Packaging Assemblies And Methods

Abstract

A packaging assembly including an outer sleeve, a tray, and an insert arranged within the tray. The tray may be arranged within and slidably engage with the outer sleeve. The tray may include a base, a first and second lateral sidewall, and a first and second longitudinal sidewall. The first and second lateral sidewalls each may include a first, a second, and a third portion. The first, second, and third portions are folded to form the first and second lateral sidewalls. The first and second longitudinal sidewalls each may include a first and a second flap. The first and the second flap may be arranged on opposite ends of the first and second longitudinal sidewalls. The first flaps may be arranged between the first and third portions of the first lateral sidewall, and the second flaps may be arranged between the first and third portions of the second lateral sidewall.

Description

BACKGROUND

Field

The present specification generally relates to packaging assemblies and methods and, more specifically, to packaging assemblies formed from flat material and folded to create the packaging assembly components and methods for assembling the same.

Technical Background

Packaging assemblies, such as cardboard boxes, can be used for cost-effective packaging. However cardboard boxes are limited to the size which the boxes are manufactured to, and do not include additional inserts which can be used for specific applications. As such, additional packaging material, such as foam, may be required to keep objects within a cardboard box from moving during transit. Additionally, cardboard boxes only have a single opening, which requires tape or some other form of securement means to keep lid of the cardboard box secured shut.

Accordingly, a need exists for alternative packaging assemblies which can be assembled from flat material, while also having interchangeable inserts for specific applications.

SUMMARY

According to a first aspect, a packaging assembly including an outer sleeve, a tray, and an insert. The outer sleeve may include an aperture. The tray may be arranged within the aperture and slidably engage with the outer sleeve. The tray may include a base, a first lateral sidewall, a second lateral sidewall, a first longitudinal sidewall, and a second longitudinal sidewall. The first lateral sidewall and a second lateral sidewall each may include a first portion, a second portion, and a third portion. The first, second, and third portions are folded to form the first and second lateral sidewalls. The first longitudinal sidewall and a second longitudinal sidewall may each include a first flap and a second flap. The first flap and the second flap may be arranged on opposite ends of the first and second longitudinal sidewalls. The first flaps may be arranged between the first portion and third portion of the first lateral sidewall, and the second flaps may be arranged between the first portion and third portion of the second lateral sidewall. The insert may be arranged within the tray.

Another aspect includes a packaging assembly according to any of the previous aspects, where the first portions are parallel to the third portion when in a folded configuration to form the first and second lateral sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, where the second portions are parallel to the base when in a folded configuration to form the first and second lateral sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, further comprising tabs arranged on the third portions of the first and second lateral sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, where the tabs of the third portions engage with apertures formed in the base of the tray to secure the first, second, and third portions in a folded configuration, forming the first and second lateral sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, where the flaps of the first and second longitudinal sidewalls are perpendicular to the first and second longitudinal sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, where the flaps of the first and second longitudinal sidewalls are encapsulated by the base and first, second, and third portions of the first and second lateral sidewalls when in a folded configuration to form the first and second longitudinal sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, where the first, second, and third portions of the first and second lateral sidewalls and the first and second longitudinal sidewalls fold along indentations formed within the tray.

Another aspect includes a packaging assembly according to any of the previous aspects, further comprising at least one divider integrally arranged on the insert.

Another aspect includes a packaging assembly according to any of the previous aspects, where the at least one divider is formed integrally within the insert by folding a portion of the insert along a plurality of indentations formed within the insert.

Another aspect includes a packaging assembly according to any of the previous aspects, the divider is substantially flush with the first and second longitudinal sidewalls and the first and second lateral sidewalls.

Another aspect includes a packaging assembly according to any of the previous aspects, where at least one goods receiving channel is formed between the tray and the insert.

Another aspect includes a packaging assembly according to any of the previous aspects, where the insert secures within the tray through a friction force which the insert exerts on the tray.

Another aspect includes a packaging assembly according to any of the previous aspects, where the insert engages a channel formed between a first and second lateral sidewalls and the base of the tray.

According to a second aspect, a method of forming a packaging assembly may include forming an outer sleeve, a tray, and an insert. A first flat material may be folded along a plurality of indentations formed within the first flat material to form the outer sleeve. The outer sleeve may include an aperture formed therein. The tray may be formed by creating a first longitudinal sidewall, a second longitudinal sidewall, a first lateral sidewall, and a second lateral sidewall. A second flat material may be folded along a first longitudinal indentation formed within the second flat material to form the first longitudinal sidewall. A first flap and a second flap of the first longitudinal sidewall may be folded perpendicular to the first longitudinal sidewall. The second flat material may be folded along a second longitudinal indentation formed within the second flat material to form the second longitudinal sidewall. A first flap and a second flap of the second longitudinal sidewall may be folded perpendicular to the second longitudinal sidewall. The second flat material may be folded along a first lateral indentation formed within the second flat material to form the first lateral sidewall. The second flat material may be folded along a second lateral indentation formed within the second flat material to form the second lateral sidewall. The first longitudinal sidewall, second longitudinal sidewall, first lateral sidewall, and second lateral sidewall form a base of the tray. A third flat material may be folded along a first indentation and a second indentation formed within the third flat material to form the insert including at least one divider. The insert may be arranged within the tray, and the tray and insert may be arranged within the aperture of the outer sleeve, where the tray slidably engages with the outer sleeve.

Another aspect includes a method according to any of the previous aspects, further comprising folding the second flat material along a third lateral indentation and a fourth lateral indentation formed within the second flat material to form a first portion, a second portion, and a third portion of the first lateral sidewall.

Another aspect includes a method according to any of the previous aspects, further comprising folding the second flat material along a fifth lateral indentation and a sixth lateral indentation formed within the second flat material to form a first portion, a second portion, and a third portion of the second lateral sidewall.

Another aspect includes a method according to any of the previous aspects, where the first portions of the first and second lateral sidewalls are parallel to the third portions of the first and second lateral sidewalls when in a folded configuration to form the first and second lateral sidewalls.

Another aspect includes a method according to any of the previous aspects, where the second portions of the first and second lateral sidewalls are parallel to the base when in a folded configuration to form the first and second lateral sidewalls.

Another aspect includes a method according to any of the previous aspects, where the base and first, second, and third portions of the first and second lateral sidewalls encapsulate the first and second flaps of the first and second longitudinal sidewalls.

Another aspect includes a method according to any of the previous aspects, further comprising arranging a first tab arranged on the third portion of the first lateral sidewall within a first aperture arranged within the base of the tray, and arranging a second tab arranged on the third portion of the second lateral sidewall within a second aperture arranged within the base of the tray.

According to a third aspect, a method of packaging baked goods using a packaging assembly is provided. The method includes forming an outer sleeve comprising a top, a bottom and sides that extend between the top and the bottom. The outer sleeve has an aperture that extends between opposite ends of the sleeve. A tray is formed that includes a front wall, a rear wall, side walls that extend between the front wall and the rear wall and a bottom that extends between the front wall, the rear wall and the side walls. The tray is sized to be slidably received within the aperture of the outer sleeve. An insert including a base and multiple dividers that extend upwardly from the base is formed to form channels that are separated from one another. The insert sized to be received within the tray such that the base covers the bottom of the tray within areas between the dividers. The insert is placed within the tray. At least one of the channels is filled with baked goods that are sized to be received within the aperture of the sleeve. The baked good rest on the base of the insert. The tray and baked goods are slid within the aperture of the sleeve from an open configuration to a closed configuration.

Another aspect includes a method according to any of the previous aspects, wherein the insert is formed by folding a flat cardboard material into the multiple dividers.

Additional features and advantages of the embodiments described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side perspective view of a packaging assembly, according to one or more embodiments shown or described herein;

FIG. 1B is a side perspective view of the packaging assembly of FIG. 1A, according to one or more embodiments shown or described herein;

FIG. 2A is a side perspective view of an outer sleeve, according to one or more embodiments shown or described herein;

FIG. 2B is a top view of the unfolded outer sleeve of FIG. 2A, according to one or more embodiments shown or described herein;

FIG. 2C is a side perspective view of the outer sleeve of FIG. 2A in a flat configuration, according to one or more embodiments shown or described herein;

FIG. 3A is a side perspective view of a tray, according to one or more embodiments shown or described herein;

FIG. 3B is a top view of the unfolded tray of FIG. 3A, according to one or more embodiments shown or described herein;

FIG. 4A is a side perspective view of an insert, according to one or more embodiments shown or described herein;

FIG. 4B is a top view of the unfolded insert of FIG. 4A, according to one or more embodiments shown or described herein;

FIG. 5A is a side perspective view of an insert, according to one or more embodiments shown or described herein;

FIG. 5B is a top view of the unfolded insert of FIG. 5A, according to one or more embodiments shown or described herein;

FIG. 6 is a partial side perspective view of a tray and insert, according to one or more embodiments shown or described herein;

FIG. 7 is a side perspective view of the packaging assembly containing goods, according to one or more embodiments shown or described herein; and

FIG. 8 is a flowchart depicting a method of forming a packaging assembly, according to one or more embodiments shown or described herein.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of packaging assemblies and methods of forming the same, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

As used herein, the term “lateral direction” refers to the forward-rearward direction (i.e., in the +/−Z-direction of the depicted coordinate axes). The term “longitudinal direction” refers to the cross-direction (i.e., in the +/− vehicle X-direction of the depicted coordinate axes), and is transverse to the lateral direction. The term “vertical direction” refers to the upward-downward direction (i.e., in the +/− vehicle Y-direction of the depicted coordinate axes). As used herein, “upper” and “above” are defined as the positive Y direction of the coordinate axis shown in the drawings. “Lower” and “below” are defined as the negative Y direction of the coordinate axis shown in the drawings.

Embodiments of a packaging assembly may include an outer sleeve, a tray, and an insert. The outer sleeve, tray, and insert may all be formed from flat material and then folded along indentation or perforations formed in the flat material in order to form the outer sleeve, tray, and insert. The outer sleeve may include an aperture that passes completely through the outer sleeve so the tray can slidably engage with the outer sleeve and be removed from the outer sleeve in either direction, or the aperture may be arranged in a single side of the outer sleeve to only allow access to a single side of the outer sleeve. The tray may include a base, a first lateral sidewall, a second lateral sidewall, a first longitudinal sidewall, and a second longitudinal sidewall. The first longitudinal sidewall may include a first flap and a second flap arranged on opposite ends of the first longitudinal sidewall. The second longitudinal sidewall may include a first flap and a second flap arranged on opposite ends of the second longitudinal sidewall. The flaps of the first and second longitudinal sidewalls may be folded perpendicular to the first and second longitudinal sidewalls. The insert may be arranged within the tray while the tray is arranged within the outer sleeve. The insert may include a plurality of dividers either arranged along the lateral or longitudinal direction. Various embodiments of packaging assemblies and methods for assembling the same will be described herein with specific reference to the appended drawings.

Embodiments according to the present disclosure include components that allow a packaging assembly to be assembled from flat material which is folded along indentations and perforations in order to create the packaging assembly components. Additionally, the removable insert allows for the same sized tray to be used for different applications, depending what item(s) need to be arranged within the tray for packaging. For example, the removable insert can include additional indentations in either the longitudinal or lateral direction in order to create more dividers and goods receiving channels within the removable insert.

As used herein, the term “flat material” refers to any rigid or semi-rigid substrates of material including, but not limited to cardboard, plastic, or the like. Flat materials are materials that have a resistance to bending under the force of gravity and remain flat when held in a cantilevered fashion. Such flat material can be stamped and/or perforated to provide fold lines along which the flat material may be folded to form a desired structure.

Referring now to FIGS. 1A and 1B, an embodiment of a packaging assembly 100 is schematically depicted. The packaging assembly 100 generally includes an outer sleeve 102, a tray 104, and an insert 120. The insert 120 may be arranged within the tray 104, and the tray 104 may be slidably engaged with the outer sleeve 102 so as to be able to slide in and out of the outer sleeve 102 in the longitudinal direction (+/−X-axis). The outer sleeve 102, tray 104, and insert 120 may be manufactured from pieces of flat material (e.g., substrates made from cardboard, plastic, or similar materials) which are stamped and/or perforated along predetermined lines and then folded along such predetermined lines to form the outer sleeve 102, tray 104, and insert 120.

Referring now to FIGS. 2A and 2B, an embodiment of the outer sleeve 102 is schematically depicted. The outer sleeve 102 generally includes a first portion 102A (a top), a second portion 102B (a side), a third portion 102C (a side), a fourth portion 102D (a bottom), a fifth portion 102E (a bottom), indentations 103, overlapping portion 106, overlapping portion 108. When assembled, as illustrated in FIG. 2A, the outer sleeve 102 forms an aperture 110 for receiving the tray 104 and insert 120. When unfolded, the outer sleeve 102 may be a flat rectangular piece of material. Such flat orientation may provide a reduced profile, which may allow for compact storage. In order to create the outer sleeve 102, the outer sleeve 102 may be folded along the indentations 103 at 90-degree angles, forming the outer sleeve 102. The indentations 103 may be created within the outer sleeve 102 through a stamping and/or scoring process.

Referring still to the embodiment depicted in FIGS. 2A and 2B, in a folded configuration, the first portion 102A, the fourth portion 102D, and the fifth portion 102E may extend in the X-Z plane. Additionally, the second portion 102B and the third portion 102C may extend in the X-Y plane. The fourth portion 102D and the fifth portion 102E each may include overlapping portions 106, 108, respectively. Once each portion 120A-120E is folded at a 90-degree angle along indentations 103, the overlapping portions 106, 108 will overlap one another in the vertical direction (+/−Y-axis). The overlapping portion 106, 108 can be secured to one another by an adhesive, mechanical means, or the like, in order to keep the outer sleeve 102 in the folded configuration. Additionally, in some embodiments and as depicted in FIG. 2C, the outer sleeve 102 may be pre-adhered and flattened along the indentations 103, where the aperture 110 is created by unflattening the outer sleeve 102 and spacing the first portion 102A and fourth and fifth portions 102D, 102E vertically apart from one another. With the outer sleeve 102 in the folded configuration, the aperture 110 is formed between the first portion 102A, the second portion 102B, the third portion 102C, the fourth portion 102D, and the fifth portion 102E. The aperture 110 extends through the entire outer sleeve 102 so that the tray 104 may be slid out of the outer sleeve 102 in either direction longitudinally (+/−X-axis). In some embodiments, one end of the outer sleeve 102 may be enclosed so that the aperture 110 does not pass through the entire outer sleeve 102.

Referring now to FIGS. 3A and 3B, an embodiment of a tray 104 is schematically depicted. The tray 104 generally includes a first longitudinal sidewall 112 (a side), a second longitudinal sidewall 114 (a side), a first lateral sidewall 116 (a front), a second lateral sidewall 118 (a rear), and a base 119 (a bottom). The first and second longitudinal sidewalls 112, 114 may be connected to the base 119 at the first and second longitudinal indentations 140A, 140B, which allow the first and second longitudinal sidewalls 112, 114 to be folded at 90-degree angles relative to the base 119 in order to form the first and second longitudinal sidewalls 112, 114. The first longitudinal sidewall 112, the second longitudinal sidewall 114, the first lateral sidewall 116, the second lateral sidewall 118, and the base 119 may form an insert space 132, where the insert 120 may be arranged within the tray 104. Additionally, the first and second longitudinal sidewalls 112, 114 may each include first and second flaps 134A, 134B, which may be arranged on opposite ends of each of the first and second longitudinal sidewall 112, 114. The first and second flaps 134A, 134B may be folded at a 90-degree angle along indentations 143, making the first and second flaps 134A, 134B perpendicular to the first and second longitudinal sidewalls 112, 114 in a folded configuration.

Referring still to the embodiment depicted in FIGS. 3A and 3B, each of the first and second lateral sidewalls 116, 118 may include a first portion 116A, 118A, a second portion 116B, 118B, and a third portion 116C, 118C. The first portions 116A, 118A may be folded along a first lateral indentation 141A and a second lateral indentation 141B at a 90-degree angle with respect to the base 119 in a folded configuration. Additionally, the second portions 116B, 118B may be folded along a third lateral indentation 141C and a fourth lateral indentation 141D at a 90-degree angle with respect to the first portions 116A, 118A. Even further, the third portions 116C, 118C may be folded along a fifth lateral indentation 141E and a sixth lateral indentation 141F at a 90-degree angle with respect to the second portions 116B, 118B. The combination of folds along the lateral indentations 141A-141F between the first portions 116A, 118A, the second portions 116B, 118B, the third portions 116C, 118C, and the base 119 arranges the first portions 116A, 118A parallel to the third portions 116C, 118C, and arranges the second portions 116B, 118B parallel with the base 119, respectively. A first channel 135 may form in-between the first portion 116A, the second portion 116B, the third portion 116C, and the base 119 in a folded configuration. Additionally, second channel 137 may form in-between the first portion 118A, the second portion 118B, the third portion 118C, and the base 119 in a folded configuration.

The first and second flaps 134A, 134B of the first and second longitudinal sidewalls 112, 114 may be disconnected from the first portions 116A, 118A via cuts 139, allowing the first and second flaps 134A, 134B to move and be folded independently of the first portions 116A, 118A of the first and second lateral sidewalls 116, 118. When folded, the first flaps 134A of the first longitudinal sidewall 112 and the second longitudinal sidewall 114 may arranged within the first channel 135 formed by the first portion 116A and the third portion 116C of the first lateral sidewall 116, and the second flaps 134B of the first longitudinal sidewall 112 and the second longitudinal sidewall 114 may be arranged within the second channel 137 formed by the first portion 118A and the third portion 118C of the second lateral sidewall 118 in a folded configuration. By arranging the first and second flaps 134A, 134B within the first and second lateral sidewalls 116, 118, the first and second longitudinal sidewalls 112, 114 are secured in a folded configuration. In the folded configuration, the first and second flaps 134A, 134B may be encapsulated by the base 119, first portions 116A, 118A, second portions 116B, 118B, and third portions 116C, 118C of the first and second lateral sidewalls 116, 118 when folded to form the first and second longitudinal sidewalls 112, 114.

Referring still to the embodiment depicted in FIGS. 3A and 3B, the base 119 may further include apertures 138A, 138B arranged therein. Additionally, the third portions 116C, 118C may include tabs 136A, 136B arranged on the ends of the third portions 116C, 118C and configured to be inserted into the apertures 138A, 138B, respectively. For example, when the first portion 118A, the second portion 118B, the third portion 118C, and the base 119 are in a folded configuration, the tabs 136A, 136B are aligned in the vertical direction (+/−Y-axis) and may be inserted into the apertures 138a, 138B within the base 119. The interaction between the tabs 136A, 136B and the apertures 138A, 138B secure the first portions 116A, 118A, the second portions 116B, 118B, and the third portions 116C, 118C in a folded configuration to form the first and second lateral sidewalls 116, 118.

Referring now to FIGS. 4A and 4B, an embodiment of an insert 120 is schematically depicted. The insert 120 generally includes a divider 122, a base portion 124, and a base portion 126. Together, the base portions 124 and 126 may form a floor of the tray 104 and may cover at least about 90 percent of an interior surface area of the base 119. The divider 122 may include a vertical portion 122A, a horizontal portion 122B, and a vertical portion 122C. The vertical portion 122A may be folded at a 90-degree angle with respect to the base portion 126 in order to arranged the vertical portion 122A in the vertical direction (+/−Y-axis). Additionally, the vertical portion 122C may be folded at a 90-degree angle with respect to the base portion 124 in order to arranged the vertical portion 122C in the vertical direction (+/−Y-axis). The vertical portions 122A, 122C may be folded at a 90-degree angle along indentations 130A, 130B with respect to the horizontal portion 122B. The combination of folds along perforations 128A, 128B and indentations 130A, 130B between the vertical portion 122A, horizontal portion 122B, vertical portion 122C, the base portion 124, and the base portion 126 creates the divider 122 integrally within the insert 120. Once the divider 122 is formed within the insert 120, the insert 120 may be correctly sized to be arranged within the insert space 132 of the tray 104 (FIG. 1B). The divider 122, when folded may have a height (in the +/−Y direction of the depicted coordinate axes), which when inserted into the tray 104 is substantially flush with a top of the sidewalls 112, 114, 116, and 118 when the insert 120 is arranged within the tray 104.

Referring now to FIGS. 5A and 5B, an embodiment of an insert 120′ is schematically depicted. In some embodiments, the insert 120′ may replace the insert 120 within the tray 104 if more dividers are desired for a specific application (e.g., holding various rows of baked goods). Additionally, even though the insert 120′ is depicted with only three dividers, it should be appreciated that any number of dividers may be formed within the insert 120′ (e.g., 2 or more, 3 or more, 4 or more, 5 or more, etc.). The insert 120′ generally includes a base portion 154, a base portion 156, a base portion 158, a base portion 160, a divider 162, a divider 164, and a divider 166. Together, the base portions 154, 156 and 158 may cover at least about 90 percent of an interior surface area of the base 119. The divider 162 may include a vertical portion 162A, a horizontal portion 162B, and a vertical portion 162C. The vertical portion 162A may be folded at a 90-degree angle with respect to the base portion 154 along perforation 168A in order to arrange the vertical portion 162A in the vertical direction (+/−Y-axis). Additionally, the vertical portion 162C may be folded at a 90-degree angle with respect to the base portion 156 along perforation 168B in order to arrange the vertical portion 162C in the vertical direction (+/−Y-axis). The vertical portions 162A, 162C may be folded at a 90-degree angle along indentations 170A, 170B with respect to the horizontal portion 162B. The combination of folds along perforations 168A, 168B and indentations 170A, 170B between the vertical portion 162A, horizontal portion 162B, vertical portion 162C, the base portion 154, and the base portion 156 creates the divider 162 integrally within the insert 120′.

Referring still to the embodiment depicted in FIGS. 5A and 5B, the divider 164 may include a vertical portion 164A, a horizontal portion 164B, and a vertical portion 164C. The vertical portion 164A may be folded at a 90-degree angle with respect to the base portion 156 along perforation 168C in order to arrange the vertical portion 164A in the vertical direction (+/−Y-axis). Additionally, the vertical portion 164C may be folded at a 90-degree angle with respect to the base portion 158 along perforation 168D in order to arrange the vertical portion 164C in the vertical direction (+/−Y-axis). The vertical portions 164A, 164C may be folded at a 90-degree angle along indentations 170C, 170D with respect to the horizontal portion 164B. The combination of folds along perforations 168C, 168D and indentations 170C, 170D between the vertical portion 164A, horizontal portion 164B, vertical portion 164C, the base portion 156, and the base portion 158 creates the divider 164 integrally within the insert 120′.

Referring still to the embodiment depicted in FIGS. 5A and 5B, the divider 166 may include a vertical portion 166A, a horizontal portion 166B, and a vertical portion 166C. The vertical portion 166A may be folded at a 90-degree angle with respect to the base portion 158 along perforation 168E in order to arrange the vertical portion 166A in the vertical direction (+/−Y-axis). Additionally, the vertical portion 166C may be folded at a 90-degree angle with respect to the base portion 160 along perforation 168F in order to arrange the vertical portion 166C in the vertical direction (+/−Y-axis). The vertical portions 166A, 166C may be folded at a 90-degree angle along indentations 170E, 170F with respect to the horizontal portion 166B. The combination of folds along perforations 168E, 168F and indentations 170E, 170F between the vertical portion 166A, horizontal portion 166B, vertical portion 166C, the base portion 158, and the base portion 160 creates the divider 166 integrally within the insert 120′. Once the dividers 162, 164, and 166 are formed within the insert 120′, the insert 120′ may be correctly sized to be arranged within the insert space 132 of the tray 104 (as depicted in FIG. 3A). It is important to note that the insert 120 may be arranged so that the divider 122 extends in the longitudinal direction (+/−X-axis). Additionally, the insert 120′ may be arranged so that the dividers 162, 164, and 166 extend in the lateral direction (+/−Z-axis). Also, the dividers 162, 164, and 166 may have the a vertical height (+/−Y-axis) so that the horizontal portions 162B, 164B, and 166B may be flush with the sidewalls 112, 114, 116, and 118 when the insert 120′ is arranged within the tray 104.

Referring now to FIG. 6, an embodiment of a tray 104 and insert 120′ is schematically depicted. The second flap 134B of the first longitudinal sidewall 112 is not illustrated for simplicity. As the first portion 118A, second portion 118B, and the third portion 118C are folded to create the second lateral sidewall 118, a small gap 171 may form between the base 119 of the tray 104 and the second lateral sidewall 118. As the insert 120′ is arranged within the insert space 132 of the tray 104, a portion 172 of the base portion 160 may be arranged within the gap formed between the base 119 and the second lateral sidewall 118. The portion 172 may secure the insert 120′ within the tray 104. Additionally, if a gap is not formed within the tray 104, the insert 120′ may engage the first and second lateral sidewalls 116, 118 so as to be held in place within the tray 104 due to a friction or pressure between the first and second lateral sidewalls 116, 118 and the insert 120′. For example, the insert 120′ may exert a friction force against the first and second lateral sidewalls 116, 118. The force exerted by the insert 120′ as the insert 120′ attempts to unfold within the tray 104 may secure the insert 120′ within the tray 104.

Referring now to FIG. 7, the packaging assembly 100 filled with goods 50 is depicted. In some embodiments, the combination of the tray 104 and the insert 120 may form goods receiving channels 131 when the insert 120 is arranged within the tray 104. The goods receiving channels 131 may be used to store goods 50 within the packaging assembly 100, such as baked goods (e.g., cookies, cakes, pastries, etc.), and prevent the goods 50 from shifting or becoming damaged during transportation. The insert 120 may include a plurality of goods receiving channels 131, and may be directly related to the number of dividers 122 arranged within the insert 120. Additionally, it should be appreciated that the goods receiving channels 131 may be various forms, such as rectangles, squares, or the like without departing from the scope of this disclosure.

Referring now to FIG. 8, a flow chart depicting a method 200 for assembling the packaging assembly 100 (as illustrated in FIGS. 1-6) is depicted. It is noted that while a number of steps are shown in a specific order, embodiments may include a greater or fewer number of steps in varying orders without departing from the scope of the present disclosure. To begin, at step 202 the method 200 may include folding a first flat material 10 for folding into the outer sleeve 102 along a plurality of indentations 103 formed within the first flat material 10 to form the outer sleeve 102. For example, and with reference to FIGS. 2A and 2B, the outer sleeve 102 may be made from a single piece of flat material 10, where the indentations 103 are formed in the outer sleeve 102 in order to fold the outer sleeve 102 from a flat material 10 into a folded configuration. In some embodiments, the first flat material 10 may be pre-adhered and flattened prior to assembly of the packaging assembly 100, where the flat material 10 is folded into a standing position such as illustrated in FIG. 2C in order to form the outer sleeve 102.

Referring again to FIG. 8, step 204 may include folding a second flat material 20 for folding into the tray 104 along a first longitudinal indentation 140A formed within the second flat material 20 to form a first longitudinal sidewall 112. For example, and as described above, the tray 104 may be formed from a single piece of flat material 20, where the first longitudinal sidewall 112 is folded at a 90-degree angle with respect to the base 119 to form the first longitudinal sidewall 112. Step 206 may include folding a first flap 134A and a second flap 134B of the first longitudinal sidewall 112 perpendicular to the first longitudinal sidewall 112. For example, and with reference to FIGS. 3A and 3B, the first and second flaps 134A, 134B may be folded at a 90-degree angle along indentations 143.

Referring again to FIG. 8, step 208 may include folding the second flat material 20 for folding into the tray 104 along a second longitudinal indentation 140B formed within the second flat material 20 to form a second longitudinal sidewall 114. For example, and as described above, the tray 104 may be formed from a single piece of flat material 20, where the second longitudinal sidewall 114 is folded at a 90-degree angle with respect to the base 119 to form the second longitudinal sidewall 114. Step 210 may include folding a first flap 134A and a second flap 134B of the second longitudinal sidewall 114 perpendicular to the second longitudinal sidewall 114. For example, and with reference to FIGS. 3A and 3B, the first and second flaps 134A, 134B may be folded at a 90-degree angle along indentations 143.

Referring again to FIG. 8, step 212 may include folding the second flat material 20 for folding into the tray 104 along a first lateral indentation 141A formed within the second flat material 20 to form a first lateral sidewall 116. For example, and with reference to FIGS. 3A and 3B, the first lateral sidewall 116 is formed from first portion 116A, second portion 116B, and third portion 116C, all of which are folded at a 90-degree angle with respect to one another to form the first lateral sidewall 116. Step 214 may include folding the second flat material 20 along a second lateral indentation 141B formed within the second flat material 20 to form a second lateral sidewall 118. For example, and with reference to FIGS. 3A and 3B, the second lateral sidewall 118 is formed from first portion 118A, second portion 118B, and third portion 118C, all of which are folded at a 90-degree angle with respect to one another to form the second lateral sidewall 118.

Referring again to FIG. 8, step 216 may include folding a third flat material 30 for folding into the insert 120 along a first indentation 130A and a second indentation 130B formed within the third flat material 30 to form an insert 120 including at least one divider 122. For example, and with reference to FIGS. 4A-5B, the insert 120 may include a single or a plurality of dividers 122, where the dividers 122 are formed by folding the insert 120 at a 90-degree angle along the perforations 128A, 128B or the indentations 130A, 130B. It should be noted that the insert 120 can include a plurality of dividers arranged in either the longitudinal or longitude direction, for example, insert 120′ depicted in FIG. 5A. Step 218 may include arranging the insert 120 within the tray 104. For example, and as described above, once the insert 120 is in a folded configuration, the insert 120 can be arranged within the insert space 132 of the tray 104.

Referring again to FIG. 8, step 220 may include arranging the tray 104 and insert 120 within the aperture 110 of the outer sleeve 102, where the tray 104 slidably engages with the outer sleeve 102. For example, and with reference to FIG. 1B, the tray 104 is slidably engaged within the aperture 110 of the outer sleeve 102, allowing the tray 104 to be removed from the outer sleeve 102 in either longitudinal direction (+/−X-axis).

The method may further include arranging baked goods (e.g., cookies, cakes, etc.) within the goods receiving channels of the tray. Rows of the baked good may be separated by the dividers. The method may further include shipping the packaging assembly to a recipient.

It should now be understood that embodiments described herein are directed to a packaging assembly and methods of assembly of the packaging assembly. The packaging assembly may include an outer sleeve, a tray, and an insert. The outer sleeve may include an aperture that passes completely through the outer sleeve so the tray can slidably engage with the outer sleeve and be removed from the outer sleeve in either direction. The tray may include a base, lateral sidewalls, and longitudinal sidewalls. The lateral sidewalls and longitudinal sidewalls are folded with respect to the base in order to form the tray. The insert may be arranged within the tray while the tray is arranged within the outer sleeve. The insert may include a plurality of dividers either arranged in the lateral or longitudinal direction.

It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.

Claims

1. A packaging assembly, comprising:

an outer sleeve, wherein the outer sleeve comprises an at least one aperture;

a tray arranged within the aperture, wherein the tray slidably engages with the outer sleeve, the tray comprising: a base; a first lateral sidewall and a second lateral sidewall arranged opposite from one another and coupled to the base, each of the first lateral sidewall and the second lateral sidewall comprising: a first portion; a second portion; and a third portion, wherein the first, second, and third portions are folded to form the first and second lateral sidewalls; a first longitudinal sidewall and a second longitudinal sidewall arranged opposite from one another and coupled to the base, each of the first longitudinal sidewall and the second longitudinal sidewall comprising: a first flap; and a second flap, wherein the first flap and the second flap are arranged on opposite ends of the first and second longitudinal sidewalls, and the first flaps are arranged between the first portion and third portion of the first lateral sidewall, and the second flaps are arranged between the first portion and third portion of the second lateral sidewall; and

an insert arranged within the tray.

2. The packaging assembly of claim 1, wherein the first portions of the first and second lateral side walls are parallel to the third portions of the first and second lateral side walls when the tray is in a folded configuration.

3. The packaging assembly of claim 2, wherein the second portions of the first and second lateral sidewalls are parallel to the base when the tray is in the folded configuration.

4. The packaging assembly of claim 3, further comprising tabs extending from the third portions of the first and second lateral sidewalls.

5. The packaging assembly of claim 4, wherein the tabs of the third portions engage with apertures formed in the base of the tray to secure the first, second, and third portions in the folded configuration, forming the first and second lateral sidewalls.

6. The packaging assembly of claim 5, wherein the flaps of the first and second longitudinal sidewalls are perpendicular to the first and second longitudinal sidewalls when in the folded configuration.

7. The packaging assembly of claim 6, wherein the flaps of the first and second longitudinal sidewalls are encapsulated by the base and first, second, and third portions of the first and second lateral sidewalls when in the folded configuration to form the first and second longitudinal sidewalls.

8. The packaging assembly of claim 1, further comprising at least one divider integrally arranged on the insert.

9. The packaging assembly of claim 8, wherein the at least one divider is formed integrally within the insert by folding a portion of the insert along a plurality of indentations formed within the insert.

10. The packaging assembly of claim 9, wherein the at least one divider substantially flush with the first and second lateral sidewalls and the first and second longitudinal sidewalls.

11. The packaging assembly of claim 9, wherein at least one goods receiving channel is formed between the tray and the insert.

12. The packaging assembly of claim 10, wherein the insert secures within the tray through a friction force which the insert exerts on the tray.

13. The packaging assembly of claim 10, wherein the insert engages a channel formed between a first and second lateral sidewalls and the base of the tray.

14. A method of packaging baked goods using a packaging assembly, the method comprising:

forming an outer sleeve comprising a top, a bottom and sides that extend between the top and the bottom, the outer sleeve having an aperture that extends between opposite ends of the sleeve;

forming a tray comprising a front wall, a rear wall, side walls that extend between the front wall and the rear wall and a bottom that extends between the front wall, the rear wall and the side walls, wherein the tray is sized to be slidably received within the aperture of the outer sleeve;

forming an insert comprising a base and multiple dividers that extend upwardly from the base to form channels that are separated from one another, the insert sized to be received within the tray such that the base covers the bottom of the tray within areas between the dividers;

placing the insert within the tray;

filling at least one of the channels with baked goods that are sized to be received within the aperture of the sleeve, the baked good resting on the base of the insert; and

sliding the tray and baked goods within the aperture of the sleeve from an open configuration to a closed configuration.

15. The method of claim 14, wherein the insert is formed by folding a flat cardboard material into the multiple dividers.

16. A method of forming a packaging assembly, comprising:

folding a first flat material along a plurality of indentations formed within the first flat material to form an outer sleeve, the outer sleeve comprising an aperture;

forming a tray, comprising: folding a second flat material along a first longitudinal indentation formed within the second flat material to form a first longitudinal sidewall; folding a first flap and a second flap of the first longitudinal sidewall perpendicular to the first longitudinal sidewall; folding the second flat material along a second longitudinal indentation formed within the second flat material to form a second longitudinal sidewall; folding a first flap and a second flap of the second longitudinal sidewall perpendicular to the second longitudinal sidewall; folding the second flat material along a first lateral indentation formed within the second flat material to form a first lateral sidewall; and folding the second flat material along a second lateral indentation formed within the second flat material to form a second lateral sidewall, wherein the first lateral sidewall, the second lateral sidewall, the first longitudinal sidewall, and the second longitudinal sidewall form a base of the tray; folding a third flat material along a first indentation and a second indentation formed within the third flat material to form an insert, the insert comprising at least one divider; arranging the insert within the tray; and arranging the tray and insert within the aperture of the outer sleeve, wherein the tray slidably engages with the outer sleeve.

17. The method of forming a packaging assembly of claim 16, further comprising folding the second flat material along a third lateral indentation and a fourth lateral indentation formed within the second flat material to form a first portion, a second portion, and a third portion of the first lateral sidewall.

18. The method of forming a packaging assembly of claim 17, further comprising folding the second flat material along a fifth lateral indentation and a sixth lateral indentation formed within the second flat material to form a first portion, a second portion, and a third portion of the second lateral sidewall.

19. The method of forming a packaging assembly of claim 18, wherein the first portions of the first and second lateral sidewalls are parallel to the third portions of the first and second lateral sidewalls when in a folded configuration to form the first and second lateral sidewalls.

20. The method of forming a packaging assembly of claim 19, wherein the second portions of the first and second lateral sidewalls are parallel to the base when folded to form the first and second lateral sidewalls.