Packaging Tray with Interlocking Sidewalls

Description

SUMMARY

A packaging tray with interlocking sidewalls configured to physically support an electronic device is described herein. In aspects, the packaging tray includes a center panel, a first opposing sidewall, a second opposing sidewall, a first compartment, and a second compartment. The center panel includes a first pair of opposing fold edges and a second pair of opposing fold edges, where the fold edges of the first and second pairs are oriented substantially perpendicular to one another. The first opposing sidewall extends from a first fold edge and the second opposing sidewall extends from a second fold edge, substantially perpendicular to the first opposing sidewall. The first compartment is defined in the first opposing sidewall and includes a first locking portion. The second compartment is defined in the second opposing sidewall and includes a second locking portion. The second locking portion is configured to engage the first locking portion to connect the first and second opposing sidewalls. This configuration provides enhanced structural integrity to the packaging tray, allowing the sidewalls to interlock when assembled.

In some implementations, the first and second compartments may be trapezoidal-prism shaped, and the respective locking portions may be defined in the lateral faces of these shapes. The first locking portion may further include a rib that extends inwardly into the first compartment, and the second locking portion may include a channel that extends outwardly from the second compartment. The rib can be slightly larger than the channel, creating an interference fit when inserted, thereby interlocking the first and second locking portions together and securely connecting the sidewalls.

The center panel may be spaced apart from the opposing sidewalls by the fold edges, defining an accessory space between an underside of the center panel and inside faces of the first and second compartments. This accessory space is configured to receive a product accessory (e.g., a cable), preventing unwanted movement and integrating the accessory with the supported electronic device. Additionally, the center panel may define at least one receiving cavity configured to receive a portion of the electronic device. A packaging base that defines a recess configured to receive the packaging tray, along with a packaging lid that is configured to slidably fit over the packaging base, may also be included as part of a complete packaging system.

This Summary is provided to introduce simplified concepts for packaging trays with interlocking sidewalls, which are further described below in the Detailed Description and is illustrated in the Drawings. This Summary is intended neither to identify essential features of the claimed subject matter nor for use in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more aspects of packaging trays with interlocking sidewalls are described in this document with reference to the following Drawings. The use of same numbers in different instances may indicate similar features or components. Series 100 numbers may refer to features originally found in FIG. 1, series 200 numbers may refer to features originally found in FIG. 2, series 300 numbers may refer to features originally found in FIG. 3, and so on.

FIG. 1 perspective view of a packaging system including a packaging tray with interlocking sidewalls.

FIG. 2 is a top side view of a packaging tray with interlocking sidewalls.

FIG. 3 is a bottom side view of the packaging tray of FIG. 2.

FIG. 4 is a first top side perspective view of the packaging tray of FIG. 2 after the installation of the electronic device into the packaging tray, in an unfolded configuration.

FIG. 5 is a bottom side view of the packaging tray of FIG. 2, which illustrates the folding of the interlocking sidewalls.

FIG. 6 is a bottom side view of the packaging tray of FIG. 2, which illustrates the packaging tray in its folded and interlocked configuration.

FIG. 7 is a top side perspective view of the packaging tray of FIG. 2, where the packaging tray is in the folded and interlocked configuration.

DETAILED DESCRIPTION

Overview

The field of packaging often employs trays that are positioned within a packaging box to secure and protect articles during transit and storage. One example of such a packaging tray includes a center panel with downwardly extending legs that support the center panel above a surface. The sidewalls of such trays often necessitate manual retention during the process of inserting the tray into an outer box or container. This manual retention can introduce inefficiencies in packaging assembly. Furthermore, existing packaging tray designs typically lack dedicated features for securing additional articles (e.g., cables, other accessories). Accommodating these accessory items commonly requires the inclusion of a separate insert structure within the packaging assembly. The use of a distinct insert for accessories can add complexity to the manufacturing process, increase material costs, and potentially contribute to a larger overall packaging footprint. Current packaging tray structures may also exhibit insufficient rigidity when subjected to the weight of certain articles. For example, heavier articles can cause the sidewalls of a conventional packaging tray to bow outwards, potentially compromising the stability of the article within the packaging or leading to an undesired aesthetic. This lack of inherent structural reinforcement can undermine the protective function of the packaging tray.

Therefore, there is a technical need for an improved packaging tray that addresses these limitations, specifically by providing enhanced structural integrity, eliminating the need for manual retention during assembly, and integrating features for securing ancillary items without requiring additional components.

This document describes techniques and apparatuses for packaging trays with interlocking sidewalls. Aspects of the packaging trays are configured to address challenges in packaging (e.g., providing enhanced structural integrity and efficiently securing accessories). For example, a packaging tray may enable the automated and stable assembly of a packaging system.

When the sidewalls are folded and engaged, they interlock, creating a stable support structure beneath a center panel. This configuration significantly increases the structural stability of the packaging tray, which can lead to a more efficient packaging process by reducing or eliminating the need for manual retention of components during assembly. The enhanced structural support provided by the interconnected sidewalls also helps maintain the stability of articles (e.g., electronic devices) placed within the tray, preventing unwanted movement and protecting the contents.

Additionally, a packaging tray with interlocking sidewalls may form an integrated accessory space when assembled. For instance, the center panel can be spaced apart from the opposing sidewalls by fold edges, which define an accessory space between an underside of the center panel and inside faces of the compartments. The accessory space is configured to receive and secure a product accessory, e.g., a cable. By integrating accessory retention directly into the tray structure, the design minimizes the need for separate inserts, which can reduce complexity in manufacturing, lower material costs, and potentially decrease the overall packaging footprint.

The disclosed packaging trays provide a more robust packaging solution that can enhance protection for electronic devices and accessories during transport and storage. The improvements in structural reinforcement allow the packaging to support heavier articles without deformation. For example, the interlocking engagement of the sidewalls may increase the rigidity of the assembly, which can prevent sidewall bowing when under load. This integrated structural integrity provides a reliable and cost-effective method for packaging a variety of products, offering substantial commercial value through improved product protection and manufacturing efficiencies.

This is but one example of how the described packaging trays are configured to address challenges in packaging. Other examples and implementations are described throughout this document.

Example Apparatuses and Systems

This Detailed Description sets forth various implementations of packaging trays with interlocking sidewalls, which are configured to physically support an electronic device. These designs address several challenges in packaging, for example, providing enhanced structural integrity and efficiently securing accessories, thereby enabling a more automated and stable assembly of a packaging system. When the sidewalls are folded and engaged, they interlock, creating a stable support structure beneath a center panel. This configuration significantly increases the structural stability of the packaging tray, which can lead to a more efficient packaging process by reducing or eliminating the need for manual retention of components during assembly. The enhanced structural support provided by the interconnected sidewalls also helps maintain the stability of articles placed within the tray, preventing unwanted movement and protecting the contents. Additionally, a packaging tray with interlocking sidewalls may form an integrated accessory space when assembled. By integrating accessory retention directly into the tray structure, the design minimizes the need for separate inserts, which can reduce complexity in manufacturing, lower material costs, and potentially decrease the overall packaging footprint. The disclosed packaging trays provide a more robust packaging solution that can enhance protection for electronic devices and accessories during transport and storage. The improvements in structural reinforcement allow the packaging to support heavier articles without deformation. For example, the interlocking engagement of the sidewalls may increase the rigidity of the assembly, which can prevent bowing when under load. This integrated structural integrity provides a reliable and cost-effective method for packaging a variety of products, offering substantial commercial value through improved product protection and manufacturing efficiencies.

Referring initially to FIG. 1, illustrated is a packaging system 100 that includes a packaging tray 110 for an electronic device 120 (e.g., a camera), a base 130 for receiving the packaging tray 110, and a lid 140 for covering the assembly. The base 130 may define a recess 132 that is configured to receive the packaging tray 110 therein. The recess 132 may include a ledge 134. The lid 140 is configured to slidably fit over the base 130. The packaging system 100 provides comprehensive protection for the electronic device 120 and its product accessory 122 (e.g., a cable, an integrated power connector). The recess 132 in the base 130 securely holds the packaging tray 110, preventing shifting within the packaging tray 110. The slidably fitting lid 140 provides an additional layer of protection and security, ensuring that the contents remain undisturbed from manufacturing through to the end-user. This integrated packaging system 100 offers a robust and aesthetically pleasing packaging solution, suitable for a variety of electronic devices.

Referring now to FIGS. 2-7, illustrated is a second aspect of a packaging tray 200 configured to physically support an article (e.g., electronic device 120). The packaging tray 200 includes a center panel 202 having a first pair of opposing fold edges (e.g., fold edge 204 and fold edge 206) and a second pair of opposing fold edges (e.g., fold edge 208 and fold edges 210/212). In other aspects, a packaging tray may include more or fewer fold edges. The fold edges are configured for folding. A fold edge may include multiple fold edges, for example, a fold edge includes fold edge 210 and fold edge 212, which are separated by a notch 290 that is defined in the center panel 202. The notch 290 may be configured to receive a cable of a product accessory 122 (e.g., a cable, an integrated power connector) therethrough, as illustrated in FIG. 7.

The fold edges of the first and second pairs of opposing fold edges may be oriented substantially perpendicular to one another. For example, fold edge 206 is substantially perpendicular to fold edges 208 and 212 and fold edge 204 is substantially perpendicular to fold edges 208 and 210. As used herein, “substantially” in terms of “substantially perpendicular” can connote different ranges depending on context. For example, “substantially” can correspond to being as “perpendicular” as is feasible given a particular technology's capabilities. As another example, “substantially” can connote being within 50%, 25%, 10%, 5%, or even 1% of being fully “perpendicular.”

Sidewalls extend from respective fold edges and are thus configured to be foldingly positioned relative to the center panel 202. In the aspect illustrated in FIGS. 2-7, sidewall 214 extends from fold edge 204, sidewall 216 extends from fold edge 206, sidewall 218 extends from fold edge 208, sidewall 220 extends from fold edge 210, and sidewall 222 extends from fold edge 212. The first opposing sidewalls (e.g., sidewall 214 and sidewall 216) may be oriented substantially perpendicular to the respective second opposing sidewalls (e.g., sidewall 218, sidewalls 220 and 222). As illustrated in FIG. 5, the packaging tray 200 is configured to fold at the fold edges to enable the locking portions to interlock, movable from an unfolded configuration (illustrated in FIG. 5) to a folded and interlocked configuration (illustrated in FIGS. 6 and 7).

A sidewall may define a compartment, which may extend therein and/or therefrom. For example, sidewall 214 includes a compartment 224, sidewall 216 includes compartment 226, sidewall 218 includes compartment 228, sidewall 220 includes compartment 230, and sidewall 222 includes compartment 232. The compartments may have a concave interior shape, which may improve the rigidity and strength of the packaging tray 200 for supporting heavier articles.

The compartments may include at least one locking portion configured to engage a locking portion of another compartment to connect the respective sidewalls together. For example, compartment 224 includes a locking portion 234 that is configured to engage locking portion 242 of compartment 228, compartment 224 further includes a locking portion 238 that is configured to engage locking portion 262 of compartment 230, compartment 228 further includes a locking portion 246 that is configured to engage locking portion 250 of compartment 226, and compartment 226 further includes a locking portion 254 that is configured to engage locking portion 258 of compartment 232. Engagement between locking portions connects the sidewalls together. This engagement capability facilitates automated assembly processes by eliminating the need for manual retention of the sidewalls when the tray is inserted into a box or a base, which is a common inefficiency in traditional packaging designs.

The locking portions include ribs and/or channels. The ribs may be slightly larger (e.g., 0.3 mm) than the channels, such that when the rib is inserted into the channel an interference fit is created to interlock the locking portions to connect the respective sidewalls together. This interference fit provides a robust and reliable self-locking mechanism that significantly enhances the structural integrity of the packaging tray 200. In this way, the locking portions can be described as snapping together. The secure interlocking prevents inadvertent separation of the sidewalls, which helps to maintain the form and protective function of the packaging, even when subjected to external forces during transport or handling. This can eliminate the problem of sidewalls of the tray bowing out due to increased weight, as seen in previous designs.

The ribs and channels may have elongated shapes, which helps to keep the adjacent compartments aligned to one another when connected together. The ribs may extend outwardly from a surface of the compartment and the channels may extend inwardly into a surface of the compartment. In the illustrated example, locking portion 234 is a rib 236, locking portion 238 is a rib 240, locking portion 242 is a channel 244, locking portion 246 is a channel 248, locking portion 250 is a rib 252, locking portion 254 is a rib 256, locking portion 258 is a channel 260, and locking portion 262 is a channel 264. The arrangement of ribs and channels in FIGS. 2-7 is merely an example. In other aspects, the arrangement of ribs and channels may be rearranged.

In some implementations, a compartment (e.g., compartment 224, compartment 226, compartment 228, compartment 230, compartment 232) may have a trapezoidal-prism shape that provides structural stability for the packaging tray 200 when assembled. For example, the geometry of these compartments can enhance the load-bearing capacity of the sidewalls and resist deformation, particularly when supporting heavier electronic devices 120. Engaging locking portions (e.g., locking portion 234 and locking portion 238) may be defined in lateral faces of the respective trapezoidal-prism shapes. For example, rib 236 defined in lateral face 310 of compartment 224, rib 240 defined in lateral face 312 of compartment 224, channel 244 defined in lateral face 314 of compartment 228, channel 248 defined in lateral face 316 of compartment 228, rib 252 defined in lateral face 318 of compartment 226, rib 256 defined in lateral face 320 of compartment 226, channel 260 defined in lateral face 322 of compartment 232, and/or channel 264 defined in lateral face 324 of compartment 230. This strategic placement of the locking portions within the robust geometry of the trapezoidal-prism shaped compartments ensures a secure and stable connection between the sidewalls.

The center panel 202 is spaced apart from the opposing sidewalls (e.g., sidewall 214 and sidewall 218) by the fold edges (e.g., fold edge 204 and fold edge 208) to define an accessory space 304 between an underside 302 of the center panel 202 and inside faces (e.g., inside face 330, inside face 332, inside face 334, inside face 336, inside face 338) of the compartments. The accessory space 304 is configured to receive a product accessory 122. For example, the accessory space 304 can be configured as a 6 mm pocket for storing a 5 mm cable. This integrated accessory space 304 eliminates the need for a separate insert structure to accommodate cables or other accessories. The unification of the product accessory 122 with the electronic device 120 within the same tray structure simplifies the packaging assembly process, reduces material costs by removing the need for additional components, reduces waste, and can contribute to a more compact overall packaging footprint. The accessory space 304 may also prevent unwanted movement of the product accessory 122 during transit, protecting both the accessory and the primary electronic device 120. In aspects, an accessory space may be omitted.

The center panel 202 also defines at least one receiving cavity 270 configured to receive a portion of the electronic device 120. This receiving cavity 270 may be molded to conform to the contours of the electronic device 120, providing a secure and customized fit that minimizes movement within the packaging tray 200. This tailored fit contributes to enhanced protection of the electronic device 120 against impact and abrasion during shipping and handling, which is a significant improvement over generic packaging solutions. In aspects, a receiving cavity may be omitted.

The packaging tray may be fabricated of any suitable material, including, but not limited to, plastic, cardboard, and molded fiber (e.g., a packaging material that is typically made from recycled paper pulp molded into a particular shape via a pressure molding/forming process).

Example Methods

This section describes an example technique (method) for assembling a packaging tray with interlocking sidewalls. In the following description, the example method is described as a set of blocks that specify operations performed but are not necessarily limited to the order or combinations shown for performing the operations by the respective blocks. Further, any of one or more of the operations may be repeated, combined, reorganized, or linked to provide a wide array of additional and/or alternate methods.

An example method for assembling a packaging tray configured to physically support an electronic device includes: providing a center panel including a first pair of opposing fold edges and a second pair of opposing fold edges, the fold edges of the first and second pairs of opposing fold edges oriented substantially perpendicular to one another; extending at least one first opposing sidewall from a first fold edge of the fold edges; extending at least one second opposing sidewall from a second fold edge of the fold edges, the second opposing sidewall extending substantially perpendicular to the first opposing sidewall; defining a first compartment in the first opposing sidewall, the first compartment including a first locking portion; defining a second compartment in the second opposing sidewall, the second compartment including a second locking portion; and engaging the second locking portion with the first locking portion to connect the first and second opposing sidewalls together. Engaging the second locking portion with the first locking portion may include: providing the first locking portion with a rib that is located in and extends inwardly into the first compartment; providing the second locking portion with a channel that is located on and extends outwardly from the second compartment; and inserting the rib into the channel, wherein the rib is slightly larger than the channel to create an interference fit and interlock the first locking portion and the second locking portion.

The method may further include: spacing the center panel apart from the opposing sidewalls by the fold edges to define an accessory space between an underside of the center panel and inside lateral faces of the first and second compartments; and receiving a product accessory in the accessory space. The method may include defining at least one receiving cavity in the center panel, the at least one receiving cavity configured to receive a portion of the electronic device. The method may include: providing a base including a left wall, a right wall, a front wall, a back wall, and a bottom wall, the base defining a recess; and receiving the packaging tray in the recess, and in aspects may further include slidably fitting a lid over the base.

Interpretation

As used herein, a phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover a, b, c, a-b, a-c, b-c, and a-b-c, as well as any combination with multiples of the same element (e.g., a-a, a-a-a, a-a-b, a-a-c, a-b-b, a-c-c, b-b, b-b-b, b-b-c, c-c, and c-c-c or any other ordering of a, b, and c).

CONCLUSION

Although concepts of packaging trays with interlocking sidewalls have been described in language specific to techniques and/or apparatuses, it is to be understood that the subject of the appended claims is not necessarily limited to the specific techniques or apparatuses described. Rather, the specific techniques and apparatuses are disclosed as example implementations of ways in which packaging trays with interlocking sidewalls may be implemented.