Product mailing and method of assembling product mailing

Abstract

A product mailing (150) has an envelope (152) and a first card (12a) positioned within the envelope. The first card has a bottom surface and a plurality of receptacles (14a, 16a, 18a, 20a) mounted on the bottom surface of the first card. Each of the receptacles mounted on the first card defines a cavity sized to contain a respective product. A second card (12b) is positioned within the envelope. The second card has a bottom surface opposite the bottom surface of the first card. A plurality of receptacles (14b, 16b, 18b, 20b) are mounted on the bottom surface of the second card. Each of the receptacles mounted on the second card defines a cavity sized to contain a respective product. The receptacles mounted on the first card are offset from the receptacles mounted on the second card.

Description

Technical Field

[0001] The present invention relates generally to packaging for consumer products, and more specifically to direct-to-consumer packaging that can be shipped via standard mail systems. Background Technology

[0002] More consumers are beginning to prefer shopping online and receiving products in the mail rather than making purchases in person at a store. As a result, manufacturers have introduced direct-to-consumer (DTC) packaging to securely and economically ship their products to consumers. Another consumer trend is sustainability. Consumers prefer products and packaging that are more sustainable, generate less waste, and have a smaller environmental impact. The cost of shipping products via mail systems is typically borne by the manufacturer. Therefore, manufacturers need to minimize costs as much as possible to maintain profit margins similar to those of selling the same products in stores. Shipping products in boxes is generally more expensive than shipping in sleeves. However, shipping products in sleeves requires that the products being shipped be below a certain thickness and meet flexibility requirements. For example, the U.S. Postal Service requires that when products are placed in standard shipping sleeves, the sleeves must be flexible along both axes of the sleeve so that current sorting equipment can successfully handle the sleeves. It is also preferable to send more products within sleeves to reduce overall shipping costs. However, product displacement within the sleeve can negatively affect the sleeve's flexibility, depending on the product's position within the sleeve.

[0003] More packaging is being designed for direct-to-consumer product supply. However, consumers expect the same ease of use and functionality from both the products and their packaging sold in stores. Despite the use of known packaging technologies, further modifications to consumer product packaging are needed to provide packaging that allows manufacturers to reliably, economically, and efficiently deliver products to consumers without negatively impacting the consumer experience. Summary of the Invention

[0004] In one aspect, generally speaking, the present invention is characterized by a product mailing item having a sleeve and a first cardboard plate positioned within the sleeve. The first cardboard plate has a bottom surface and a plurality of containers mounted on the bottom surface of the first cardboard plate. Each of these containers mounted on the first cardboard plate defines a cavity sized to accommodate a corresponding product. A second cardboard plate is positioned within the sleeve. The second cardboard plate has a bottom surface opposite to the bottom surface of the first cardboard plate. The plurality of containers are mounted on the bottom surface of the second cardboard plate. Each of these containers mounted on the second cardboard plate defines a cavity sized to accommodate a corresponding product. The containers mounted on the first cardboard plate are offset from the containers mounted on the second cardboard plate.

[0005] In another aspect, generally speaking, the invention is characterized by a product mailing package with a sleeve. A first card is positioned within the sleeve. The first card has four quadrants, a top surface, and a bottom surface. Containers extend from each of the four quadrants of the bottom surface of the first card. A second card is positioned within the sleeve. The second card has four quadrants, a top surface, and a bottom surface facing the bottom surface of the first card. Containers extend from each of the four quadrants of the bottom surface of the second card. At least two of the containers on the second card are positioned between at least two of the containers on the first card.

[0006] In another aspect, generally speaking, the invention is characterized by a method of assembling product mailings by sealing a plurality of containers to the bottom surface of a first pallet. The plurality of containers are sealed to the bottom surface of a second pallet. The product is positioned within a cavity defined by each of the containers sealed to the first pallet. The first pallet is positioned above the second pallet. The bottom surface of the first pallet contacts one or more of the containers sealed to the second pallet. Attached Figure Description

[0007] Figure 1 This is an assembly view of one possible implementation of the packaging.

[0008] Figure 2A yes Figure 1 The front and bottom perspective views of the packaging.

[0009] Figure 2B yes Figure 1 The back and bottom perspective view of the packaging.

[0010] Figure 3 yes Figure 1 Top perspective view of a portion of the packaging.

[0011] Figure 4 The handle is inserted. Figure 3 Top perspective view of the packaging.

[0012] Figure 5 From Figure 3 A top perspective view of the handle of the product removed from the container.

[0013] Figure 6 This is an assembled view of the product shipment.

[0014] Figure 7 It is a connection Figure 2A Bottom view of two packages in the package. Detailed Implementation

[0015] refer to Figure 1 The image shows an assembled view of one possible embodiment of the package 10. The package 10 may include a pallet 12 (e.g., a first pallet) and one or more containers 14, 16, 18, and 20 mounted on the bottom surface 22 of the pallet 12. The pallet 12 and / or containers 14, 16, 18, and 20 may include one or more plant-based materials, such as cardboard or bamboo. One or more products 24, 26, 28, and 30 may be positioned within the storage areas 32, 34, 36, and 38 of the respective containers 14, 16, 18, and 20. Although... Figure 1 Products 24, 26, 28, and 30 shown are kits for (e.g., for shaving), but it should be understood that other consumer products, such as toothbrushes, may be used. Each of the storage areas 32, 34, 36, and 38 may be defined by a corresponding sidewall 40, 42, 44, and 46 extending upward from the lower areas 48, 50, 52, and 54 to the top surface (such as flanges 56, 58, 60, and 62). A retainer 12 may be mounted on flanges 56, 58, 60, and 62. In some embodiments, the plurality of containers 14, 16, 18, and 20 may be mounted and / or secured to the bottom surface 22, for example, using adhesives or other conventional methods known to those skilled in the art.

[0016] The card plate 12 may have a leading edge 64 and an opposing trailing edge 66. The leading edge 64 may be opposite and parallel to the trailing edge 66. The card plate 12 may have a first pair of perforated segments 68 and 70 and a second pair of perforated segments 72 and 74 extending inwardly from the leading edge 64. In some embodiments, the first pair of perforated segments 68 and 70 and the second pair of perforated segments 72 and 74 may extend to corresponding crease lines 76 and 78. The leading edge 64 may have one or more curved regions 80 and 82 associated with containers 14 and 18, respectively. Perforated segments 68 and 70 may extend from curved region 80, and perforated segments 72 and 74 may extend from curved region 82. In some embodiments, the first pair of perforated segments 68 and 70 may extend from curved region 80 to crease line 76. Similarly, the second pair of perforated segments 72 and 74 (associated with container 18) may extend from curved region 82 to crease line 78. In some embodiments, crease lines 76 and 78 may extend in a direction generally parallel to the leading edge 64 and / or the curved regions 80 and 82.

[0017] The card plate 12 may have a first pair of perforated segments 84 and 86 and a second pair of perforated segments 88 and 90 extending inwardly from the trailing edge 66. In some embodiments, the first pair of perforated segments 84 and 86 and the second pair of perforated segments 88 and 90 may extend to corresponding crease lines 92 and 94. The trailing edge 66 may have one or more curved regions 96 and 98 from which the corresponding perforated segments 84, 86, 88 and 90 extend. For example, the first pair of perforated segments 84 and 86 may extend from the curved region 96 to the crease line 92. Similarly, the second pair of perforated segments 88 and 90 may extend from the curved region 98 to the crease line 84. In some embodiments, the crease lines 92 and 94 may extend in a direction generally parallel to the trailing edge 66 and / or the curved regions 96 and 98.

[0018] The pallet 12 may have one or more perforated tabs 100, 102, 104, and 106 associated with one of the containers 14, 16, 18, and 20 to facilitate removal of the respective products 24, 26, 28, and 30 from the package 10. For example, tearing perforated segments 68 and 70 by lifting the perforated tab 100 (e.g., the first perforated tab) facilitates access to and removal of product 24 from the package 10. The first perforated tab 100 may be defined by a crease line 76 and perforated segments 68 and 70. The crease line 76 facilitates holding the perforated tab 100 in the open position, thereby providing improved access to and removal of product 24. A curved area 80 provides a more visual identification and lifting of the tab 100.

[0019] Container 16 (e.g., a second container) can be aligned with perforated tab 102 (e.g., a second perforated tab). Therefore, tearing perforation segments 84 and 86 by lifting perforated tab 102 facilitates access to and removal of product 26 from package 10. Perforated tab 102 may be defined by crease line 92 and perforation segments 84 and 86. Crease line 92 facilitates holding perforated tab 102 in the open position, thereby providing improved access to and removal of product 26. A curved area 96 provides a more visual identification and lifting of tab 102.

[0020] Container 18 (e.g., a third container) can be aligned with perforated tab 104 (e.g., a third perforated tab). Therefore, tearing perforation segments 72 and 74 by lifting perforated tab 104 facilitates access to and removal of product 28 from package 10. Perforated tab 104 may be defined by crease line 78 and perforation segments 72 and 74. Crease line 78 facilitates holding perforated tab 104 in the open position, thereby providing improved access to and removal of product 28. A curved area 82 provides more visual identification and lifting of tab 104.

[0021] Container 20 (e.g., a fourth container) may have a perforated tab 106 (e.g., a fourth perforated tab). Therefore, tearing perforation segments 88 and 90 by lifting the perforated tab 106 facilitates access to and removal of product 30 from package 10. The perforated tab 106 may be defined by a crease line 94 and perforation segments 88 and 90. The crease line 94 facilitates holding the perforated tab 106 in the open position, thereby providing improved access to and removal of product 30. A curved area 98 provides a more visually identifiable and lifting feature for the tab 106.

[0022] refer to Figure 2A and Figure 2B The image shows a bottom perspective view of package 10. In some embodiments, pallet 12 may include four quadrants 15a, 15b, 15c, and 15d. One of containers 14, 16, 18, and 20 may be positioned in each of quadrants 15a, 15b, 15c, and 15d. Containers 14, 16, 18, and 20 may extend from the bottom surface 22 of pallet 12. Pallet 12 may have tear lines 108, 110, 112, and 114 extending around the respective containers 14, 16, 18, and 20 to facilitate separation of the individual containers 14, 16, 18, and 20. Tear line 108 may extend from leading edge 64 to a first outer edge 120 transverse to leading edge 64. Tear line 110 may extend from trailing edge 66 to the first outer edge 120. Tear line 116 may extend from leading edge 64 to a second outer edge 122. The first outer edge 120 may be parallel to the second outer edge 122. The tear line 118 may extend from the second outer edge 122 to the trailing edge 66. The tear lines 108, 110, 112 and 114 may divide the card into corresponding quadrants 15a, 15b, 15c and 15d.

[0023] like Figure 2A As shown, the sidewall 42 of container 16 may include a front end face 124 defining an opening 126 extending into storage region 34. The sidewall 46 of container 20 may include a front end face 128 defining an opening 130 extending into storage region 34. Openings 126 and 130 may face the same direction and may be defined by a portion of trailing edge 66 (e.g., curved regions 96 and 98). Front end faces 124 and 128 may have corresponding arcuate edges 132 and 134 to allow improved access and removal of products 26 and 30 from containers 16 and 20. Openings 126 and 130 may extend in a direction generally parallel to the pallet 12. Openings 126 and 130 may face the same direction (e.g., the same direction as trailing edge 66). The outward-facing openings 126 and 130 at trailing edge 66 facilitate the insertion of a handle (not shown) into openings 126 and 130 because openings 126 and 130 are not obstructed by another structure.

[0024] like Figure 2BAs shown, the sidewall 40 of container 14 may include a front end face 136 defining an opening 138 extending into storage region 32. The sidewall 44 of container 18 may include a front end face 140 defining an opening 142 extending into storage region 36. Openings 138 and 142 may extend in a direction generally parallel to the card plate 12. Openings 138 and 142 may face the same direction (e.g., the same direction as the leading edge 64). The outward-facing openings 138 and 142, positioned at the leading edge 64, facilitate the insertion of a handle (not shown) into openings 138 and 142, as openings 138 and 142 are not obstructed by another structure. Therefore, openings 138 and 142 may face the same direction as openings 126 and 130 ( Figure 2A The openings 138 and 142 are in opposite directions. They may be defined by a portion of the leading edge 64 (e.g., curved regions 80 and 82). The front end faces 136 and 140 may have corresponding arcuate edges 144 and 146 to allow improved access and removal of products 24 and 28 from containers 14 and 18. The openings 138 and 142 may extend in a direction generally parallel to the pallet 12 (e.g., not entering or passing through the pallet 12). Although Figure 2A and Figure 2B The clamp 12 shown is rectangular, but it should be understood that the clamp 12 may have other geometries to facilitate the positioning of openings 126, 130, 138 and 142, all of which face outwards to facilitate insertion of the handle (not shown). For example, the clamp 12 may have a circular shape with the openings facing outwards.

[0025] Figures 3 to 5 It shows from Figure 1 Products 24, 26, 28, and 30 are removed from the corresponding containers 14, 16, 18, and 20 shown. It should be understood that package 10 may include a pallet 12 having multiple containers 14, 16, 18, and 20 (e.g., Figure 1 (as shown) or a pallet 12 with a portion removed by a single container (as shown) Figures 3 to 5 (As shown). For example, Figures 3 to 5 The package 10 shown may indicate that the pallet 12 has been cut along the tear line 108. Figure 2A The opening 138, defined by the front end face 136, may have a length "L1" that prevents the product 24 from accidentally falling out of the container 14. However, the size of the opening 138 may be designed to receive the handle 148. Figure 4 The handle 148 can be attached to the product 24 through the opening 138. During insertion, the handle 148 can extend generally parallel to the retaining plate 12. The perforated sections 68 and 70 facilitate the separation of the tab 100 from a portion of the retaining plate 12. For example, as... Figure 5As shown, the tab 100 can be peeled back toward the crease line 76, thereby tearing the card plate 12 along the perforated sections 68 and 70. The length "L2" between the perforated sections 68 and 70 defines a sleeve opening 145, which can be greater than or equal to the length "L3" of the product 24, thus allowing the product 25 to be removed from the storage area 32 of the container 14 (e.g., via the sleeve opening 145 created by lifting the tab 100). Therefore, the product 24 cannot be removed through the opening 138, but can be removed through the sleeve opening 145 created by the tab 100.

[0026] refer to Figure 6 The image illustrates a possible embodiment of the invention, showing an assembled view of a product mailing package 150. The product mailing package 150 may include a shipping envelope 152 that defines a pocket 154 configured to receive one or more of the packages 10 (e.g., a first package 10a and a second package 10b), as previously described. For example, Figure 6 Two packages 10a and 10b are shown placed in a sleeve 152; however, it should be understood that only one of packages 10a and 10b may be placed in the sleeve 152, or more packages 10a and 10b may be placed in a larger sleeve. It should be understood that the first package 10a and the second package 10b are structurally identical to the previously described package 10, and therefore, the same numerals will be used to describe the first package 10 and the second package 10b. The first package 10a may include a first pallet 12a, and the second package 10b may include a second pallet 12b. The first pallet 12a may have a bottom surface 22a. A plurality of containers 14a (hidden and not visible), 16a, 18a, and 20a may extend from the bottom surface 22a of the first pallet 12a. The second pallet 12b may have a similar configuration to the first pallet 12a. For example, the second pallet 12b may have a bottom surface 22b. The bottom surface 22b of the second pallet 12b may face the bottom surface 22a of the first pallet 12a. A plurality of containers 14b, 16b, 18b and 20b may extend from the bottom surface 22b of the second pallet 12b.

[0027] Containers 18a and 20a of the first pallet 12a may be offset from containers 14b and 16b of the second pallet 12b to facilitate compact stacking of packages 12a and 12b. In some embodiments, one or more of the containers 14b and 16b of the second pallet 12b may contact the bottom surface 22a of the first pallet 10a. Similarly, one or more of the containers 18a and 20a of the first pallet 12a may contact the bottom surface 22b of the second pallet 12b. This offset configuration of containers 14b and 16b of the second pallet 10b from containers 18a and 20a of the first pallet 10a provides efficient use of space within the pocket 154 of the envelope 152 and allows the envelope 152 to have sufficient flexibility during processing by equipment used for sorting envelopes and packages.

[0028] refer to Figure 7 The diagram shows a bottom view of a first card plate 12a and a second card plate 12b. In some embodiments, the first card plate 12a may be interconnected with the second card plate 12b via one or more bridging members 156 and 158. Bridging members 156 and 158 may extend from a first outer edge 120a of the first card plate 12a to a second outer edge 122b of the second card plate 12b. Bridging members 156 and 158 may be formed as an integral component as part of the first card plate 12a and the second card plate 12b. Bridging members 156 and 158 are spaced apart by a gap 160 to provide sufficient flexibility to allow the first card plate 12a and the second card plate 12b to fold together, thereby allowing the first card plate 12a and the second card plate 12b to be fitted within a sleeve 152, such as... Figure 6 As shown. Containers 14a and 16a may be spaced apart, and containers 18a and 20b may be spaced apart to define a gap 162a extending along the bottom surface 22a. The gap 162a may be sized to receive the two containers 16b and 20b of the second plate 12b (e.g., when the second plate 12b is folded on top of the first plate 12a, containers 16b and 20b may be positioned on the gap 162a of the bottom surface 22a of the first plate 12a). Similarly, the second plate 12b may have a gap 162b defined by the spacing between containers 14b and 16b and between 18b and 20b. The containers 14a, 16a, 18a, and 20a of the first plate 12a may be spaced apart to define a second gap. Gap 164a extends laterally to gap 162a. Similarly, containers 14a, 16a, 18a, and 20a of the second pallet 12b may be spaced apart to define a second gap 164b, which extends laterally to gap 162a. Gap 162a, 162b, 164a, and 164b provide flexibility along both axes of the first package 10a and the second package 10b, thus facilitating proper handling and sorting by shipping companies (e.g., the U.S. Postal Service) when they are inserted into envelope 152.

[0029] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​cited. Rather, unless otherwise specified, each such dimension is intended to represent the stated value and a range around which it is functionally equivalent. For example, a dimension disclosed as “40 mm” is intended to represent “about 40 mm”. Furthermore, dimensions should not be maintained to an impossibly high standard of metaphysical identity, which does not take into account differences arising from typical manufacturing tolerances. Therefore, the term “about” should be understood as being within the range of typical manufacturing tolerances.

[0030] Unless expressly excluded or otherwise limited, every reference cited herein, including any cross-references or related patents or applications, is incorporated herein by reference in its entirety. Reference to any reference is not an endorsement of its existence as prior art to any disclosed or protected art herein, nor is it an endorsement of any such invention, either on its own or in combination with any one or more references. Furthermore, where any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in referenced documents, the meaning or definition given to that term in this invention shall prevail.

[0031] While specific embodiments of the invention have been illustrated and described by way of example, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended that all such changes and modifications falling within the scope of the invention be covered by the appended claims.

Claims

1. A product mailing document (150), said product mailing document comprising: Envelope (152); A first card plate (12, 12a) is positioned within the envelope, and the first card plate has a bottom surface (22, 22a). Multiple containers (14a, 16a, 18a and 20a) are mounted on the bottom surface of the first pallet, and each container on the first pallet defines a storage area (32, 34, 36 and 38), the storage area being sized to accommodate the corresponding product (24, 26, 28 and 30). A second card plate (12, 12b) is positioned within the sleeve, the second card plate having a bottom surface (22, 22b) facing the bottom surface of the first card plate. Multiple containers (14b, 16b, 18b, and 20b) are mounted on the bottom surface of the second pallet. Each container mounted on the second pallet defines a storage area (32, 34, 36, and 38), the dimensions of which are designed to accommodate a corresponding product (24, 26, 28, and 30). The containers mounted on the first pallet are offset from those mounted on the second pallet. Each of the containers includes an opening on its front face that extends into the storage area, and the opening is not blocked by another structure.

2. The product mailing item according to claim 1, wherein the first card plate (20a) has one or more perforated tabs (100, 102, 104 and 106) associated with one of the containers (14, 16, 18 and 20).

3. The product mailing item according to claim 2, wherein each of the perforated tabs (100, 102, 104 and 106) includes a corresponding crease line (76, 92, 78, 94).

4. The product mailing item according to claim 2, wherein each of the perforated tabs (100, 102, 104 and 106) comprises a pair of perforated segments (68, 70, 72, 74, 84, 86, 88, 90).

5. The product mailing according to any one of claims 1-4, wherein at least one of the containers (14a, 16a, 18a and 20a) mounted on the first pallet (12a) is in contact with the bottom surface (22b) of the second pallet (14b).

6. The product mailing item according to claim 5, wherein the first pallet (12a) has four quadrants (15a, 15b, 15c and 15d), and one of the plurality of containers (14a, 16a, 18a and 20a) mounted on the bottom surface (22a) of the first pallet extends from each of the four quadrants.

7. The product mailing according to claim 6, wherein the containers (14a, 16a, 18a and 20a) of the first cardboard (12a) each have flanges (56, 58, 60 and 62) sealed to the bottom surface (22a) of the first cardboard.

8. The product mailing according to claim 6 or 7, wherein the first cardboard (12) has multiple tear lines (108, 110, 112 and 114) extending around the respective containers (14a, 16a, 18a and 20a) for easy separation.

9. The product mailing package of claim 1, wherein the product mailing package further comprises interconnecting the first card plate (12a) and the second card plate (12b) with one or more bridging members (156, 158) and folding the second card plate on top of the first card plate.

10. A method for assembling a product mailing package (150), the method comprising: Multiple containers (14a, 16a, 18a and 20a) are sealed to the bottom surface (22a) of the first pallet (12, 12a). Seal multiple containers (14b, 16b, 18b and 20b) to the bottom surface of the second pallet (12b); The products (24, 26, 28 and 30) are positioned within the storage areas (32, 34, 36 and 38) defined by each of the containers in the containers sealed to the first pallet; The products (24, 26, 28 and 30) are positioned within the storage areas (32, 34, 36 and 38) defined by each of the containers in the containers sealed to the second pallet; Position the first card above the second card; The container sealed to the first card plate is offset from the container sealed to the second card plate; as well as Position the first card plate and the second card plate inside the envelope (152). Each of the containers includes an opening on its front face that extends into the storage area, and the opening is not blocked by another structure.

11. The method of claim 10, wherein positioning the products (24, 26, 28 and 30) within the storage area (32, 34, 36 and 38) defined by each of the containers (14a, 16a, 18a and 20a) sealed to the first pallet (12a) is performed prior to sealing the plurality of containers to the bottom surface (22a) of the first pallet.

12. The method according to claim 10 or 11, the method further comprising forming a plurality of perforated tabs (100, 102, 104 and 106) on the first card plate (12a) and aligned with one of the respective containers (14a, 16a, 18a and 20a) sealed to the first card plate.

13. The method of claim 10, further comprising contacting the bottom surface (22a) of the first card plate (12a) with one or more of the containers (14b, 16b, 18b and 20b) sealed to the second card plate (12b).

14. The method of claim 10, further comprising interconnecting the first card plate (12a) and the second card plate (12b) using one or more bridging elements (156, 158).

15. The method of claim 14, further comprising folding the second card plate (12b) over the top of the first card plate (12a).

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