Molded Paperboard Packaging and Methods of Making the Same

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/663,936, filed 25 Jun. 2024, the disclosure of which is now expressly incorporated herein by reference.

The present disclosure relates to improved paperboard packaging. Specifically, the present disclosure may include formed paperboard packaging having a plurality of formed pockets or depressions.

The vast majority of product packaging is made using one-time use plastic due to abundance, relatively inexpensive cost, ease of use, resilience, printability, and versatility. Indeed, for example, one-time use plastics may easily be made to be opaque, transparent and/or translucent, which may be useful for displaying products within product packaging made therefrom.

While one-time use plastic has advantages making it appealing, there are several serious disadvantages. Specifically, plastic is difficult to decompose and therefore much of it ends up in landfills, waterways, and, generally, as a pollutant in the environment. While recycling of one-time use plastics may be done, it is estimated that a very small percentage of plastic packaging is, actually, recycled. Moreover, recycling plastic requires energy and chemical usage which itself may be harmful to the environment. Moreover, most food products are not recycled because they tend to be mixed with residual food products.

Paperboard packaging decomposes much more quickly and is easier to recycle that one-time use plastics. Moreover, paperboard packaging may be easily printed and cut into particular flat shapes. Paperboard packaging may also has certain disadvantages. Paperboard packaging can be difficult to make into desired shapes when forming. Likewise, paperboard packaging can suffer from effects of moisture and other environmental conditions.

The present disclosure provides paperboard packaging that may easily be molded or formed into desired shapes to hold products therein. More specifically, the present disclosure provides paperboard packaging that may be made from various types of paperboard dependent upon desired characteristics.

According to one aspect of the present disclosure, a paperboard packaging may comprise a formed paperboard tray having a plurality of formed pockets or depressions. The formed pockets or depressions may have varying depths from a base surface depth level.

In some embodiments, at least one formed pocket or depression included in the plurality of formed pockets or depressions may be wholly contained within another formed pocket or depression. In some embodiments, at least one formed pocket or depression included in the plurality of formed pockets or depressions may be partially or wholly contained within another formed pocket or depression.

In some embodiments, the paperboard packaging may further comprise at least one cut-out opening or window. The cut-out opening or window may be disposed in one or a plurality of the formed pockets or depressions.

In some embodiments, the paperboard packaging may comprise a first pocket of a first depth and a second pocket of a second depth. The second pocket may be within the first pocket. In some embodiments, deeper pockets or depressions included in the plurality of formed pockets or depressions are disposed within shallower pockets.

In some embodiments, the paperboard packaging may further comprise a panel. The panel may be adapted to fit on or be adhered to a top portion of the formed paperboard tray thereby forming packaging in which products may be contained and stored within the plurality of formed pockets or depressions.

In some embodiments, the formed paperboard tray may be formed from a paperboard blank. The paperboard blank may have one or more creases configured to aid in forming the paperboard blank into the formed paperboard tray when pressed in a press.

According to another aspect of the present disclosure, a formed paperboard tray product may comprise a paperboard tray. The paperboard tray may include a paperboard base that defines a first pocket having a first depth measured from a surface of an unformed part of the paperboard base to a bottom surface of the first pocket, and a second pocket having a second depth measured from the surface of the unformed part of the paperboard base to a bottom surface of the second pocket. The first and second depths may be different.

In some embodiments, the formed paperboard tray product may further comprise at least one window disposed within at least one of the first or second pockets. In some embodiments, the second pocket may be partially disposed within the first pocket.

In some embodiments, the paperboard base may define a third pocket having a third depth measured from the surface of the unformed part of the paperboard base to a bottom surface of the third pocket. The first and second depths may be different from the third depth. In some embodiments, the third pocket may be partially or completely disposed within the second pocket.

In some embodiments, the formed paperboard tray product may further comprise a panel adapted to fit on or be adhered to the unformed part of the paperboard base of the paperboard tray thereby forming packaging in which products may be contained and stored within the pockets or depressions. The panel may comprise paperboard. The panel may comprise a plurality of pockets of varying depths.

In some embodiments, the paperboard tray may be formed from a paperboard blank. The paperboard blank may have one or more creases configured to aid in forming the paperboard blank into the paperboard tray when pressed in a press.

According to another aspect of the present disclosure, a method of assembling a package with one or more products therein may comprise providing a paperboard blank with predetermined dimensions based on the one or more products to be packaged, applying one or more creases to the paperboard blank at predetermined locations to aid in forming a formed paperboard tray from the paperboard blank, arranging the paperboard blank with the one or more creases applied thereto in a press, pressing the paperboard blank in the press at least once while applying heat to the paperboard blank to provide the formed paperboard tray including a base that defines a plurality of pockets or depressions and a planar lip that extends from and around the base to define a boundary of the formed paperboard tray, arranging the one or more products in the plurality of pockets or depressions of the formed paperboard tray, providing a tray cover with predetermined dimensions based on the formed paperboard tray, and coupling the tray cover to the tray lip of the formed paperboard tray after arranging the one or more products in the plurality of pockets or depressions to trap the one or more products therebetween.

In some embodiments, the method may further comprise pressing the paperboard blank in the press includes multiple pressing steps while applying heat to the paperboard blank to the paperboard blank to provide the formed paperboard tray. In some embodiments, the method may further comprise applying a printed label to the paperboard blank. In some embodiments, the method may further comprise cutting out one or more windows from the paperboard blank.

Additional features and advantages of the present disclosure are described in, and will be apparent from, the detailed description of the presently preferred embodiments and from the drawings.

A packageaccording to an embodiment of the present disclosure is shown inand-B. The packageincludes a trayand a tray coveras shown inand-B. The formed paperboard trayis formed to define a plurality of formed pockets or depressions,,configured to receive and hold one or more productstherein. The tray cover, also sometimes referred to as a panel, is coupled to the trayto close an opening to the pockets or depressions,,of the trayand block removal of the productfrom the traythereby sealing the product(s)therein.

The trayof the packageis a formed paperboard trayformed from a flat paperboard blank or sheet′ via a pressas shown in. The flat paperboard blank′ has predetermined dimensions (e.g., size and shape) based on a product type or productto be held or stored within the package(e.g., health/beauty products (razors, toothbrush, toothpaste, lip balm, vitamins, cosmetics, sunscreen), electronics (phone, tablet), cleaning products, drink products (coffee grounds, powdered drink mix), medication (pills, tablets, or other like pharmaceuticals), laundry detergent, batteries, medical devices, food items, eyeglasses, and food products). The flat paperboard blank′ is pressed between mold tools,of the presswhile applying heat to the paperboard blank′ to provide the formed paperboard tray.

The resulting formed paperboard trayincludes a baseand a planar lipthat extends from and around an edge of the baseas shown inand-B. The basedefines pockets or depressions,,configured to receive one or more productstherein. The pockets or depressions,,, and thus the base, are formed by pressing the flat paperboard blank′ in the press. The flat paperboard blank′ has one or more creases′ configured to aid in forming the paperboard blank′ into the formed paperboard traywithout tearing or destroying the paperboard blank when pressed in a press.

As shown inand-B, the baseof the paperboard trayincludes a first pocket or depression, a second pocket or depression, and a third pocket or depression. The number of pockets or depressions may vary based on the product(s)to be packaged. For example, the paperboard traymay be formed to define more than three pockets or depressions. In some embodiments, the paperboard traymay be formed to define less than three pockets or depressions.

The plurality of pockets or depressions,,have varying depths as shown inand-B. The pockets or depressions,,have varying depths such that each pocket or depression,,has a different depth. The first pockethas a first depth d′, the second pockethas a second depth d″, and the third pockethas a third depth d″″ as shown inandA-B. The deeper pockets are partially or wholly disposed within shallower pockets. Therefore, the second pocketis partially or wholly disposed within the first pocketand the third pocketis partially or wholly disposed within the first pocketand the second pocket.

The vast majority of product packaging is made using one-time use plastic due to abundance, relatively inexpensive cost, ease of use, resilience, printability, and versatility. Indeed, for example, one-time use plastics may easily be made to be opaque, transparent and/or translucent, which may be useful for displaying products within product packaging made therefrom. However, plastic is difficult to decompose and therefore much of it ends up in landfills, waterways, and, generally, as a pollutant in the environment. While recycling of one-time use plastics may be done, it is estimated that a very small percentage of plastic packaging is, actually, recycled. Moreover, recycling plastic requires energy and chemical usage which itself may be harmful to the environment. Moreover, most food products are not recycled because they tend to be mixed with residual food products.

Unlike plastic packaging, paperboard packaging decomposes more quickly and is easier to recycle that one-time use plastics. Moreover, paperboard packaging may be easily printed and cut into particular flat shapes. Even still, the paperboard material may not be as easy to formed into desired shapes. Thus, the paperboard trayhas creasesthat aid in the formation of the tray. The creases′ in the paperboard blank′ aid in forming the paperboard blank′ into a three-dimensional traywith the pocketwithout tearing or destroying the paperboard blank′, or otherwise forming uncontrolled creases in the traythat may be unsightly and induce locations of weakness in the paperboard that may lead to tearing of the same when in use.

Additionally, the multiple pockets or depressions,,and the unique arrangement of pockets or depressions,,may minimize the number of creasesused to aid in forming the paperboard traysince the arrangement of the pockets or depressions,,provide a place for the paperboard to go as it is formed. Also, due to the unique arrangement of pockets or depressions,,, each having a depth that is different, productscontained therein may be uniquely arranged and held therein.

With the packageof the present disclosure initially described above, the packageand a methodof forming the packageis now described in more detail. The packageincludes a trayand a tray coveras shown in. The trayis a formed/pressed paperboard traymade from paperboard material. Similarly, the tray coveris a paperboard panel from paperboard material. Preferably, the paperboard material is a dry paperboard. The dry paperboard material may have a moisture content between about 5% to 10%. In some embodiments, the paperboard material may have a moisture content between about 8% to 10%.

The formed/pressed paperboard trayincludes a baseand a planar lipas shown in. The basemay also be referred to as a bodyof the tray. The planar lip, also referred to as an outer rim, extends from and around a perimeter edge of the baseto define a boundary of the tray. The basedefines a plurality of pockets or depressions,,as shown in. The pockets or depressions,,are configured to receive one or more productstherein. An opening to the pockets or depressions,,is defined by the planar lipas shown in. The pockets or depressions,,extend from the opening in the planar lip.

The plurality of pockets or depressions,,have varying depths as shown inand-B. The pockets or depressions,,have varying depths such that each pocket or depression,,has a different depth. The first pockethas a first depth d′, the second pockethas a second depth d″, and the third pockethas a third depth d″″ as shown inandA-B. The deeper pockets are partially or wholly disposed within shallower pockets. Therefore, the second pocketis partially or wholly disposed within the first pocketand the third pocketis partially or wholly disposed within the first pocketand the second pocket.

The first pocket or depressionincludes a bottom surfaceand at least one side walldisposed partially or completely therearound as shown inand-B. The bottom surfaceis spaced apart from the planar lip. The wallextends between the planar lipand the bottom surfacesuch that the first pocket or depressionhas a first depth d. The first depth d is defined between the bottom surfaceof the depressionand a surfaceof an unformed part of the paperboard tray, i.e., the planar lip.

The second pocket or depressionincludes a bottom surfaceand a first side walldisposed partially or completely therearound as shown inand-B. The first side wallpartially circumscribes the second pocket or depressionsince the second pocket or depressionis disposed within the first pocket or depression. The first side wallpartially circumscribes the second pocket or depressionat a distance d′ from the bottom surfaceof the second pocket or depressionto the bottom surfaceof the first pocket or depression.

The second pocket or depressionfurther includes a second side walldisposed partially around the bottom surfaceas shown inand-B. The second side wallpartially circumscribes the second pocket or depressionat a distance d″ from the bottom surfaceof the second pocket or depressionto the surfaceof the unformed part of the paperboard tray, i.e. the planar lip. The distance d″ is the sum of the distance d and the distance d′. Thus, the second pocket or depressionhas a second depth d″.

The third pocket or depressionincludes a bottom surfaceand a first side walldisposed partially or, as illustrated inand-B, completely therearound. The first side wallof the third pocket or depressionmay circumscribe the third pocket or depressionat a distance d′″ from the bottom surfaceof the third pocket or depressionto the bottom surfaceof the second pocket or depression. The third pocket or depressionhas a third depth d″″ defined between the bottom surfaceof the third pocket or depressionand the surfaceof the unformed part of the paperboard tray. Thus, the third depth d″″ is the sum of the distance d′″ from the bottom surfaceof the third pocket or depressionto the bottom surfaceof the second pocket or depression, the distance d′ from the bottom surfaceof the second pocket or depressionto the bottom surfaceof the first pocket or depression, and the distance d from the bottom surfaceof the first pocket or depressionto the surfaceof the unformed part of the paperboard tray.

The tray coveris coupled to or adhered to the planar lipas shown in FIGS. ##. The tray covermay be heat sealed to the planar lipto couple the tray coverto the trayas suggested in. The heat seal between the planar lipand the tray covercreates a perimeter seal around the planar lipat adheres the tray coverto the tray. The shape of the traymakes heat sealing the tray coverto the trayeasier because the same mold tool,may be used. In other words, the mold tool,need not be changed out for heat sealing equipment. In other embodiments, the tray covermay be coupled to the planar lipusing another suitable method.

In some embodiments, the tray covermay be a formed/pressed paperboard tray cover instead of a paperboard sheet. The tray covermay be a formed paperboard tray cover formed from another paperboard blank′ having one or more creases′ configured to aid in forming the paperboard blank′ into the formed paperboard tray coverwithout tearing or destroying the paperboard blank′ when pressed in the presslike the tray cover. The tray covermay include a plurality of pockets or depressions that mirror the pocket or depressions,,in the tray. The pockets/depressions in the trayand the tray coverwould cooperate to receive the productswhen coupled together.

The trayand/or tray covermay also include a printed label, graphic, and/or logoattributed to the productin the pockets or depressions,,. The paperboard material make it possible to directly print the label, graphic, and/or logoonto the trayand/or tray cover. Other paperboard packaging, like molded paperboard pulp material, the label, graphic, or logo has to be separate and attached thereto using a suitable method.

In some embodiments, the trayor the tray covermay have a perforated sectionthat is removable to expose the productswithin the packageso that the productsmay be removed from the package. The perforated sectionis attached with perforations to enable the perforated sectionto be removed. As shown in, the tray coveris formed to include a perforated section. In other embodiments, the perforated sectionmay be included in the formed paperboard tray.

Another embodiment of a packagein accordance with the present disclosure is shown in. The packageis substantially similar to the packageshown inand-B. and described herein. Accordingly, similar reference numbers in theseries indicate features that are common between the packageand the package. The description of the packageis incorporated by reference to apply to the package, except in instances when it conflicts with the specific description and the drawings of the package.

The packageincludes a trayand a tray cover as shown in. Like the tray, the trayis a formed/pressed paperboard traymade from paperboard material. As shown in, the trayfurther includes at least one windowdisposed therein for viewing productin the package.

The formed/pressed paperboard trayincludes a baseand a planar lipas shown in. The planar lipextends from and around a perimeter edge of the baseto define a boundary of the tray. The basedefines a plurality of pockets or depressions,,as shown in. The pockets or depressions,,are configured to receive one or more productstherein.

The plurality of pockets or depressions,,are similar, if not the same as the pockets or depressions,,inand-B. The plurality of pockets or depressions,,have varying depths such that each pocket or depression,,has a different depth as shown in. The first pockethas a first depth d′, the second pockethas a second depth d″, and the third pockethas a third depth d″″. The deeper pockets are partially or wholly disposed within shallower pockets. Therefore, the second pocketis partially or wholly disposed within the first pocketand the third pocketis partially or wholly disposed within the first pocketand the second pocket.

The first pocket or depressionincludes a bottom surfaceand at least one side walldisposed partially or completely therearound as shown in. The second pocket or depressionincludes a bottom surface, a first side walldisposed partially or completely therearound, and a second side walldisposed partially around the bottom surfaceas shown in FIGS.. The third pocket or depressionincludes a bottom surfaceand a first side walldisposed completely therearound as illustrated in.

The windowis formed in the bottom surfaceof the second pocket or depressionas shown in. In some embodiments, the window or windowsmay be formed in the bottom surfaceof the first pocket or depression, the bottom surfaceof the second pocket or depression, and/or the bottom surfaceof the third pocket or depression. In some embodiments, the window or windowsmay extend across the pockets or depressions,,.

In the illustrative embodiment, the windowis open and no material is disposed thereover as shown in. In some embodiments, the windowmay be covered or material is disposed thereover. For example, a transparent thermoplastic film thereon may cover the windows. The transparent thermoplastic film may be any apparent to those skilled in the art; however, a preferable thermoplastic film may be made from polylactic acid (PLA), which may degrade in the presence of time and moisture, and therefore may be considered environmentally friendly.

In some embodiments, the windowmay be covered by a paper-based film that may be transparent or translucent. The translucent paper material, when present in the embodiments provided herein, may be made from glassine, which is a translucent paper-based material, so that the entirety of the paperboard packaging may be recyclable and/or compostable without separation of elements therefrom, such as, for example, plastic films or the like. Of course, other paper-based materials that may have transparent and/or translucent properties may also be used to cover the window, and the present disclosure should not be limited as described herein.

In some embodiments, the windowmay be covered by a scrim material, preferably made from a plurality of filaments interweaved together, thereby forming a barrier through which large products are prevented from passing through, but allowing viewability of the products contained therein, and for the passage of air. The scrim material may be made from any kind of filaments, such as, for example, CLAF®, which is a cross laminated polyolefin open mesh nonwoven material. Preferably, the scrim material may be made from natural fibers or filaments, such as made from paper materials or cotton, or other plant-based materials, that are easily recyclable and/or compostable with the paperboard material, so that when recycled or composted, the scrim material need not be removed from the paperboard material. Moreover, the scrim material may be adhered as a layer on the flat blank or applied in individual locations discretely over the windowsand adhered to the paperboard material.

A methodof forming and assembling the packagewith the productarranged therein includes a pre-processing stage, a pressing or forming stage, and a packaging stageas shown in. In the pre-processing stage, the paperboard blank or sheet′ is processed prior to the pressing/forming stagebased on the type of productto be packaged. In the pressing or forming stage, the paperboard blank′ is fed through the pressto be formed into the formed paperboard tray. In the packaging stage, the product(s)is arranged in the trayand the package, i.e., the trayand the tray coverare assembled.

The methodincludes providing a paperboard blank′ with predetermined dimensions based on the type of productto be packaged as suggested by block. The paperboard blank′ has predetermined dimensions (e.g., size and shape) based on the productto be held or stored within the package. For example, the paperboard blank′ for a larger productmay be larger than the paperboard blank′ for a smaller product.