US20170334602A1

US20170334602A1 - Nested packaging assemblies

Info

Publication number: US20170334602A1
Application number: US15/523,200
Authority: US
Inventors: John Church; Christopher Bray; Joy CHRISTENSEN
Original assignee: POLYONE DESIGNED STRUCTURES AND SOLUTIONS LLC
Current assignee: Spartech LLC
Priority date: 2014-10-31
Filing date: 2015-10-28
Publication date: 2017-11-23
Also published as: CN107108072A; WO2016069698A1; EP3212528A1

Abstract

A packaging assembly includes a plurality of individual packages. Each of the plurality of individual packages is adjoined to at least one other of the plurality of individual packages. The individual packages can be adjoined by hinged and/or detachable connections. Each of the plurality of individual packages has a base, a sidewall integral with and extending from the base, and an opening defined by an end of the sidewall distal from the base. Any conceivable product can be packaged in the packaging assembly. The packaging assembly can be configured in a nested manner and has a ratio of a packaged product volume to an occupied space volume that is at least 0.5 and less than 1.

Description

CLAIM OF PRIORITY

This application claims priority from U.S. Provisional Patent Application Ser. No. 62/073,122 bearing Attorney Docket Number 12014019 and filed on Oct. 31, 2014, which is incorporated by reference.

FIELD OF THE INVENTION

This invention relates to packaging assemblies, and, more particularly, packaging assemblies which include a plurality of adjoined individual packages that can be configured in a nested manner.

BACKGROUND OF THE INVENTION

Demand exists for unique packaging solutions, especially for various consumer packaged goods. Unique packaging solutions can desirably provide a combination of required functionality and distinctive aesthetics, for example, to preserve the quality and freshness of the product while also serving to reinforce attributes of a particular brand and differentiate a particular product in the eyes of consumers.
Increasingly, demand exists for consumer packaged goods such as foods or snacks to be packaged in individual serving sizes. Non-limiting examples of such food or snack products include yogurt, pudding, applesauce, fruit salad, gelatin products, ice cream, cheese snacks, oatmeal and other breakfast cereal, peanut butter, salsa, hummus, guacamole, other dips or spreads, vegetable salad, tuna salad, soup, pasta, and the like. Such individual serving size packaged products are often sold in multi-unit packs (i.e., packaging assemblies that include several individual serving size packages which are bundled together).
In general, available packaging options for multi-unit packs of individual serving size packages include rigid packaging and flexible packaging. For certain products or applications, rigid packaging such as cups or containers or trays can be a necessity or at least preferable over flexible packaging such as pouches. However, such multi-unit packs typically require a tradeoff between the amount or volume of product contained by the packaging relative to the space or volume occupied by the packaged product, especially if rigid packaging is required or preferred.
In particular, multi-unit packs of individual serving size rigid packages typically are less efficient as compared to single bulk rigid packages with respect to a ratio of the volume of product contained by the packaging relative to the volume of space occupied by the packaged product. Such a ratio equals one for packaging of a theoretically maximum efficiency (i.e., when the volume of product contained by the packaging equals the volume of space occupied by the packaged product). But, in practice, the ratio is something less than one for most packaged products, especially those packaged in rigid packages, because of inefficiencies. For multi-unit packs, such inefficiencies can include space occupied by the packaging itself as well as voids between bundled individual packages that can occur at least in part because of the spacing between the individual packages or the shape of the individual packages or other factors.
Inefficiencies that result in a lower ratio of the volume of product contained by the packaging relative to the volume of space occupied by the packaged product can lead to increased costs throughout the value chain. For example, shipping and warehousing can be more expensive for products packaged in the form of multi-unit packs of individual serving size rigid packages. Likewise, stocking multi-unit packs of individual serving size rigid packages on retailers' store shelves can be more expensive.
Indeed, given that retailers' shelf space typically is a limited and highly valuable resource, packaging solutions that deliver greater efficiency with respect to the ratio of the volume of product contained by the packaging relative to the volume of space occupied by the packaged product for multi-unit packs, and, especially those that do so while also providing distinctive aesthetics or increased surface area for presenting promotional information to consumers, would be highly beneficial to both retailers and the manufacturers which compete to have their products placed on retailers' limited shelf space.

SUMMARY OF THE INVENTION

Consequently, a need exists for packaging solutions, especially rigid packaging solutions, that can provide improved efficiency regarding the amount or volume of product contained by packaging assemblies such as multi-unit packs relative to the space or volume occupied by the packaging assemblies. A need also exists for packaging solutions to provide the aforementioned efficiency while also providing distinctive aesthetics or increased surface area for presenting promotional information to consumers.
The aforementioned needs are met by one or more aspects of the present invention.
One aspect of the invention is a packaging assembly including a plurality of individual packages. Each of the plurality of individual packages is adjoined to at least one other of the plurality of individual packages. The packaging assembly has a ratio of a packaged product volume to an occupied space volume that is at least 0.5 and less than 1.
Another aspect of the invention is a packaging assembly such as the aforementioned packaging assembly wherein at least a first package is adjoined to at least a second package by a hinged connection. Such a packaging assembly can be nested. That is, for example, the first package can be rotated relative to the second package about the hinged connection such that at least a portion of the base of the first package is adjacent to at least a portion of the sidewall of the second package.
Yet another aspect of the invention is a packaging assembly such as the aforementioned packaging assembly wherein each of the plurality of individual packages has a base and an opening that are both substantially L-shaped.
A further aspect of the invention is a packaging assembly such as the aforementioned packaging assembly wherein each of the plurality of individual packages has a base and an opening that are both substantially rectangular.
An even further aspect of the invention is a packaging assembly such as the aforementioned packaging assembly which includes a secondary exterior package that encases at least a portion of the plurality of individual packages. The secondary exterior package can contribute to bundling and/or securing the plurality of individual packages while also providing increased surface area for presenting promotional information to consumers.
Another aspect of the invention is a method of packaging a product. The method includes the steps of providing a packaging assembly such as the aforementioned packaging assembly, and filling the product into one or more of the plurality of individual packages.
Features of the invention will become apparent with reference to the following embodiments. There exist various refinements of the features noted in relation to the above-mentioned aspects of the present invention. Additional features may also be incorporated in the above-mentioned aspects of the present invention. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the described aspects of the present invention may be incorporated into any of the described aspects of the present invention alone or in any combination.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 2 is a front view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 3 is back view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 4 is a right side view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 5 is a left side view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 6 is a top view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 7 is a bottom view of a first embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 8 is a perspective view of a first embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 9 is a front view of a first embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 10 is a side view of a first embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 11 is a top view of a first embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 12 is a perspective view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 13 is a front view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 14 is a back view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 15 is a right side view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 16 is a left side view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 17 is a top view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 18 is a bottom view of a second embodiment of a packaging assembly of the present invention in a nested configuration.

FIG. 19 is a perspective view of a second embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 20 is a front view of a second embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 21 is a side view of a second embodiment of a packaging assembly of the present invention in an unnested configuration.

FIG. 22 is a top view of a second embodiment of a packaging assembly of the present invention in an unnested configuration.

EMBODIMENTS OF THE INVENTION

In some embodiments, the present invention is directed to a packaging assembly including a plurality of individual packages.
In other embodiments, the present invention is directed to a method of packaging a product.
Required and optional features of these and other embodiments of the present invention are described.
As used herein, the term “nested” means that a packaging assembly is configured whereby each individual package of the packaging assembly is rotated relative to at least one other individual package of the packaging assembly such that at least a portion of the base of the individual package is adjacent to at least a portion of the sidewall of the at least one other individual package.
As used herein, the term “occupied space volume” means the quantity of three-dimensional space taken up by a packaging assembly as determined by the product of multiplying the measured length by the measured width by the measured height of the exterior dimensions of the packaging assembly. For a packaging assembly with non-uniform dimensions, the maximum of each of the length dimension, width dimension, and height dimension is utilized.
As used herein, the term “packaged product volume” means the quantity of three-dimensional space that is intended to be available within the total of the cavities of the plurality of individual packages of a packaging assembly and can be filled by one or more products.
As used herein, the term “ratio of packaged product volume to occupied space volume” means the quotient of the packaged product volume divided by the occupied space volume for a given packaging assembly when the packaged product volume and the occupied space volume are expressed in the same unit of measurement.
As used herein, “unnested” means that a packaging assembly is configured in a manner that is not nested.
Packaging Assembly
A packaging assembly of the present invention includes a plurality of individual packages each of which is adjoined to at least one other of the plurality of individual packages.
The packaging assembly has a ratio of a packaged product volume to an occupied space volume that is at least 0.5 and less than 1. For example, the packaging assembly can have a ratio of packaged product volume to occupied space volume that is, in some embodiments, at least 0.50, and, in other embodiments, at least 0.51. In some embodiments, the packaging assembly can have a ratio of a packaged product volume to an occupied space volume that is at least 0.5 and also less than 1.0, or less than 0.9, or less than 0.8, or less than 0.7, or less than 0.6.
The packaging assembly can be in a nested configuration or an unnested configuration. However, to achieve a ratio of packaged product volume to occupied space volume that is at least 0.5, it is presently believed that the packaging assembly must be in a nested configuration.
The packaging assembly includes a plurality of individual packages. Packaging assemblies of the present invention are not limited to any particular number of individual packages, and a suitable number of individual packages can be determined by one of ordinary skill in the art without undue experimentation based on the specific requirements of the use or application of the packaging assembly. For example, the number of individual packages can be, in some embodiments, a multiple of two, and, in other embodiments, a multiple of three, and, in further embodiments, a multiple of four, and in even further embodiments, a multiple of six.
Each of the plurality of individual packages has a base, a sidewall integral with and extending from the base, and an opening defined by an end of the sidewall distal from the base. In some embodiments, the sidewall extends substantially perpendicularly from the base. For example, the angle between the base and the sidewall can be, for example, from about 75 degrees to about 115 degrees, or, for example, about 90 degrees.
The base, the sidewall, and the opening together define a cavity having an available volume into which one or more product can be added and thus packaged within the individual package. To enclose the product within the individual package until a time when the product is accessed by a consumer, the individual package can further include a closure, such as a removable closure, that covers and preferably removably seals the opening. Any suitable closure, including but not limited to a lid, a cap, a foil, or the like, can be employed.
Each of the plurality of individual packages has a three-dimensional shape. In some embodiments, the three-dimensional shape of at least one of the plurality of individual packages can be different from the three-dimensional shape of at least one other of the plurality of individual packages. In other embodiments, the three-dimensional shape of each of the plurality of individual packages can be substantially the same as the three-dimensional shape of each other of the plurality of individual packages. For example, in some embodiments, at least one of the plurality of individual packages has a base and an opening that are both substantially L-shaped, and, in other embodiments, at least one of the plurality of individual packages has a base and an opening that are both substantially rectangular. Alternatively, in some embodiments, each of the plurality of individual packages has a base and an opening that are both substantially L-shaped, and, in other embodiments, each of the plurality of individual packages has a base and an opening that are both substantially rectangular. In some embodiments, one or more of the plurality of individual packages is substantially rigid or semi-rigid.
Furthermore, each of the plurality of individual packages is adjoined to at least one other of the plurality of individual packages by a connection. In some embodiments, at least one individual package can be directly or indirectly adjoined to at least one, or two, or three, or four, or more other individual packages to provide a set of adjoined individual packages. The packaging assembly of the present invention can include one or more sets of adjoined individual packages, for example, at least two or more sets, or at least three or more sets, or at least four or more sets, which can be configured together in a nested manner.
In some embodiments, the connection can be hinged, and, in other embodiments the connection can be detachable such as a perforated connection. In further embodiments, the connection can be both hinged and detachable.
For embodiments in which the connection is hinged, at least one of the individual packages adjoined by the hinged connection to another of the individual packages can be rotated relative to the other individual package about the hinged connection. In some embodiments, one individual package can be rotated relative to another individual package about a longitudinal axis of the hinged connection that adjoins the individual packages. For example, a first individual package can be rotated, in some embodiments, from about 75 degrees to about 115 degrees, and, in other embodiments, about 90 degrees, relative to a second individual package about the hinged connection that adjoins the first and second individual packages. As a further example, a first individual package can be rotated relative to a second individual package, for example, about the hinged connection that adjoins the first and second individual packages, such that at least a portion of the base of the first package is adjacent to at least a portion of the sidewall of the second package.
In some embodiments, the packaging assembly can further include a secondary exterior package that encases at least a portion of the plurality of individual packages. The secondary exterior package can contribute to bundling and/or securing the plurality of individual packages while also providing increased surface area for presenting promotional information to consumers. The secondary exterior package can be made of any suitable material, including but not limited to plastic, foil, paperboard, or the like. For example, the secondary exterior package can include a shrink-wrap package or a wrap-around package.
With reference to FIGS. 1 to 11, a first exemplary embodiment of a packaging assembly 100 according to the present invention is described. The packaging assembly 100 includes a plurality of individual packages 101. More particularly, as depicted in FIGS. 1 to 7, the packaging assembly 100 is in a nested configuration and includes four individual packages 101 a, 101 b, 101 c, and 101 d. Further, as depicted in FIGS. 8 to 11, the packaging assembly 100′ is in an unnested configuration and includes two adjoined individual packages 101 a and 101 b or 101 c and 101 d. In this embodiment, two or more of the unnested packaging assemblies 100′ can be configured together to provide a nested packaging assembly 100 having a ratio of a packaged product volume to an occupied space volume that is at least 0.5 according to the present invention.
As depicted in FIGS. 1 to 11, individual package 101 a has a base 102 a, a sidewall 103 a, and an opening 104 a; and, individual package 101 b has a base 102 b, a sidewall 103 b, and an opening 104 b; and, individual package 101 c has a base 102 c, a sidewall 103 c, and an opening 104 c; and, individual package 101 d has a base 102 d, a sidewall 103 d, and an opening 104 d. Individual package 101 a and individual package 101 b are adjoined by connection 105 ab; and individual package 101 c and individual package 101 d are adjoined by connection 105 cd.
As further depicted in FIGS. 1 to 11, each individual package 101 has a base 102 and an opening 104 that are both substantially L-shaped. That is, the shape of each of the base 102 and the opening 104 is generally in the shape of a capital letter “L” or has an “L-shape”.
In some embodiments, the L-shape of the base 102 and the opening 104 can include a heel section 106 and a toe section 107. For example, as depicted in FIG. 8, a first individual package 101 a, 101 c has a heel section 106 a, 106 c and a toe section 107 a, 107 c. Likewise, a second individual package 101 b, 101 d has a heel section 106 b, 106 d and a toe section 107 b, 107 d.
As depicted in FIG. 8, when the first individual package 101 a, 101 c is adjoined to the second individual package 101 b, 101 d, the first individual package 101 a, 101 c can be configured relative to the second individual package 101 b, 101 d such that at least a portion of the toe section 107 a, 107 c of the first individual package 101 a, 101 c is adjacent to at least a portion of the toe section 107 b, 107 d of the second individual package 101 b, 101 d.
As depicted in FIG. 11, the first individual package 101 a, 101 c can have a first sidewall portion 103 a-1, 103 c-1 opposite from a third sidewall portion 103 a-3, 103 c-3 and a fifth sidewall portion 103 a-5, 103 c-5, and a second sidewall portion 103 a-2, 103 c-2 opposite from a fourth sidewall portion 103 a-4, 103 c-4 and a sixth sidewall portion 103 a-6, 103 c-6. Each of the first sidewall portion 103 a-1, 103 c-1, the third sidewall portion 103 a-3, 103 c-3, and the fifth sidewall portion 103 a-5, 103 c-5 has a length that is substantially parallel to the length of each other of the first sidewall portion 103 a-1, 103 c-1, the third sidewall portion 103 a-3, 103 c-3, and the fifth sidewall portion 103 a-5, 103 c-5. The length of the first sidewall portion 103 a-1, 103 c-1 is greater than the length of the third sidewall portion 103 a-3, 103 c-3 and the length of the fifth sidewall portion 103 a-5, 103 c-5. Likewise, each of the second sidewall portion 103 a-2, 103 c-2, the fourth sidewall portion 103 a-4, 103 c-4, and the sixth sidewall portion 103 a-6, 103 c-6 has a length that is substantially parallel to the length of each other of the second sidewall portion 103 a-2, 103 c-2, the fourth sidewall portion 103 a-4, 103 c-4, and the sixth sidewall portion 103 a-6, 103 c-6. The length of the second sidewall portion 103 a-2, 103 c-2 is greater than the length of the fourth sidewall portion 103 a-4, 103 c-4 and the length of the sixth sidewall portion 103 a-6, 103 c-6. The lengths of the first sidewall portion 103 a-1, 103 c-1, the third sidewall portion 103 a-3, 103 c-3, and the fifth sidewall portion 103 a-5, 103 c-5 are substantially perpendicular to the lengths of the second sidewall portion 103 a-2, 103 c-2, the fourth sidewall portion 103 a-4, 103 c-4, and the sixth sidewall portion 103 a-6, 103 c-6.
Similarly, as further depicted in FIG. 11, the second individual package 101 b, 101 d can have a first sidewall portion 103 b-1, 103 d-1 opposite from a third sidewall portion 103 b-3, 103 d-3 and a fifth sidewall portion 103 b-5, 103 d-5, and a second sidewall portion 103 b-2, 103 d-2 opposite from a fourth sidewall portion 103 b-4, 103 d-4 and a sixth sidewall portion 103 b-6, 103 d-6. Each of the first sidewall portion 103 b-1, 103 d-1, the third sidewall portion 103 b-3, 103 d-3, and the fifth sidewall portion 103 b-5, 103 d-5 has a length that is substantially parallel to the length of each other of the first sidewall portion 103 b-1, 103 d-1, the third sidewall portion 103 b-3, 103 d-3, and the fifth sidewall portion 103 b-5, 103 d-5. The length of the first sidewall portion 103 b-1, 103 d-1 is greater than the length of the third sidewall portion 103 b-3, 103 d-3 and the length of the fifth sidewall portion 103 b-5, 103 d-5. Likewise, each of the second sidewall portion 103 b-2, 103 d-2, the fourth sidewall portion 103 b-4, 103 d-4, and the sixth sidewall portion 103 b-6, 103 d-6 has a length that is substantially parallel to the length of each other of the second sidewall portion 103 b-2, 103 d-2, the fourth sidewall portion 103 b-4, 103 d-4, and the sixth sidewall portion 103 b-6, 103 d-6. The length of the second sidewall portion 103 b-2, 103 d-2 is greater than the length of the fourth sidewall portion 103 b-4, 103 d-4 and the length of the sixth sidewall portion 103 b-6, 103 d-6. The lengths of the first sidewall portion 103 b-1, 103 d-1, the third sidewall portion 103 b-3, 103 d-3, and the fifth sidewall portion 103 b-5, 103 d-5 are substantially perpendicular to the lengths of the second sidewall portion 103 b-2, 103 d-2, the fourth sidewall portion 103 b-4, 103 d-4, and the sixth sidewall portion 103 b-6, 103 d-6.
As depicted in FIGS. 1 to 7, the packaging assembly 100 includes at least a first set of adjoined individual packages defined by a first individual package 101 a adjoined to a second individual package 101 b by a first hinged connection 105 ab, and at least a second set of adjoined individual packages defined by a third individual package 101 c adjoined to a fourth individual package 101 d by a second hinged connection 105 cd. The first set of adjoined individual packages is configured whereby the first individual package 101 a is rotated relative to the second individual package 101 b about the first hinged connection 105 ab such that at least a portion of the base 102 a of the first individual package 101 a is adjacent to at least a portion of the sidewall 103 b of the second individual package 101 b. Likewise, the second set of adjoined packages is configured whereby the third individual package 101 c is rotated relative to the fourth individual package 101 d about the second hinged connection 105 cd such that at least a portion of the base 102 c of the third individual package 101 c is adjacent to at least a portion of the sidewall 103 d of the fourth individual package 101 d. Furthermore, the first set of adjoined individual packages is configured relative to the second set of adjoined individual packages such that at least a portion of the base 102 a of the first individual package 101 a is adjacent to at least a portion of the base 102 c of the third individual package 101 c, and at least a portion of the sidewall 103 a of the first individual package 101 a is adjacent to at least a portion of the base 102 d of the fourth individual package 101 d, and at least a portion of the base 102 b of the second individual package 101 b is adjacent to at least a portion of the sidewall 103 c of the third individual package 101 c.
With reference to FIGS. 12 to 22, a second exemplary embodiment of a packaging assembly 200 according to the present invention is described. The packaging assembly 200 includes a plurality of individual packages 201. More particularly, as depicted in FIGS. 12 to 18, the packaging assembly 200 is in a nested configuration and includes four individual packages 201 a, 201 b, 201 c, and 201 d. Further, as depicted in FIGS. 19 to 22, the packaging assembly 200′ is in an unnested configuration and includes four individual packages 201 a, 201 b, 201 c, and 201 d. In this embodiment, one or more of the unnested packaging assemblies 200′ can be configured to provide a nested packaging assembly 200 having a ratio of a packaged product volume to an occupied space volume that is at least 0.5 according to the present invention.
As depicted in FIGS. 12 to 22, individual package 201 a has a base 202 a, a sidewall 203 a, and an opening 204 a; and, individual package 201 b has a base 202 b, a sidewall 203 b, and an opening 204 b; and, individual package 201 c has a base 202 c, a sidewall 203 c, and an opening 204 c; and, individual package 201 d has a base 202 d, a sidewall 203 d, and an opening 204 d. Individual package 201 a and individual package 201 b are adjoined by connection 205 ab; and, individual package 201 b and individual package 201 c are adjoined by connection 205 bc; and, individual package 201 c and individual package 201 d are adjoined by connection 205 cd.
As further depicted in FIGS. 12 to 22, each individual package 201 has a base 202 and an opening 204 that are both substantially rectangular. That is, the shape of each of the base 202 and the opening 204 is generally in the shape of a rectangle including but not limited to the general shape of a square.
In some embodiments, each of the plurality of individual packages can have a first corner section, a second corner section, a third corner section, and fourth corner section, respectively defined in a clockwise manner. For example, as depicted in FIGS. 19 to 22, a first individual package 201 a has a first corner section 208 a-1, a second corner section 208 a-2, a third corner section 208 a-3, and fourth corner section 208 a-4. Likewise, a second individual package 201 b has a first corner section 208 b-1, a second corner section 208 b-2, a third corner section 208 b-3, and fourth corner section 208 b-4; and, a third individual package 201 c has a first corner section 208 c-1, a second corner section 208 c-2, a third corner section 208 c-3, and fourth corner section 208 c-4; and, a fourth individual package 201 d has a first corner section 208 d-1, a second corner section 208 d-2, a third corner section 208 d-3, and fourth corner section 208 d-4.
Further, in some embodiments, at least a first individual package of the plurality of individual packages can be adjoined in an offset manner to at least a second individual package of the plurality of individual packages such that at least a portion of the second corner section of the first individual package is adjacent to at least a portion of the fourth corner section of the second individual package. For example, as depicted in FIGS. 19 to 22, the first individual package 201 a is adjoined to individual package 201 b by connection 205 ab such that at least a portion of the section corner section 208 a-2 of individual package 201 a is adjacent to at least a portion of the fourth corner section 208 b-4 of the second individual package 201 b.
Additionally, in some embodiments, at least a third individual package of the plurality of individual packages is adjoined in an offset manner to the second individual package such that at least a portion of the first corner section of the second individual package is adjacent to at least a portion of the third corner section of the third individual package. For example, as depicted in FIGS. 19 to 22, the third individual package 201 c is adjoined to the second individual package 201 b by connection 205 bc such that at least a portion of the first corner section 208 b-1 of the second individual package 201 b is adjacent to at least a portion of the third corner section 208 c-3 of the third individual package 201 c.
Likewise, in some embodiments, at least a fourth individual package of the plurality of individual packages can adjoined in an offset manner to the third individual package such that at least a portion of the second corner section of the third individual package is adjacent to at least a portion of the fourth corner section of the fourth individual package. For example, as depicted in FIGS. 19 to 22, the fourth individual package 201 d is adjoined to the third individual package 201 c such that at least a portion of the second corner section 208 c-2 of the third individual package 201 c is adjacent to at least a portion of the fourth corner section 208 d-4 of the fourth individual package 201 d.
In further embodiments, the first, second, third, and fourth individual packages can be configured in a nested or folder configuration. That is, the individual packages can be configured relative to each other such that at least a portion of the base of the first individual package is adjacent to at least a portion of the base of the third individual package; and, at least a portion of the base of the second individual package is adjacent to at least a portion of the base of the fourth individual package; and, at least a portion of the sidewall of the first individual package and at least a portion of the sidewall of the third individual package are adjacent to at least a portion of the sidewall of the second individual package and at least a portion of the sidewall of the fourth individual package. For example, as depicted in FIGS. 12 to 18, the first individual package 201 a, the second individual package 201 b, the third individual package 201 c, and the fourth individual package 201 d are configured relative to each other such that at least a portion of the base 202 a of the first individual package 201 a is adjacent to at least a portion of the base 202 c of the third individual package 201 c; and, at least a portion of the base 202 b of the second individual package 201 b is adjacent to at least a portion of the base 202 d of the fourth individual package 201 d; and, at least a portion of the sidewall 203 a of the first individual package 201 a and at least a portion of the sidewall 203 c of the third individual package 201 c are adjacent to at least a portion of the sidewall 203 b of the second individual package 201 b and at least a portion of the sidewall 203 d of the fourth individual package 201 d.
Processing
The packaging assemblies of the present invention and the plurality of individual packages thereof can be formed by any suitable forming or molding process known to those of ordinary skill in the art and used for producing parts from any suitable formable or moldable material.
Non-limiting examples of suitable forming processes generally include molding, casting, and pressing. More specific examples include but are not limited to compression molding, injection molding, blow molding, thermoforming, pressure forming, vacuum forming, and 3D printing.
Without undue experimentation, those of ordinary skill in the art can select one or more suitable materials to form the packaging assemblies and the individual packages thereof based upon, for example, application requirements, a product to be packaged therein, processing requirements for the product, a barrier requirement, and/or a shelf stabilization requirement. In general, suitable materials can include, but are not limited to, polymeric materials such as thermoplastic or thermosetting polymeric materials. Polymeric materials can be petroleum derived and/or derived from renewable sources. Suitable materials also can include, but are not limited to, metals, glass, clays, ceramics, wood, pulp, paper, fibers, cellulosics, starches, grasses, peat, coir, biomass, and the like. Blends or mixtures of two or more suitable materials can be used.
Non-limiting examples of suitable thermoplastic materials generally include styrenes, polyolefins, vinyls, cellulosics, polyesters, polyamides, acrylics, and polycarbonates, including copolymers and blends of any of the foregoing. More particular non-limiting examples include polyethylene terephthalate (PET), copolyester (PETG), polystyrene (PS), high-impact polystyrene (HIPS), oriented polystyrene (OPS), polypropylene (PP), copolymer polypropylene (COPP), polyethylene (PE), high density polyethylene (HDPE), low density polyethylene (LDPE), polyvinyl chloride (PVC), acrylonitriles (BAREX), and polylactic acid (PLA), including copolymers and blends of any of the foregoing. Virgin, reground, and/or post-consumer recycled thermoplastic materials can be used.
In some embodiments, the individual packages can be formed from a coextruded multilayer sheet that includes one or more layer of one or more thermoplastic material and/or one or more barrier material and/or one or more inorganic filler and/or one or more additives. Suitable thermoplastic materials can include, but are not limited to, those mentioned above. Suitable barrier materials can include any known material that can provide desirable barrier properties, for example, moisture barrier properties and/or oxygen barrier properties. Non-limiting examples of suitable barrier materials include poly(ethylene vinyl alcohol) (EVOH), polyvinyl alcohol (PVOH), polyvinylidine chloride (PVDC), polyamide, acrylate copolymers, cyclic olefin copolymers (COC), and the like. Suitable inorganic fillers can include, but are not limited to, talc, glass, clay, silica, mica, and the like. Suitable additives, such as antioxidants, processing aids, foaming agents, and colorants or pigments, can be selected without undue experimentation but with reference to such treatises as Plastics Additives Database (2004) from Plastics Design Library (elsevier.com).
It is understood, however, that each individual package of the packaging assembly can be made of the same or different materials from each other without departing from the scope of this invention.

Usefulness of the Invention

The packaging assemblies of the present invention can be used to package one or more products with a ratio of packaged product volume to occupied space volume that is at least 0.5.
With efficiencies that result in a higher ratio of packaged product volume to occupied space volume as compared to that of conventional multi-unit packs, use of the packaging assemblies of the present invention can lead to lower costs throughout the value chain, such as lower costs for packing, shipping, warehousing, and stocking.
Moreover, the packaging assemblies of the present invention can achieve the aforementioned efficiencies and related cost-savings without sacrificing a capability of providing distinctive aesthetics and/or surface area that is desirable for presenting promotional information to consumers.
The packaging assemblies of the present invention can be used to package any conceivable product. Such products can include, for example, food products or non-food products as well as shelf-stable products or non-shelf stable products. In some embodiments, the packaging assemblies of the present invention can be used to package products, for example, in individual sizes, such as individual serving sizes, individual dosage sizes, or individual application sizes.
Non-limiting examples of food or snack products include yogurt, pudding, applesauce, fruit salad, gelatin products, ice cream, cheese snacks, oatmeal and other breakfast cereal, peanut butter, salsa, hummus, guacamole, other dips or spreads, vegetable salad, tuna salad, soup, pasta, and the like.
Food or snack products are not limited to food or snack products for humans, but also can include food or snack products for non-human animals, such as pet food or pet nutrition or other animal nutrition products.
Non-limiting examples of non-food products include medical products and pharmaceuticals as well as consumer and/or professional products for health care, personal care, beauty care, household care, laundry care, baby care, lawn and garden care, pest control, building and construction, home improvement, automotive care, novelty and entertainment, and the like.
Any conceivable product can be packaged according to a method of the present invention that includes the steps of providing a packaging assembly of the present invention and filling the product into one or more of the plurality of individual packages of the packaging assembly.
In some embodiments, further steps of the aforementioned method can include providing a closure that seals at least one of the openings of the plurality of individual packages, and/or manipulating at least one of the plurality of individual packages to configure the packaging assembly from an unnested configuration into a nested configuration, and/or providing a secondary exterior package that encases at least a portion of the plurality of individual packages.

EXAMPLES

The packaged product volume and the occupied space volume were determined for each of several exemplary packaging assemblies of the present invention and for each of several commercially available conventional packaging assemblies. The ratio of packaged product volume to occupied space volume was then calculated for each example.
For the several exemplary packaging assemblies of the present invention, the packaged product volume was as specified for the design of the exemplary embodiment. The occupied space volume was determined by measurement of the length, width, and height of the packaging assembly.
For the several exemplary conventional packaging assemblies, the packaged product volume was as reported by the manufacturer. The occupied space volume was determined by measurement of the length, width, and height of the packaging assembly.
Table 1 below shows the results for Examples 1 to 3, which are non-limiting examples of packaging assemblies of the present invention. Example 1 is representative of a packaging assembly including four individual packages of an L-shaped design as depicted in FIGS. 1 to 11. Example 2 is representative of a packaging assembly including four individual packages of a rectangular design as depicted in FIGS. 12 to 22. Example 3 is representative of a packaging assembly including six individual packages of a rectangular design which is analogous to the rectangular design of the 4-package embodiment depicted in FIGS. 12 to 22.

TABLE 1

Example Packaging Assemblies of the Present Invention

Example

	1	2	3

Package Description	L-shaped	Rectangular	Rectangular
Volume of Product Per	4	4	4
Package (oz.)
Number of Packages Per	4	4	6
Assembly
Total Packaged Product	16	16	24
Volume (oz.)
Occupied Space Volume	56.23	52.74	76.74
(cubic inches)
Occupied Space Volume (oz.)*	31.24	29.3	42.63
Ratio (oz./oz. = unitless)	0.512	0.546	0.563

*1 oz. (US, liquid) equals about 1.8 cubic inches

Tables 2A, 2B, and 2C below show the results for Comparative Examples A to G of several commercially available conventional packaging assemblies.

TABLE 2A

Comparative Example Packaging Assemblies

Comp. Example

	A	B	C

Package Description**	Smucker's ®	Roundy's ®	Snack Pack ®
	Fruit-Fulls ™	Super Fruit	Pudding
	Pouches	Pouches	Cups
Volume of Product Per	4	4	3.25
Package (oz.)
Number of Packages	4	4	4
Per Assembly
Total Packaged Product	16	16	13
Volume (oz.)
Occupied Space Volume	94.66	92.66	64.44
(cubic inches)
Occupied Space	52.59	51.48	35.80
Volume (oz.)*
Ratio (oz./oz. = unitless)	0.304	0.311	0.363

*1 oz. (US, liquid) equals about 1.8 cubic inches
**All trademarks are the property of their respective owners

TABLE 2B

Comparative Example Packaging Assemblies

Comp. Example

	D	E	F

Package Description**	Del Monte	JELL-O Brand	Yoplait ®
	Brand	Pudding Cups	Trix ® Yogurt
	Mixed Fruit		Cups
	Cups
Volume of Product Per	4	3.875	4
Package (oz.)
Number of Packages	4	4	4
Per Assembly
Total Packaged Product	16	15.5	16
Volume (oz.)
Occupied Space Volume	72.76	65.59	65.42
(cubic inches)
Occupied Space Volume	40.42	36.44	36.34
(oz.)*
Ratio (oz./oz. = unitless)	0.396	0.425	0.440

*1 oz. (US, liquid) equals about 1.8 cubic inches
**All trademarks are the property of their respective owners

TABLE 2C

Comparative Example Packaging Assemblies

	Comp. Example
	G

Package Description**	Mott's ® Applesauce Cups
Volume of Product Per Package (oz.)	4
Number of Packages Per Assembly	6
Total Packaged Product Volume (oz.)	24
Occupied Space Volume (cubic inches)	89.35
Occupied Space Volume (oz.)*	49.64
Ratio (oz./oz. = unitless)	0.484

*1 oz. (US, liquid) equals about 1.8 cubic inches
**All trademarks are the property of their respective owners

As shown by Table 1 above, Examples 1 to 3 each had a ratio of packaged product volume to occupied space volume of at least 0.5. In contrast, Comparative Examples A to G each had a ratio of packaged product volume to occupied space volume of less than 0.5.
For 4-package multi-unit packs, Examples 1 and 2 can be compared with Comparative Examples A to F. Within this comparison, Example 2 provided the most efficient packaging configuration with a ratio of packaged product volume to occupied space volume of 0.546, whereas the Comparative Examples had a ratio of packaged product volume to occupied space volume as low as 0.304 (Comparative Example A) and as high as 0.440 (Comparative Example F). Therefore, with respect to packaged product volume relative to occupied space volume, the configuration of Example 2 is about 79% more efficient than the configuration of Comparative Example A and about 24% more efficient than the configuration of Comparative Example F.
For 6-package multi-unit packs, Example 3 can be compared with Comparative Example G. Within this comparison, Example 3 had a ratio of packaged product volume to occupied space volume of 0.563, whereas Comparative Example G had a ratio of packaged product volume to occupied space volume of 0.484. Therefore, with respect to packaged product volume relative to occupied space volume, the configuration of Example 3 is about 16% more efficient than the configuration of Comparative Example G.
Without undue experimentation, those having ordinary skill in the art can utilize the present disclosure including the Description of the Embodiments and the Examples to make packaging assemblies of the present invention that can be more effective with respect to packaged product volume relative to occupied space volume as compared to conventional multi-unit packs.
All documents cited in the Embodiments of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
While particular embodiments of the present invention have been illustrated and described, it would be obvious 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. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of the present invention.

Claims

1. A packaging assembly comprising:

a plurality of individual packages;

wherein each of the plurality of individual packages is adjoined to at least one other of the plurality of individual packages; and

wherein the packaging assembly has a ratio of a packaged product volume to an occupied space volume that is at least 0.5 and less than 1.

2. The packaging assembly according to claim 1, wherein each of the plurality of individual packages comprises a base, a sidewall integral with and extending from the base, and an opening defined by an end of the sidewall distal from the base.

3. The packaging assembly according to claim 1, wherein at least a first package of the plurality of individual packages is rotated relative to at least a second package of the plurality of individual packages.

4. The packaging assembly according to claim 3, wherein at least a first package of the plurality of individual packages is adjoined to at least a second package of the plurality of individual packages by a hinged connection.

5. The packaging assembly according to claim 4, wherein the first package is rotated relative to the second package about a hinged connection such that at least a portion of the base of the first package is adjacent to at least a portion of the sidewall of the second package.

6. The packaging assembly according to claim 5, wherein the first package is rotated from about 75 degrees to about 115 degrees relative to the second package about the hinged connection.

7. The packaging assembly according to claim 6, wherein the second package is adjoined to the first package by a detachable connection.

8. The packaging assembly according to claim 1, wherein each of the plurality of individual packages has a three-dimensional shape that is substantially the same as the three-dimensional shape of each other of the plurality of individual packages.

9. The packaging assembly according to claim 8, wherein each of the plurality of individual packages has a base and an opening that are both substantially L-shaped.

10. The packaging assembly according to claim 9, wherein at least a first package of the plurality of individual packages is adjoined to at least a second package of the plurality of individual packages, and the L-shape of the base and the opening of each of the first and second packages comprises a heel section and a toe section, and the first package is configured relative to the second package such that at least a portion of the toe section of the first package is adjacent to at least a portion of the toe section of the second package.

11. The packaging assembly according to claim 9, wherein each of the plurality of individual packages comprises:

(a) a first sidewall portion opposite from a third sidewall portion and a fifth sidewall portion, wherein each of the first, third, and fifth sidewall portions has a length that is substantially parallel to the length of each other of the first, third, and fifth sidewall portions, and the length of the first sidewall portion is greater than the length of the third sidewall portion and the length of the fifth sidewall portion; and

(b) a second sidewall portion opposite from a fourth sidewall portion and a sixth sidewall portion, wherein each of the second, fourth, and sixth sidewall portions has a length that is substantially parallel to the length of each other of the second, fourth, and sixth sidewall portions, and the length of the second sidewall portion is greater than the length of the fourth sidewall portion and the length of the sixth sidewall portion; and

wherein the lengths of each of the first, third, and fifth sidewall portions is substantially perpendicular to the lengths of each of the second, fourth, and sixth sidewall portions.

12. The packaging assembly according to claim 9, wherein the plurality of individual packages comprises:

(a) at least a first set of adjoined packages defined by a first package adjoined to a second package by a first hinged connection; and

(b) at least a second set of adjoined packages defined by a third package adjoined to a fourth package by a second hinged connection;

wherein the first set of adjoined packages is configured such that the first package is rotated relative to the second package about the first hinged connection such that at least a portion of the base of the first package is adjacent to at least a portion of the sidewall of the second package;

wherein the second set of adjoined packages is configured such that the third package is rotated relative to the fourth package about the second hinged connection such that at least a portion of the base of the third package is adjacent to at least a portion of the sidewall of the fourth package; and

wherein the first set of adjoined packages is configured relative to the second set of adjoined packages such that:

(x) at least a portion of the base of the first package is adjacent to at least a portion of the base of the third package;

(y) at least a portion of the sidewall of the first package is adjacent to at least a portion of the base of the fourth package; and

(z) at least a portion of the base of the second package is adjacent to at least a portion of the sidewall of the third package.

13. The packaging assembly according to claim 8, wherein each of the plurality of individual packages has a base and an opening that are both substantially rectangular.

14. The packaging assembly according to claim 13, wherein each of the plurality of individual packages comprises a first corner section, a second corner section, a third corner section, and fourth corner section, respectively defined in a clockwise manner, and at least a first package of the plurality of individual packages is adjoined in an offset manner to at least a second package of the plurality of individual packages such that at least a portion of the second corner section of the first package is adjacent to at least a portion of the fourth corner section of the second package.

15. The packaging assembly according to claim 14, wherein at least a third package of the plurality of individual packages is adjoined in an offset manner to the second package such that at least a portion of the first corner section of the second package is adjacent to at least a portion of the third corner section of the third package, and at least a fourth package of the plurality of individual packages is adjoined in an offset manner to the third package such that at least a portion of the second corner section of the third package is adjacent to at least a portion of the fourth corner section of the fourth package.

16. The packaging assembly according to claim 15, wherein the first package is adjoined to the second package by a first hinged connection, the second packaging is adjoined to the third package by a second hinged connection, and the third package is adjoined to the fourth package by a third hinged connection, and wherein the first, second, third, and fourth packages are configured relative to each other such that:

(a) at least a portion of the base of the first package is adjacent to at least a portion of the base of the third package;

(b) at least a portion of the base of the second package is adjacent to at least a portion of the base of the fourth package; and

(c) at least a portion of the sidewall of the first package and at least a portion of the sidewall of the third package are adjacent to at least a portion of the sidewall of the second package and at least a portion of the sidewall of the fourth package.

17. The packaging assembly according to claim 1, wherein the packaging assembly further comprises a secondary exterior package that encases at least a portion of the plurality of individual packages.

18. The packaging assembly according to claim 17, wherein the secondary exterior package comprises a shrink-wrap package or a wrap-around package.

19. A method of packaging a product, the method comprising the steps of:

(a) providing a packaging assembly according to claim 1; and

(b) filling the product into one or more of the plurality of individual packages.

20. The method according to claim 19, wherein the method further comprises the step of manipulating one or more of the plurality of individual packages to configure the packaging assembly into a nested configuration.