell” type configuration for the outer container. In at least one example embodiment, the first sectionand the second sectionare identical to each other and are therefore interchangeable with each other.

In at least one example embodiment, a ridgeof a first tray(see at least) extends between the first sectionand the second sectionwhen the outer containeris in a “closed” configuration and the outer containercontains the first tray(see). In at least one example embodiment, the ridgehelps form part of an outer surfaceof a packagethat includes the outer container(see), and an outer surfaceof the ridgeis therefore substantially visible, when the outer containeris in the “closed” configuration and the outer containercontains the first tray. In at least one example embodiment, the outer surfaceof the ridgeis flush with an outer surfaceof the first sectionand the second section, when the outer containeris in the “closed” configuration (see).

In at least one example embodiment, the outer surfacesof the first sectionand the second sectioneach have a flat major surface(). In at least one example embodiment, the flat major surfaceof the first sectionand the second sectionare parallel to each other and oppose each other on the outer container. In at least one example embodiment, the flat major surfacehas a rectangular shape with rounded corners. In at least one example embodiment, the outer surfaceof the first sectionand the second sectionhave rounded side edges(see).

is an illustration of an exploded view of major elementsof the package(see), in accordance with at least one example embodiment.

In at least one example embodiment, the major elementsinclude the outer container(the first sectionand the second section), the first tray, a second trayand a band. In at least one example embodiment, when the outer containeris in the “closed” configuration, the outer containercan contain both the first trayand the second tray. In at least one example embodiment, the first trayand the second trayare removable from the outer container, and the first trayand the second trayare able to be inserted back into the outer containerafter being removed from the outer container. In at least one example embodiment, the bandcircumscribes at least a portion of the outer containerto form the package(see). In at least one example embodiment, the bandis a “belly band” that circumscribes at least a portion of a mid-section of the outer container(as shown in at least).