System comprising a first tray and a second tray, and corresponding method of packaging

Abstract

A system includes a first tray (100) including a base (102) having an interior space (104) shaped to receive an item. The system includes a second tray (800) including a base (802) having an interior space (804) shaped to receive the first tray and a structural element (808) shaped to support the first tray. A density of the first tray is greater than a density of the second tray. A thickness of the first tray is less than a thickness of the second tray. A method of packaging a device includes providing a device tray (100) having an impression (106) substantially conforming to a shape of an item to retain the item in the device tray. The method includes providing a structural tray (800). The method includes placing the device tray (100) in the structural tray (800) and placing the item in the impression (106) of the device tray.

Description

SYSTEM COMPRISING A FIRST TRAY AND A SECOND TRAY, AND CORRESPONDING METHOD OF PACKAGINGBACKGROUND

[0001] Packaging is used to protect products during shipment and merchandising. It may be desirable in some marketplaces to have the packaging be interesting or at least visually pleasing to consumers of the product. Packaging may be used to generate consumer interest, to advertise, and to protect the brand of the company who produces the product. For example, branding may be particularly important in competitive markets, for example, consumer electronics. Packaging design for these markets generally aims to present a product as aesthetically pleasing as possible. It is also desirable to use recycled materials for packaging and / or to have the packaging itself be recyclable.SUMMARY

[0002] According to one embodiment, a system includes a first tray including a base having an interior space shaped to receive an item. The system includes a second tray including a base having an interior space shaped to receive the first tray and a structural element shaped to support the first tray. A density of the first tray is greater than a density of the second tray. A thickness of the first tray is less than a thickness of the second tray.

[0003] In various embodiments, the density of the first tray may be in a range of 550 kg / m3and 750 kg / m3. The density of the second tray may be different than the density of the first tray and may be in a range of 400 kg / m3and 600 kg / m3. The thickness of the first tray may be in a range of 0.5 mm to 1.5 mm. The thickness of the second tray may be different than the thickness of the first tray and is in a range of 0.8 mm to 2.5 mm. The interior space of the first tray may include an impression substantially conforming to a shape of the item to retain the item in the first tray. The base of the second tray may include a compartment formed in the interior space and the compartment of the second tray may be shaped to receive the impression of the first tray. The first tray may include a ledge formed along the perimeter of the interior space of the base for supporting the first tray in the second tray. The second tray may support the first tray via the structural element and the compartment. The first tray may include a 65% bamboo and 35% bagasse. The first tray may be characterized by a burst strength in a range of 450 kPa to 1200 kPa. The second tray may include recycled kraft pulp. The second tray may be characterized by a burst strength in a range of 400 kPa to 1000 kPa. At least a portion of a surface of the first tray may be characterized by a surface roughness in a range of 3 pm to 5 pm. At least a portion of a surface of the second tray may be characterized by a surface roughness in a range of 8 pm to 12 pm. Thesystem may further include an enclosure shaped to enclose the item, the first tray, and the second tray.

[0004] According to another embodiment, a method of packaging a device includes providing a device tray, the device tray having an impression substantially conforming to a shape of an item to retain the item in the device tray. The method also includes providing a structural tray. The structural tray includes a compartment shaped to receive the impression of the device tray and a structural element perpendicular to a top surface of the structural tray for supporting the device tray and the item in a predetermined position. The method further includes placing the device tray in the structural tray and placing the item in the impression of the device tray. A density of the device tray is greater than a density of the structural tray and a thickness of the device tray is less than a thickness of the structural tray.

[0005] In various embodiments, the density of the device tray may be in a range of 550 kg / m3and 750 kg / m3, wherein the density of the second tray may be different than the density of the first tray and is in a range of 400 kg / m3and 600 kg / m3. The thickness of the device tray may be in a range of 0.5 mm to 1.5 mm. The thickness of the second tray may be different than the thickness of the first tray and may be in a range of 0.8 mm to 2.5 mm.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0007] FIG. 1 illustrates a perspective view of an embodiment of a device tray.

[0008] FIG. 2 illustrates a top view of an embodiment of a device tray.

[0009] FIG. 3 illustrates a bottom view of an embodiment of a device tray.

[0010] FIG. 4 illustrates a front view of an embodiment of a device tray.

[0011] FIG. 5 illustrates a rear view of an embodiment of a device tray.

[0012] FIG. 6 illustrates a first side view of an embodiment of a device tray.

[0013] FIG. 7 illustrates a second side view of an embodiment of a device tray.

[0014] FIG 8 illustrates a perspective view of an embodiment of a structural tray.

[0015] FIG. 9 illustrates a top view of an embodiment of a structural tray.

[0016] FIG. 10 illustrates a bottom view of an embodiment of a structural tray.

[0017] FIG. 11 illustrates a front view of an embodiment of a structural tray.

[0018] FIG. 12 illustrates a rear view of an embodiment of a structural tray.

[0019] FIG. 13 illustrates a first side view of an embodiment of a structural tray.

[0020] FIG. 14 illustrates a second side view of an embodiment of a structural tray.

[0021] FIG. 15 illustrates an expanded view of an embodiment of an assembly including a device tray and a structural tray.

[0022] FIG 16 illustrates an assembled view of an embodiment of an assembly including a device tray and a structural tray.

[0023] FIG. 17 illustrates a flowchart of an embodiment of a method.DETAILED DESCRIPTION

[0024] Packaging for products, such as relatively heavy products like electronics, often includes additional substructure to support the product during shipping and merchandising. Packaging substructure may include corrugate substructure which is expensive and often requires assembly including many folding and adhesion steps. Corrugate substructures perform well to protect the product but usually require 5 to 50 folding steps and adhesion to function properly.

[0025] Various embodiments are described related to nested device and Old Corrugated Cardboard (OCC) molded fiber trays. These device (e.g., cosmetic) trays and OCC (e.g., structural) trays may be used together to support a product during shipping and merchandising. Molded fiber cosmetic trays are a molded drop-in solution that do not need additional assembly. Cosmetic molded fiber trays according to various embodiments described herein may be supported by OCC structural molded fiber trays for relatively heavy products. For example, products greaterthan or equal to 0.2 lbs may use at least some additional structural support in addition to being supported by a cosmetic molded fiber tray.

[0026] OCC is a raw material sourced from recycled kraft shipping containers and is used to form a slurry of which may be further processed to form a molded material. As detailed herein, testing showed molded materials formed from OCC performs comparably to corrugate substructure materials in drop and vibration testing. These test results were unexpected. The combination of the cosmetic device trays and the OCC structural trays as described throughout the present disclosure save time and money by reducing assembly steps and costs of materials. The combination of the cosmetic device trays and the OCC structural trays is also on average 30% lighter than solutions using corrugate substructures. The combination of the cosmetic device trays and the OCC structural trays according to various embodiments described herein does not require any adhesive or folding steps.

[0027] Various embodiments of the present invention are described in detail with reference to a few preferred embodiments thereof as illustrated in the accompanying drawings. In the following description, detailed embodiments are described in order to provide a thorough understanding of the present invention. One having ordinary skill in the art would appreciate that the present invention may be practiced without some, or all of the specific details as described herein.

[0028] FIG. 1 illustrates a perspective view of an embodiment of a device tray 100. Device tray 100 includes a base 102 having an interior space 104 shaped to receive an item (not shown), such as a tablet computer and dock system. In various embodiments, the device tray 100 may be referred to as the first tray, the cosmetic tray, the cosmetic molded fiber tray, etc. In various embodiments, the device tray 100 is a cosmetic tray which is shaped to support and display the product (e.g., otherwise referred to herein as an item or article of manufacture) as the product is shipped and up until a consumer opens the packaging for the product. Accordingly, it would be desirable to have a cosmetic device tray 100 that peaks consumer interest and highlights the design of the product by streamlining the packaging appearance.

[0029] The interior space 104 of the device tray 100 comprises an impression 106 substantially conforming to a shape of the product to retain the product on the device tray 100. The impression 106 may follow the form of the product such that the spacing between the product and the walls of the impression 106 is substantially similar around the entire surface of the product. The product may be substantially uniformly situated in the impression 106. For example, the impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging. The impression 106 generally forms an internal cavity forinternal placement of a product in the device tray 100. One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc An impression 106 may include a notch 108 to accommodate a button or other extension of the product to be supported by the device tray 100. For example, a notch 108 may be included to provide space for a power button and / or a volume button extending from the product such that the product is not powered on during shipping or other movement.

[0030] In some embodiments, the density of the device tray 100 is in a range of 550 kg / m3and 750 kg / m3, inclusive. The density of the device tray 100 is greater than a density of a second structural tray, to be described in detail below. The density of the device tray 100 is different from a density of a second structural tray, in at least some embodiments. The relatively greater density of the device tray 100 may be a result of a wet press manufacturing process that produces a smooth finish for the device tray 100. For example, the device tray 100 comprises a material including bamboo and bagasse that is wet pressed to form the cosmetic molded fiber trays. In various embodiments, the material of the device tray 100 comprises 65% bamboo and 35% bagasse, although other materials may be added. For example, wood pulp or recycled paper content may be added in nominal amounts to alter the appearance and / or physical properties of the device tray 100. The formulation of the material of the device tray 100 may vary depending on the product and / or application. In various embodiments, the device tray 100 is further cosmeticized by bleaching or otherwise dying the surface of the device tray 100. For example, the device tray 100 may be bleached white to further display the product with a clean, minimalist, and aesthetic appearance. In some embodiments, a glossy finish may be applied to the device tray 100.

[0031] The material of the device tray 100 may be characterized by a burst strength in a range of 450 kPa to 1200 kPa, inclusive. The material of the device tray 100 may also be characterized by a tensile strength in a range of 5 kgf to 25 kgf, inclusive. Corrugate substructures are characterized by a burst strength and the tensile strength that are 35% of the burst strength and tensile strength of the device tray 100 described herein. Accordingly, the device tray 100 is stronger (e g., able to accommodate heavier products) than corrugate substructures.

[0032] In various embodiments, the thickness of the device tray 100 is in a range of 0.5 mm to 1.5 mm, inclusive. The thickness of the device tray 100 is less than a thickness of the second structural tray, to be described in further detail below. The thickness of the device tray 100 different from a thickness of the second structural tray, in at least some embodiments. In various embodiments, it is desirable to have the device tray 100 be as thin as possible to reduce thematerials used in the packaging and amount of material that will eventually be recycled or otherwise disposed of by the consumer. The structural support and capabilities of the second structural tray enables the device tray 100 to be relatively thin by providing a supportive understructure.

[0033] In some embodiments, at least a portion of a surface of the device tray 100 is characterized by a surface roughness in a range of 3 pm to 5 pm, inclusive. The surface roughness of the device tray 100 is significantly less than the surface roughness of the second structural tray, to be described in further detail below. In various embodiments, it is desirable to have the device tray 100 be relatively smooth and presentable to a consumer. For example, a consumer may associate a smoother surface displaying the product with a higher quality product. Accordingly, the device tray 100 may appear to be soft and without protrusions or texture along the surface.Furthermore, a softer surface may be desired so as to further prevent scratches or unwanted friction or rubbing on a product surface such as a touch screen display on a tablet computer.

[0034] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the perimeter of the interior space 104 of the base 102 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from a topmost perimeter (e.g., perpendicular relative to the front, rear, and sides of the device tray 100) of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the topmost perimeter of the second structural tray.

[0035] According to various aspects of the present disclosure, the device tray 100 has a density that is greater than a density of a second structural tray (not shown). Furthermore, the device tray 100 has a thickness that is less than a thickness of the second structural tray. One having ordinary skill in the art would assume that the higher density tray would be used to structurally support a product and / or have a greater thickness than a cosmetic tray used for the same product. This surprising combination advantageously provides aesthetically pleasing packaging that is both lightweight and structurally supportive.

[0036] FIG. 1 illustrates relative perspectives for a top view 200, a bottom view 300, a front view 400, a rear view 500, a first side view 600 and a second side view 700, to be described in detail with respect to FIGS. 2-7 below. One having ordinary skill in the art upon reading the present disclosure would appreciate that the device tray 100 may have more or less sides than the exemplary embodiment shown in FIGS. 1-7. For example, the device tray 100 may be a circle with no sides, a triangle with three side views (and no front or rear views), a pentagon with five sides, etc.

[0037] FIG. 2 illustrates a top view of an embodiment of a device tray. Top view 200 includes a device tray 100 having an interior space 104. The interior space 104 includes an impression 106 substantially conforming to a shape of a product to retain the product on the device tray 100 For example, the impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging. One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc. An impression 106 may include a notch 108 to accommodate a button or other extension of the product to be supported by the device tray 100. For example, a notch 108 may be included to provide space for a power button and / or a volume button extending from the product such that the product is not powered on during shipping or other movement.

[0038] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the perimeter of the interior space 104 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from a topmost perimeter of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the topmost perimeter of the second structural tray.

[0039] FIG. 3 illustrates a bottom view of an embodiment of a device tray. Bottom view 300 includes a device tray 100 that includes an impression 106 substantially conforming to a shape of a product to retain the product on the device tray 100. As would be appreciated by one having ordinary skill in the art, the bottom view 300 of the impression 106 is such that the impression 106 extends outward and upward from a planar surface, rather than sunken into the page as shown in the top view 200 of FIG. 2. The impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging. One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc. An impression 106 may include a notch 108 to accommodate a button or other extension of the product to be supported by the device tray 100. Similarly, the bottom view 300 of the notches 108 shows the notches 108 extending outward and upward from a planar surface. A notch 108 may be included to provide space for a power button and / or a volume button extending from the product such that the product is not powered on during shipping or other movement.

[0040] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the perimeter of the interior space 104 of the base 102 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from atopmost perimeter of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the perimeter of the second structural tray.

[0041] FIG. 4 illustrates a front view of an embodiment of a device tray. Front view 400 includes a device tray 100 that includes an impression 106 substantially conforming to a shape of a product to retain the product on the device tray 100. The impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0042] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the base 102 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from a topmost perimeter of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the perimeter of the second structural tray.

[0043] According to at least some embodiments, the impressions 106 are not shaped to keep the device tray 100 (or the product supported by the device tray 100) upright without additional support (such as from the structural tray, to be described in further detail below). Specifically, the impressions 106 are contoured to the product to protect the product, not to provide support for the device tray 100 within the packaging. For example, and as would be appreciated by one having ordinary skill in the art, not all of the impressions 106 extend from a top surface of the device tray 100, including the ledge 110 of the device tray 100, to a bottom planar surface 402. Accordingly, the device tray 100 may be unbalanced without additional support such that a first side (such as shown by first side view 600 of FIG. 6, to be described in further detail below) lifts upward from the bottom planar surface 402 and a second side (such as shown by second side view 700 of FIG.7, to be described in further detail below) tilts downward toward the bottom planar surface 402 when the device tray 100 is set on the bottom planar surface 402 without any additional support. However, it would be appreciated by one having ordinary skill in the art that, as any number of impressions 106 may be implemented into the device tray 100, configurations where the impressions 106 support an upright position on the bottom planar surface 402 (e.g., the device tray 100 is equally supported on each side and a top surface of the device tray 100 is level with the bottom planar surface 402) are contemplated.

[0044] FIG. 5 illustrates a rear view of an embodiment of a device tray. Rear view 500 includes a device tray 100 that includes an impression 106 substantially conforming to a shape of a productto retain the product on the device tray 100. The impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging. One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0045] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the base 102 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from a topmost perimeter of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the topmost perimeter of the second structural tray.

[0046] According to at least some embodiments, the impressions 106 are not shaped to keep the device tray 100 (or the product supported by the device tray 100) upright without additional support (such as from the structural tray, to be described in further detail below). For example, and as would be appreciated by one having ordinary skill in the art, not all of the impressions 106 extend from a top surface of the device tray 100, including the ledge 110 of the device tray 100, to a bottom planar surface 402. Accordingly, the device tray 100 may be unbalanced without additional support such that a first side (such as shown by first side view 600 of FIG. 6, to be described in further detail below) lifts upward from the bottom planar surface 402 and a second side (such as shown by second side view 700 of FIG. 7, to be described in further detail below) tilts downward toward the bottom planar surface 402 when the device tray 100 is set on the bottom planar surface 402 without any additional support. However, it would be appreciated by one having ordinary skill in the art that, as any number of impressions 106 may be implemented into the device tray 100, configurations where the impressions 106 support an upright position on the bottom planar surface 402 (e.g., the device tray 100 is equally supported on each side) are contemplated.

[0047] FIG. 6 illustrates a first side view of an embodiment of a device tray. First side view 600 includes a device tray 100 that includes an impression 106 substantially conforming to a shape of a product to retain the product on the device tray 100. The impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging. One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0048] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the base 102 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from a topmost perimeter of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the topmost perimeter of the second structural tray.

[0049] According to at least some embodiments, the impressions 106 are not shaped to keep the device tray 100 (or the product supported by the device tray 100) upright without additional support (such as from the structural tray, to be described in further detail below). For example, and as would be appreciated by one having ordinary skill in the art, not all of the impressions 106 extend from a top surface of the device tray 100, including the ledge 110 of the device tray 100, to a bottom planar surface 402. Accordingly, the device tray 100 may be unbalanced without additional support such that a front side (such as shown by front view 400 of FIG. 4) tilts downward toward the bottom planar surface 402 and a rear side (such as shown by rear view 500 of FIG. 5) lifts upward from the bottom planar surface 402 when the device tray 100 is set on the bottom planar surface 402 without any additional support. However, it would be appreciated by one having ordinary skill in the art that, as any number of impressions 106 may be implemented into the device tray 100, configurations where the impressions 106 support an upright position on the bottom planar surface 402 (e.g., the device tray 100 is equally supported on each side) are contemplated.

[0050] FIG. 7 illustrates a second side view of an embodiment of a device tray. Second side view 700 includes a device tray 100 that includes an impression 106 substantially conforming to a shape of a product to retain the product on the device tray 100. The impression 106 securely holds the product such that the product remains substantially in the same position as the product is shipped in the packaging. One or more impressions 106 may be included in the interior space of the device tray 100, for example, to retain an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0051] In at least some embodiments, the device tray 100 includes a ledge 110 formed along the base 102 for supporting the device tray 100 in the second structural tray, to be described in further detail below. The ledge 110 may extend away from a topmost perimeter of the device tray 100 and the outermost perimeter of the ledge 110 may be supported by a corresponding topmost edge of the topmost perimeter of the second structural tray.

[0052] According to at least some embodiments, the impressions 106 are not shaped to keep the device tray 100 (or the product supported by the device tray 100) upright without additionalsupport (such as from the structural tray, to be described in further detail below). For example, and as would be appreciated by one having ordinary skill in the art, not all of the impressions 106 extend from a top surface of the device tray 100, including the ledge 110 of the device tray 100, to a bottom planar surface 402. Accordingly, the device tray 100 may be unbalanced without additional support such that a front side (such as shown by front view 400 of FIG. 4) tilts downward toward the bottom planar surface 402 and a rear side (such as shown by rear view 500 of FIG. 5) lifts upward from the bottom planar surface 402 when the device tray 100 is set on the bottom planar surface 402 without any additional support. However, it would be appreciated by one having ordinary skill in the art that, as any number of impressions 106 may be implemented into the device tray 100, configurations where the impressions 106 support an upright position on the bottom planar surface 402 (e.g., the device tray 100 is equally supported on each side) are contemplated.

[0053] FIG. 8 illustrates a perspective view of an embodiment of a structural tray. Stmctural tray 800 includes a base 802 having an interior space 804 shaped to receive a cosmetic device tray, such as device tray 100 shown and described above with respect to FIGS. 1-7. In various embodiments, the structural tray 800 may be referred to as the second tray, the structural tray, the OCC molded fiber tray, etc. In various embodiments, the structural tray 800 is a structural tray which is shaped to support the device tray, and a product supported by the device tray, as the product is shipped and up until a consumer opens the packaging for the product. Accordingly, it would be desirable to have a structural tray 800 that protects the device tray and the product from damage and excessive movement throughout shipping and merchandising.

[0054] The interior space 804 of the structural tray 800 comprises a compartment 806 formed in the interior space 804 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). For example, the compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging. One or more compartments 806 may be included in the interior space 804 of the structural tray, for example, to retain an impression designed for an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0055] The interior space 804 of the structural tray 800 comprises a structural element 808 shaped to support the device tray. Structural elements 808 may include shapes such as flanges, ladders, legs, ledges, rims, tabs, slots, etc., or any combination thereof. In various embodiments, one or more structural elements 808 may be used to support the device tray (and a product supported by the device tray) in an upright position. For example, a sufficient number of structural elements 808 may be provided such that the structural tray 800 is level compared to a planar surface on which the structural tray 800 is set, to be described in further detail below. Structural elements 808 may include vertical walls (e.g., perpendicular to a top surface of the structural tray 800) for supporting the device tray and the product. As would be appreciated by one having ordinary skill in the art upon reading the present disclosure, more structural elements 808 provide more strength to the structural tray 800. For example, and in contrast, the device tray impressions are substantially curved and formed to the product rather than formed as vertical walls for providing strength to the device tray. In various embodiments, the impressions are not structurally supporting for the device tray (e.g., the impression hold the product but do not keep the device tray in any predetermined position). In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806. In some embodiments, a structural element 808 may extend from one side of the structural tray 800 to another side (or from a front side to a rear side, or vice versa) to provide a stable base for the structural tray 800 such that the structural tray 800 does not experience any tipping when placed on a planar surface. Any configuration of structural elements 808 for providing a stable, structural tray 800 may be used depending on the design and dimensions of the product to be supported. For example, more "touch points" may be provided by the structural elements 808 if a shape of the product is particularly irregular, rounded, etc.

[0056] In at least some embodiments, the structural tray 800 includes at least 4 structural elements 808, one structural element 808 located at each comer of the structural tray 800 such that the structural tray 800 is level when placed on a substantially flat surface. In other embodiments, any number of structural elements 808 may be used such that the structural tray 800 is "freestanding" (in contrast to the device tray which may tip over depending on the shape and location of the impressions). For example, the structural elements 808 may provide support and reinforcement to the cosmetic device tray.

[0057] In some embodiments, the density of the structural tray 800 is in a range of 400 kg / m3and 600 kg / m3, inclusive. The density of the structural tray 800 is less than a device tray, such as device tray 100. The relatively reduced density of the structural tray 800 may be a result of a dry or semi-wet press manufacturing process that produces a rougher (e.g., less smooth) finish for thestructural tray 800 as compared to the wet press process used for the device tray. For example, the structural tray 800 comprises a material including recycled kraft pulp that is dry or semi-wet pressed to form the OCC molded fiber trays. In various embodiments, the material of the structural tray 800 comprises 100% recycled kraft pulp, although other materials may be added. For example, wood pulp or recycled paper content may be added in nominal amounts to alter the appearance and / or physical properties of the structural tray 800. The formulation of the material of the structural tray 800 may vary depending on the product and / or application.

[0058] The material of the structural tray 800 may be characterized by a burst strength in a range of 400 kPa to 1200 kPa, inclusive. The material of the structural tray 800 may also be characterized by a tensile strength in a range of 10 kgf to 35 kgf, inclusive. Corrugate substructures are characterized by a burst strength and the tensile strength that are 35% of the burst strength and tensile strength of the structural tray 800 described herein. Accordingly, the structural tray 800 is stronger (e.g., able to accommodate heavier products) than corrugate substructures.

[0059] In various embodiments, the thickness of the structural tray 800 is in a range of 0.8 mm to 2.5 mm, inclusive. The thickness of the structural tray 800 is greater than a thickness of the device tray, such as device tray 100. In various embodiments, it is desirable to have the device tray be as thin as possible to reduce the materials used in the packaging and the amount of materials that will eventually be recycled or otherwise disposed of by the consumer. The structural support and capabilities of the structural tray 800 enables the device tray to be relatively thin by providing a supportive understructure.

[0060] In some embodiments, at least a portion of a surface of the structural tray 800 is characterized by a surface roughness in a range of 8 pm to 12 pm, inclusive. The surface roughness of the structural tray 800 is significantly greater than the surface roughness of the device tray. In various embodiments, it is desirable to have the device tray be relatively smooth and presentable to a consumer. In contrast, the structural tray 800 may be produced by cheaper manufacturing methods (e.g., dry or semi-wet press processes) that do not result in as smooth a finish as the manufacturing method (e.g., wet press processes) used to form the device tray. Accordingly, the structural tray 800 may appear to be rougher and having a texture along the surface of the structural tray 800.

[0061] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 of the base 802 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). Theledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0062] According to various aspects of the present disclosure, the structural tray 800 has a density that is less than a density of the device tray. Furthermore, the structural tray 800 has a thickness that is greater than a thickness of the device tray. One having ordinary skill in the art would assume that the higher density tray would be used to structurally support a product and / or have a greater thickness than a cosmetic tray used for the same product This surprising combination advantageously provides aesthetically pleasing packaging that is both lightweight and structurally supportive.

[0063] FIG. 8 illustrates relative perspectives for a top view 900, a bottom view 1000, a front view 1100, a rear view 1200, a first side view 1300 and a second side view 1400, to be described in detail with respect to FIGS. 9-14 below. One having ordinary skill in the art upon reading the present disclosure would appreciate that the structural tray 800 may have more or less sides than the exemplary embodiment shown in FIGS. 9-14. For example, the structural tray 800 may be a circle with no sides, a triangle with three side views (and no front or rear views), a pentagon with five sides, etc.

[0064] FIG. 9 illustrates a top view of an embodiment of a structural tray. Top view 900 includes a structural tray 800 having an interior space 804 shaped to receive a cosmetic device tray, such as device tray 100 shown and described above with respect to FIGS. 1-7. The interior space 804 of the structural tray 800 comprises a compartment 806 formed in the interior space 804 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). For example, the compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging. In various embodiments, the compartment 806 does not contour to the product. Rather, the compartment 806 is shaped to encompass an impression of the product and provide support to the device tray. One or more compartments 806 may be included in the interior space 804 of the structural tray, for example, to retain an impression designed for an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0065] The interior space 804 of the structural tray 800 comprises a structural element 808 shaped to support the device tray. In various embodiments, one or more structural elements 808 may be used to support the device tray (and a product supported by the device tray) in an upright position. For example, a sufficient number of structural elements 808 may be provided such that the structural tray 800 is level compared to a planar surface on which the structural tray 800 is set, to be described in further detail below. In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806. In at least some embodiments, a structural element 808 may be distinct and separate from the compartment 806 and / or the structural element 808 may be merged with a compartment 806, as illustrated in the top right corner of FIG. 8.

[0066] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). The ledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0067] FIG. 10 illustrates a bottom view of an embodiment of a structural tray. Bottom view 1000 includes a structural tray 800 having a base 802 including a compartment 806 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). As would be appreciated by one having ordinary skill in the art, the bottom view 1000 of the compartment 806 is such that the compartment 806 extends outward and upward from a planar surface, rather than sunken into the page as shown in the top view 900 of FIG. 9. The compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging. One or more compartments 806 may be included in the interior space 804 of the structural tray, for example, to retain an impression designed for an accessory of the product such as a power cord, speaker, mouse, connectors, etc.

[0068] The structural tray 800 includes a structural element 808 shaped to support the device tray. In various embodiments, one or more structural elements 808 may be used to support the device tray (and a product supported by the device tray) in an upright position. Similarly, the bottom view 1000 of the structural elements 808 shows the structural elements 808 extendingoutward and upward from a planar surface. A sufficient number of structural elements 808 may be provided such that the structural tray 800 is level compared to a planar surface on which the structural tray 800 is set, to be described in further detail below. In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806. In at least some embodiments, a structural element 808 may be distinct and separate from the compartment 806 and / or the structural element 808 may be merged with a compartment 806, as illustrated in the top left corner of FIG. 8.

[0069] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 of the base 802 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). The ledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0070] FIG. 11 illustrates a front view of an embodiment of a structural tray. Front view 1100 includes a structural tray 800 having a base 802 including a compartment 806 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). The compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging.

[0071] The structural tray 800 includes a structural element 808 shaped to support the device tray. In various embodiments, one or more structural elements 808 may be used to support the device tray (and a product supported by the device tray) in an upright position. A sufficient number of structural elements 808 may be provided such that the structural tray 800 is level compared to a planar surface on which the structural tray 800 is set, to be described in further detail below. In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806.

[0072] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 of the base 802 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). Theledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0073] According to at least some embodiments, the structural elements 808 are shaped to keep the structural tray 800 (and the device tray the structural tray supports, and the product supported by the device tray) upright without additional support. For example, and as would be appreciated by one having ordinary skill in the art, the structural elements 808 extend from a top surface of the structural tray 800, including the topmost perimeter 810 of the structural tray 800, to a bottom planar surface 1102. Accordingly, the structural tray 800 is balanced without additional support such that a first side (such as shown by first side view 1300 of FIG. 13, to be described in further detail below) is in contact with the bottom planar surface 1102 and a second side (such as shown by second side view 1400 of FIG. 14, to be described in further detail below) is also in contact with the bottom planar surface 1102 when the structural tray 800 is set on the bottom planar surface 402 without any additional support. Any number of structural elements 808 may be implemented into the structural tray 800 such that the topmost perimeter 810 is level with (e.g., parallel with) the bottom planar surface 1102 when the structural tray 800 is placed on the bottom planar surface 1102.

[0074] FIG. 12 illustrates a rear view of an embodiment of a structural tray. Rear view 1200 includes a structural tray 800 having a base 802 including a compartment 806 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). The compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging.

[0075] The structural tray 800 includes a structural element 808 shaped to support the device tray. In various embodiments, one or more structural elements 808 may be used to support the device tray (and a product supported by the device tray) in an upright position. A sufficient number of structural elements 808 may be provided such that the structural tray 800 is level compared to a planar surface on which the structural tray 800 is set, such as bottom planar surface 1102. In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806.

[0076] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 of the base 802 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). The ledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0077] According to at least some embodiments, the structural elements 808 are shaped to keep the structural tray 800 (and the device tray the structural tray supports, and the product supported by the device tray) upright without additional support. For example, and as would be appreciated by one having ordinary skill in the art, the structural elements 808 extend from a top surface of the structural tray 800, including the topmost perimeter 810 of the structural tray 800, to a bottom planar surface 1102. Accordingly, the structural tray 800 is balanced without additional support such that a first side (such as shown by first side view 1300 of FIG. 13, to be described in further detail below) is in contact with the bottom planar surface 1102 and a second side (such as shown by second side view 1400 of FIG. 14, to be described in further detail below) is also in contact with the bottom planar surface 1102 when the structural tray 800 is set on the bottom planar surface 1102 without any additional support. Any number of structural elements 808 may be implemented into the structural tray 800 such that the topmost perimeter 810 is level with (e.g., parallel with) the bottom planar surface 1102 when the structural tray 800 is placed on the bottom planar surface 1102.

[0078] FIG. 13 illustrates a first side view of an embodiment of a structural tray. First side view 1300 includes a structural tray 800 having a base 802 including a compartment 806 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). The compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging.

[0079] The structural tray 800 includes a structural element 808 shaped to support the device tray. In various embodiments, one or more structural elements 808 may be used to support the device tray (and a product supported by the device tray) in an upright position. A sufficient number of structural elements 808 may be provided such that the structural tray 800 is levelcompared to a planar surface on which the structural tray 800 is set, such as bottom planar surface 1102. In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806.

[0080] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 of the base 802 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). The ledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0081] According to at least some embodiments, the structural elements 808 are shaped to keep the structural tray 800 (and the device tray the structural tray supports, and the product supported by the device tray) upright without additional support. For example, and as would be appreciated by one having ordinary skill in the art, the structural elements 808 extend from a top surface of the structural tray 800, including the topmost perimeter 810 of the structural tray 800, to a bottom planar surface 1102. Accordingly, the structural tray 800 is balanced without additional support such that a front side (such as shown by front view 1100 of FIG. 11) is in contact with the bottom planar surface 1102 and a rear side (such as shown by rear view 1200 of FIG. 12) is also in contact with the bottom planar surface 1102 when the structural tray 800 is set on the bottom planar surface 1102 without any additional support. Any number of structural elements 808 may be implemented into structural tray 800 such that the topmost perimeter 810 is level with (e.g., parallel with) the bottom planar surface 1102 when the structural tray 800 is placed on the bottom planar surface 1102.

[0082] FIG. 14 illustrates a second side view of an embodiment of a structural tray. Second side view 1400 includes a structural tray 800 having a base 802 including a compartment 806 that is shaped to receive a corresponding impression (e.g., such as impression 106 described above that substantially conforms to a shape of the product to retain the product on the device tray 100). The compartment 806 may be slightly larger than the impression such that the impression fits snug into the compartment 806 with little to no relative movement between the structural tray 800 and the device tray. The compartment 806 securely encompasses a corresponding impression such that the product supported by the device tray remains substantially in the same position as the product is shipped in the packaging.

[0083] The structural tray 800 includes a structural element 808 shaped to support the device tray. In various embodiments, one or more structural elements 808 may be used to support thedevice tray (and a product supported by the device tray) in an upright position. A sufficient number of structural elements 808 may be provided such that the structural tray 800 is level compared to a planar surface on which the structural tray 800 is set, such as bottom planar surface 1102. In various embodiments, the structural tray 800 supports the device tray via a structural element 808 and a compartment 806.

[0084] In at least some embodiments, the structural tray 800 includes a topmost perimeter 810 formed along the perimeter of the interior space 804 of the base 802 for supporting the device tray in the structural tray 800. Specifically, the topmost perimeter 810 engages a ledge of the device tray (such as ledge 110 extending away from a topmost perimeter of the device tray 100). The ledge of the device tray may be supported by the corresponding topmost perimeter 810 of the structural tray 800.

[0085] According to at least some embodiments, the structural elements 808 are shaped to keep the structural tray 800 (and the device tray the structural tray supports, and the product supported by the device tray) upright without additional support. For example, and as would be appreciated by one having ordinary skill in the art, the structural elements 808 extend from a top surface of the structural tray 800, including the topmost perimeter 810 of the structural tray 800, to a bottom planar surface 1102. Accordingly, the structural tray 800 is balanced without additional support such that a front side (such as shown by front view 1100 of FIG. 11) is in contact with the bottom planar surface 1102 and a rear side (such as shown by rear view 1200 of FIG. 12) is also in contact with the bottom planar surface 1102 when the structural tray 800 is set on the bottom planar surface 1102 without any additional support. Any number of structural elements 808 may be implemented into the structural tray 800 such that the topmost perimeter 810 is level with (e.g., parallel with) the bottom planar surface 1102 when the structural tray 800 is placed on the bottom planar surface 1102.

[0086] FIG. 15 illustrates an expanded view of an embodiment of an assembly including a device tray and a structural tray. According to various embodiments of the present disclosure, the assembly 1500 includes a device tray 100 and a structural tray 800 as described in detail above. As illustrated in FIG. 15, each compartment 806 of the structural tray 800 is shaped to receive a corresponding impression 106 of the device tray 100. As further shown in FIG. 15, the compartments 806 are shaped to encompass and support the impression 106 while providing additional support via vertical walls or substantially vertical walls of the compartments 806 and / or of the structural elements 808. For example, as would be appreciated by one having ordinary skill in the art, the additional vertical walls provided by the compartments 806 and / or the structuralelements 808 increase the structural integrity of the structural tray 800 such that the device tray 100 and a product supported by the device tray 100 are protected and supported in an upright position during shipping and merchandising. The structural elements 808 of the structural tray 800 provide further stability and support to the assembly 1500 such that a top surface of the assembly 1500 is level with a planar surface when the assembly 1500 is placed on the planar surface.

[0087] Device tray 100 and structural tray 800 may include, or equivalently be marked with, identifying words, pictures, graphics, etc., to convey information to the consumer or an assembly worker about the product or the device tray 100 / structural tray 800. For example, the product name or serial number may be included on the device tray 100 and / or the structural tray 800. In some embodiments, recyclable information may be included on the device tray 100 and / or the structural tray 800.

[0088] FIG. 16 illustrates an assembled view of an embodiment of an assembly including a device tray and a structural tray. According to various embodiments of the present disclosure, the assembly 1600 includes a device tray 100 and a structural tray 800 as described in detail above. As illustrated in FIG. 16, the device tray 100 fits snug into the structural tray 800. Various components of the device tray 100 and the structural tray 800 are formed to fit within each other, such as the impressions and compartments described and shown at least in FIG. 15. Device tray 100 and structural tray 800 are each integrally formed as a single piece. The device tray 100 and the structural tray 800 are designed to fit together (e.g., an interface between the device tray 100 and the structural tray 800 is a snug fit) without any additional components. Assembly 1600 advantageously does not require any adhesive or folding steps which add time and expense to other corrugate substructure packaging. Products weighing between 0.2 lbs and 12 lbs, inclusive, may be supported by an assembly 1600, according to various embodiments.

[0089] FIG. 17 illustrates a flowchart of an embodiment of a method. Method 1700 includes method of packaging a device. Method 1700 includes step 1702 that includes providing a device tray. The device tray may include any of the embodiments of the device tray 100 described in detail above and with respect to FIGS. 1-7 and 15-16. For example, the device tray includes an impression substantially conforming to a shape of an item to retain the item in the device tray. The item may be a product or any other article of manufacture which is shipped in packaging. Step 1704 includes providing a structural tray. The structural tray may include any embodiments of the structural tray 800 described in detail above and with respect to FIGS. 8-14 and 15-16. For example, the structural tray includes a compartment shaped to receive the impression of the device tray. The structural tray may also include a structural element perpendicular to a top surface of thestructural tray for supporting the device tray and the item in a predetermined position. Step 1706 includes placing the device tray in the structural tray, such as shown in FIGS. 15-16 having assemblies of the device tray 100 and the structural tray 800 Step 1708 includes placing the item in the impression of the device tray. In various embodiments, these steps may be performed in any order. For example, the item may be placed in the device tray (step 1708) may be performed before the device tray is placed in the structural tray (step 1706), as would be appreciated by one having ordinary skill in the art upon reading the present disclosure. Method 1700 further includes step 1710 including packaging the item, the device tray, and the structural tray in an enclosure, such as a box.

[0090] In various embodiments, an assembly comprising the device tray and the structural tray (and the product in the device tray) may be enclosed in an enclosure such as a box having six- walls (e.g., a top, a bottom, and four walls perpendicular to the top and bottom). In other embodiments, any shape or number of walls or sides may be used. For example, the device tray and the structural tray may be circular in shape and be further placed in a circular enclosure (such as a "hat box" shape).

[0091] In various embodiments, a density of the cosmetic device tray is greater than a density of the structural tray and a thickness of the cosmetic device tray is less than a thickness of the structural tray. The relatively greater density of the device tray may be a result of a wet press manufacturing process that produces a smooth finish for the device tray. For example, the device tray comprises a material including bamboo and bagasse that is wet pressed to form the cosmetic molded fiber trays. In various embodiments, the material of the device tray comprises 65% bamboo and 35% bagasse, although other materials may be added. For example, wood pulp or recycled paper content may be added in nominal amounts to alter the appearance and / or physical properties of the device tray. The formulation of the material of the device tray may vary depending on the product and / or application. In various embodiments, the device tray is further cosmeticized by bleaching or otherwise dying the surface of the device tray. For example, the device tray may be bleached white to further display the product with a clean, minimalist, and aesthetic appearance.

[0092] The material of the device tray may be characterized by a burst strength in a range of 450 kPa to 1200 kPa, inclusive. The material of the device tray may also be characterized by a tensile strength in a range of 5 kgf to 25 kgf, inclusive. Corrugate substructures are characterized by a burst strength and the tensile strength that are 35% of the burst strength and tensile strength of thedevice tray described herein. Accordingly, the device tray is stronger (e.g., able to accommodate heavier products) than corrugate substructures.

[0093] In various embodiments, the thickness of the device tray is in a range of 0.5 mm to 1.5 mm, inclusive. The thickness of the device tray is less than a thickness of the structural tray. In various embodiments, it is desirable to have the device tray be as thin as possible to reduce the materials used in the packaging and the materials that will eventually be recycled or otherwise disposed of by the consumer. The structural support and capabilities of the structural tray enables the device tray to be relatively thin by providing a supportive understructure.

[0094] In some embodiments, at least a portion of a surface of the device tray is characterized by a surface roughness in a range of 3 pm to 5 pm, inclusive. The surface roughness of the device tray is significantly less than the surface roughness of the structural tray. In various embodiments, it is desirable to have the device tray be relatively smooth and presentable to a consumer. For example, a consumer may associate a smoother surface displaying the product with a higher quality product. Accordingly, the device tray may appear to be soft and without protrusions along the surface.

[0095] In some embodiments, the density of the structural tray is in a range of 400 kg / m3and 600 kg / m3, inclusive. The density of the structural tray is less than the device tray. The relatively reduced density of the structural tray may be a result of a dry or semi-wet press manufacturing process that produces a rougher (e.g., less smooth) finish for the structural tray as compared to the wet press process used for the device tray. For example, the structural tray comprises a material including recycled kraft pulp that is dry or semi-wet pressed to form the OCC molded fiber trays. In various embodiments, the material of the structural tray comprises 100% recycled kraft pulp, although other materials may be added. For example, wood pulp or recycled paper content may be added in nominal amounts to alter the appearance and / or physical properties of the structural tray. The formulation of the material of the structural tray may vary depending on the product and / or application.

[0096] The material of the structural tray may be characterized by a burst strength in a range of 400 kPa to 1200 kPa, inclusive. The material of the structural tray may also be characterized by a tensile strength in a range of 10 kgf to 35 kgf, inclusive. Corrugate substructures are characterized by a burst strength and the tensile strength that are 35% of the burst strength and tensile strength of the structural tray 800 described herein. Accordingly, the structural tray is stronger (e.g., able to accommodate heavier products) than corrugate substructures.

[0097] In various embodiments, the thickness of the structural tray is in a range of 0.8 mm to 2.5 mm, inclusive. The thickness of the structural tray is greater than a thickness of the device tray. In various embodiments, it is desirable to have the device tray be as thin as possible to reduce the materials used in the packaging and the amount of materials that will eventually be recycled or otherwise disposed of by the consumer. The structural support and capabilities of the structural tray enables the device tray to be relatively thin by providing a supportive understructure

[0098] In some embodiments, at least a portion of a surface of the structural tray is characterized by a surface roughness in a range of 8 pm to 12 pm, inclusive. The surface roughness of the structural tray is significantly greater than the surface roughness of the device tray. In various embodiments, it is desirable to have the device tray be relatively smooth and presentable to a consumer. In contrast, the structural tray may be produced by cheaper manufacturing methods (e.g., dry or semi-wet press processes) that do not result in as smooth a finish as the manufacturing method (e.g., wet press processes) used to form the device tray. Accordingly, the structural tray may appear to be rougher and having a texture along the surface of the structural tray.

[0099] It should be noted that the methods, systems, and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, it should be appreciated that, in alternative embodiments, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are examples and should not be interpreted to limit the scope of the invention.

[0100] Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known, processes, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments. This description provides example embodiments only, and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the preceding description of the embodiments will provide those skilled in the art with an enabling description for implementing embodiments of the invention. Various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention.

[0101] Also, it is noted that the embodiments may be described as a process which is depicted as a flow diagram or block diagram. Although each may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process may have additional steps not included in the figure.

[0102] Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of the invention. Also, a number of steps may be undertaken before, during, or after the above elements are considered.

Claims

WHAT IS CLAIMED IS:

1. A system, the system comprising: a first tray, the first tray comprising: a base having an interior space shaped to receive an item; and a second tray, the second tray comprising: a base having an interior space shaped to receive the first tray; and a structural element shaped to support the first tray, wherein a density of the first tray is greater than a density of the second tray, and wherein a thickness of the first tray is less than a thickness of the second tray.

2. The system of claim 1, wherein the density of the first tray is in a range of 550 kg / m3and 750 kg / m3.

3. The system of claim 2, wherein the density of the second tray is different than the density of the first tray and is in a range of 400 kg / m3and 600 kg / m3.

4. The system of claim 1, wherein the thickness of the first tray is in a range of 0.5 mm to 1.5 mm.

5. The system of claim 4, wherein the thickness of the second tray is different than the thickness of the first tray and is in a range of 0.8 mm to 2.5 mm.

6. The system of claim 1, wherein the interior space of the first tray comprises an impression substantially conforming to a shape of the item to retain the item in the first tray.

7. The system of claim 6, wherein the base of the second tray comprises a compartment formed in the interior space, wherein the compartment of the second tray is shaped to receive the impression of the first tray.

8. The system of claim 1, wherein the first tray comprises a ledge formed along the perimeter of the interior space of the base for supporting the first tray in the second tray.

9. The system of claim 7, wherein the second tray supports the first tray via the structural element and the compartment.

10. The system of claim 1, wherein the first tray comprises 65% bamboo and35% bagasse.

11. The system of claim 10, wherein the first tray is characterized by a burst strength in a range of 450 kPa to 1200 kPa.

12. The system of claim 1, wherein the second tray comprises recycled kraft pulp.

13. The system of claim 12, wherein the second tray is characterized by a burst strength in a range of 400 kPa to 1000 kPa.

14. The system of claim 1, wherein at least a portion of a surface of the first tray is characterized by a surface roughness in a range of 3 pm to 5 pm.

15. The system of claim 1, wherein at least a portion of a surface of the second tray is characterized by a surface roughness in a range of 8 pm to 12 pm.

16. The system of claim 1, further comprising: an enclosure shaped to enclose the item, the first tray, and the second tray.

17. A method of packaging a device, the method comprising: providing a device tray, the device tray having an impression substantially conforming to a shape of an item to retain the item in the device tray; providing a structural tray, wherein: the structural tray comprises a compartment shaped to receive the impression of the device tray; and the structural tray comprises a structural element perpendicular to a top surface of the structural tray for supporting the device tray and the item in a predetermined position; and placing the device tray in the structural tray; and wherein: a density of the device tray is greater than a density of the structural tray, and a thickness of the device tray is less than a thickness of the structural tray.

18. The method of claim 17, wherein the density of the device tray is in a range of 550 kg / m3and 750 kg / m3, wherein the density of the second tray is different than the density of the first tray and is in a range of 400 kg / m3and 600 kg / m3.

19. The method of claim 17, wherein the thickness of the device tray is in a range of 0.5 mm to 1.5 mm.

20. The method of claim 19, wherein the thickness of the second tray is different than the thickness of the first tray and is in a range of 0.8 mm to 2.5 mm.

Images