PACKAGING SYSTEM

Abstract

A packaging system and a sub unit are provided.

Description

FIELD OF THE INVENTION

The present invention relates to a packaging system and a sub unit for packaging using the packaging system.

BACKGROUND OF THE INVENTION

Disclosure of the State of the Art

Many types of products are simultaneously packaged for many reasons, such as technical requirements relating to safety, hygiene and portions, while also for aesthetics and convenience. At the same time, it is important to make sure the packages are compact and sturdy, particularly for transport.

Many packages today satisfy only a few of these aspects. For instance, many packages are cylindrical, leaving too much space between packages when they are stacked together. Tapered structures are also known, such as sections of pyramids or cones, typically having a frustum. Also, the shape of these packages contributes to the problem of unusable space.

SUMMARY OF THE INVENTION

The packaging system according to the present invention comprises a plurality of sub units, each having a structure that tapers towards a narrow end from a first opposing surface at an end opposite the narrow end, wherein the sub units are configured to be positioned without any space between so that the first opposing surfaces form an outside of the packaging system.

The present invention also comprises a sub unit for assembling into a package unit according to the above packaging system, wherein the sub unit is formed with a body having sidewalls that taper towards a narrow end from a first opposing or outer surface of the sub unit at an end opposite the narrow end.

One typical package unit of the present invention can comprise six sub units arranged with each of their narrow ends towards the center of the assembled package unit, and their respective opposing surfaces towards the outer surface of the assembled package unit. This package unit of the inventive packaging system thus constitutes a rectangular parallelepiped, preferably a cube. Although such a cube of six sub units constitutes a feasible package, any number of sub units may be used to assemble a package unit in the system of the present invention.

A number of cubes may further be assembled to constitute a collection of cubes.

A problem to be solved by the present invention is to utilize the dead volume of space found between individual packages in conventional packaging systems of today.

Another problem to be solved by the present invention is inherent support of fragile walls of sub units. The walls of a conventional sub unit may be fragile. The claimed design of the sub units overcomes this problem and enables a substantial part of their walls to mutually support each other against outside forces when assembled in a cube, and further when stacking multiples of cubes on top of or next to each other.

When stacking together systems of rectangular parallelepipeds, e.g., cubes, into a collection of parallelepipeds, e.g., collection of cubes, the outer boundaries of the collection may be positioned adjacent the inner walls of a housing.

Therefore, a main object of the present invention is to provide a packaging system and a packaging collection that is compact and sturdy.

An object is achieved according to the present invention by a packaging system comprising a plurality of sub units, each sub unit having a structure tapering toward a narrow end from a first opposing surface at an end opposite the narrow end, and the sub units are configured to be positioned so that the first opposing surfaces form an outside of an assembled package unit of the inventive packaging system. The sub units for packaging using the inventive packaging system each have a first opposing surface that can be positioned against an inner wall of a housing and complementing the inside of the housing.

A number of non-exhaustive embodiments, variants or alternatives of the invention are defined by the appended claims.

The present invention attains the above-described objective with sub units having a structure that tapers towards a narrow end from a first opposing surface at an end opposite the narrow end, so that a plurality of sub units can be assembled into a package unit.

The technical differences over prior art is that stacking is not by layers of sub units, but by forming package units by positioning sub units so that the narrow end points towards the center of the assembled package unit.

The present invention provides in turn several further advantageous effects:

• • it makes it possible to form ready package units comprising sub units for use where different contents are required; and
  • it makes it possible to form cubic package units that can be more easily stacked and unloaded than individual sub units.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example only, with reference to the following diagrams, wherein:

FIG. 1 shows an individual package of a packaging system according to prior art;

FIG. 2A shows a sub unit of the present invention;

FIG. 2B shows another embodiment of the sub unit;

FIG. 2C shows a further embodiment of the sub unit having a frustum;

FIG. 2D shows an embodiment of the sub unit with a lid;

FIG. 2E shows another embodiment of the sub unit with the lid closed;

FIG. 3A shows a preassembled collection of sub units;

FIG. 3B shows another preassembled collection of sub units;

FIG. 3C shows a preassembled collection of sub units having a frustum;

FIG. 3D shows a further preassembled collection of sub units;

FIG. 4A shows a partially assembled package unit from a collection of sub units with one sub unit removed;

FIG. 4B shows a partially assembled package unit from a collection of sub units with one sub unit removed, and wherein the frusta of the sub units form an inner volume;

FIG. 5 shows a partially assembled package unit having four sub units on each side;

FIG. 6 shows a reversed assembly;

FIG. 7A shows a preassembled collection of sub units, each having a frustum as in FIG. 3C, about to be assembled into a package unit;

FIG. 7B shows how a vertical force applied to a package unit assembled as a cube with six sub units, each having a frustum, gets transferred to horizontal forces on the sub units;

FIG. 7C shows a collection of assembled package units of six cubes arranged to be put inside a housing; and

FIG. 7D shows the collection of assembled package units of six cubes arranged inside the housing.

DESCRIPTION OF THE REFERENCE SIGNS

The following reference numbers and signs refer to the drawings:

10      Packaging system according to prior art
100     Packaging system
110     Inner volume
11, 112 Lost volume or dead space
200     Sub unit
12, 212 Lid
204     Outer surface
20, 300 Body
34, 304 Sidewalls
36, 306 Partition wall
37, 307 End point
38, 308 Frustum, bottom face
40, 310 Enclosed volume
42, 312 Primary volume
44, 314 Secondary volume
46, 316 Primary content
48, 318 Secondary content
50      Housing

DETAILED DESCRIPTION

FIG. 1 shows a conventional package 10 according to the prior art, with a detachably attached lid 12 that, when attached to a body having sidewalls 34 and a bottom 38, forms a volume for holding contents 42. In some cases, it is preferred to have separated contents, such as yoghurt and muesli, in one such package. In such cases, the body of the package is also provided with a partition wall 36 that divides the enclosed volume 40 into two parts 42, 44.

When trying to place these shaped packages into a cubic array, a considerable amount of lost volume or dead space 11 is present between the units. Also, these packages are not suited to turn on a side, as the shape does not lend itself to this.

Central to the present invention is the adaption of sub units (end-user packages) that fit together to form an assembled package unit of a package system having little wasted space 112. Sub units 200 are formed with a structure or body 300 having sidewalls 304 that taper towards a narrow end 307, 308 from a first opposing or outer surface 204 at an end opposite the narrow end. The sub units are assembled with the narrow ends facing the center of the assembled package unit. When assembled, the first opposing surfaces of the sub units form the outer surface of the package unit of the packaging system.

In a preferred embodiment, the sub units 200 are shaped like pyramids having a square lid 212 and a body 300, wherein the body has sidewalls 304 that taper towards an end opposite the lid 212. The end can be a point 307 like the peak of a pyramid, or a frustum 308. The sidewalls 303 taper at an angle of about 45 degrees inwards. This means that four sub units can be placed together forming a periphery and two more perpendicular to these, thus forming an assembled package unit in the packaging system 100.

This assembled package unit of the packaging system is a cube where the lids 212 form the outer surface. This has the advantage of providing a convenient surface for product or contents identification, no matter from which side the cube is viewed. Moreover, the cube itself has very little dead space 112 inside. Also, cubes are well known to be stackable, having little dead space between each cube.

The sub units can be formed in many ways.

FIG. 2A shows the sub unit in the form of a pyramid having an endpoint 307. The body 300 forms an enclosed volume 310 sealed to hold in contents with a detachable lid 212 as the base of the pyramid.

FIG. 2B shows the sub unit in the form of a pyramid having a partition wall 306. The body 300 forms an enclosed volume 310 divided into a primary volume 312 and a secondary volume 314, both sealed to hold in the contents with a detachable lid 212 (shown in FIGS. 2D and 2E). Preferably, the lid seals in both volumes so that, when detaching the lid, both volumes are uncovered. More preferably, the lid is directionally openable in order to uncover one volume at a time.

FIG. 2C shows the sub unit in the form of a pyramid having a frustum 308. The body 300 forms an enclosed volume 310 sealed to hold in the contents with a detachable lid 212 (shown in FIGS. 2D and 2E). The frustum provides a convenient foot for placing the sub unit on a flat surface such as a table. For liquid contents, it is also easier to recover more of the contents from a sub unit having a frustum, and more so if the transition between the sidewalls and the frustum is curved.

The sub units then will have to be assembled into a package unit of the packaging system. Some of these are pre-assemblies wherein the sub units are provided attached edge to edge in the same direction. When such pre-assembled sub units are laid out, all the bodies are facing up, ready to be filled with contents and then closed with lids. The edge attachments can be cut to split one pre-assembly into several smaller pre-assemblies. In a more preferred embodiment, the joints are bendably flexible, elastically and/or plastically, so that a pre-assembly of sub units can be formed into an assembled package unit while minimizing cuts.

FIG. 3A shows each sub unit detached and freely selected to be assembled together into a package unit. This provides full freedom in selecting different sub systems, lids and/or contents into one assembled package of the packaging system. The selection can be made at the very end of the process just before assembling the package unit. Such single sub units can be obtained by cutting off individual sub units from a roll of many sub units.

FIG. 3B shows sub units provided on strips or rolls of many sub systems joined together. Preferably, the joints or attachments are detachable. On assembling the package unit, four sub units are cut from the strip to form a ring, and two detached sub units are placed perpendicular to these. As an alternative, two strips of three sub units each are placed facing and perpendicularly together and slotted in together to form a different package unit of the inventive packaging system.

FIG. 3C shows all sub units being provided as a pre-assembled collection, wherein all sub units required to form an assembled package unit are attached together. In a preferred embodiment for a cubic package unit, the pre-assembled collection comprises a strip of four sub units with further two sub units, wherein these are located on opposite sides of the longitudinal axis of the strip.

FIG. 4A shows a partially assembled package unit from a collection of sub units, illustrating how dead space is minimized.

FIG. 4B shows a partially assembled package unit from a collection of sub units, wherein the frusta form an inner volume 110. This inner volume has many applications.

The inner volume can be used to contain a cooling element in order to maintain a low temperature, for instance for perishable goods. In one example, ice or dry ice can be inserted. The cooling medium is typically a fluid, such as water or CO₂ gas, such that it will flow along the inner surfaces of the sub units, keeping them cool.

Dry ice is particularly beneficial, as the fluid is less affected by gravity and cools also the upper part of the assembled package unit well. On the other hand, dry ice has a sublimation point of −78.5° C. which, for some goods, may require some thermal insulation between the dry ice and the sub units to avoid excessive freezing.

When using ice or other cooling media that forms a liquid, it is beneficial to make the package system substantially water tight. If the packaging system is formed from a pre-assembled collection, the joints forming edges will easily be made water tight. Remaining edges can be made water tight using a sealant or by wrapping an outer layer around the assembled package unit. This wrapping can beneficially form the lids, or labels on the lids, on the individual sub units.

Alternatively, the inner volume as shown in FIG. 4B can be used for a heating element.

It is also beneficial to make at least one sub unit easily movable to uncover the inner volume in order to allow refilling of the cooling or heating medium at the point of purchase.

The inner volume offers a position that is protected by the surrounding sub units and is therefore suitable for fragile objects.

When heating sub units on opposite sides, certain ones of the sub units can be detached, leaving a tunnel like structure through which a fluid such as water or steam can be directed. Condensation is very efficient in transferring heat to all exposed surfaces. A plurality of such tunnels can be stacked for more efficient heating of assembled package units.

For the case of the pyramidal sub unit shown in FIG. 2A, a frame can conveniently be used for placing the sub unit on a table in order to provide further stability.

While a cubic shape for the packaging system is preferred, it is clear that deviations from this are easily achieved. For instance, the packaging system can easily be made squat or tall using rectangular sides wherein the sides are rectangles and the top and bottom faces are squares. Alternatively, all faces can be rectangular non-squares.

Higher order Platonic solid geometries also can be used, such as dodecahedrons. Also, other isogonal geometries can be used, even with different lids, such as a truncated icosahedron having pentagonal and hexagonal lids.

While a single sub unit per face is disclosed above, there are also alternatives possible. FIG. 5 shows a plurality of sub units forming a single face.

Sub units can be filled with contents before sealing with a lid and assembling into a package unit. Alternatively, it is possible to start with a pre-formed or pre-assembled package unit and inject the contents through an opening and into the body. Preferably, the pre-formed package unit comprises soft sidewalls of the sub units that are flat against the lid prior to filling. The side walls can be flexible or elastic, and thus increase the volume of the body to accommodate the content. The opening can be provided on the lid or in a part of the side wall.

During the filling process, an inner volume can be chosen simply by inserting a suitable object inside the assembled package unit. The sidewalls will expand to enclose the object and secure it.

The inventive packaging system also can be used for packaging fragile objects in the inner volume, and the enclosed volumes of the sub units can be filled with a fluid such as a shock absorbing fluid.

In this configuration, much of the air between the sub units can be pressed out.

While the sidewalls could be vulnerable to mechanical damage, such sidewalls will not be exposed to the outside. Instead, the outer surface of the packaging system will provide the protection. Alternatively, the sidewalls can be cured, or a more robust material can be applied to the outside of the sidewalls to improve mechanical strength.

In many applications, it is preferred to provide sub units with foil lids or other mechanism for easy removal and thus access to the contents. Such foils can be fragile and easily punctured. In these cases, it is possible to locate the foil lid on an inner surface of an assembled package unit and use a more robust outer surface. This outer surface could optionally be made of the same material as the side walls.

A packaging system 100 can be made where the substantial part of the outer surface, e.g., the substantial part of sidewalls 304 and the lid 212 of each sub unit 200, mutually supports at least one, preferably at least two, most preferably at least four other sub units 200. FIG. 7B shows how a vertical force on one upper sub unit 200, indicated by a vertical open arrow, gets transferred to the remaining five sub units of an assembled package unit, a cube of six sub units 200, indicated by solid arrows. If a plurality of such cubes of sub units 200 is arranged inside a housing 50, such as shown in FIGS. 7C and 7D, forces generated from, e.g., the weight of sub units 200 that are stacked and applied from above, are ultimately distributed to the walls of this housing. This mutual support, resulting in the sub units 200 being capable of withstanding considerable forces, is a fact if a substantial part of the total outer surface of the sub unit 200 is mutually supported. A substantial part of the total outer surface of the sub unit 200 is preferably intended to be more than 50%, and more preferably more than 90%. As is generally understandable, practical details in the design of edges and corners of the sub unit 200 will, in many cases, result in the fringes of the walls not getting 100% support from mutual sub units 200. This is of little consequence, as a substantial part of the surface of each sub unit is supported, and so considerable forces can be withstood.

When stacking together rectangular parallelepipeds, e.g. cubes, into a collection of parallelepipeds, e.g. collection of cubes, the outer boundaries of the collection may be positioned adjacent the inner walls of a housing.

The example housing 50 of FIGS. 7C and 7D may contain any number of rectangular parallelepipeds, e.g., cubes, in all three orthogonal axis.

The housing can be made of any material having tensile strength resisting stretching. The material may be, e.g., cardboard or plastic film.

FIG. 6 shows a reversed assembly, which is the assembly of sub units with end points pointing outwardly rather than inwardly. This can be assembled directly from strips as disclosed above, or by reversing the folding of a packaging system disclosed above. By assembling from strips, preferably long and continuous strips, pre-assembled package units can be made very compact, and then assembled on demand and on site. Likewise, such package units can be disassembled for reuse and transported in a very compact manner without the problems associated with conventional packages, e.g., expanded polystyrene.

The technical effect of this is that volume now is maximized rather than minimized, as is the case for non-reversed packaging systems.

In one application, the packaging system 100 contains, e.g., a meal. When this meal is consumed, the remaining waste, often occupying more volume than the meal itself, may be collected inside the packaging system 100, taking advantage of the fact that the reversed packaging system encloses a larger volume.

Another application of the reversed assembly can be for lighting devices such as lamps. This device can be transported as a packaging system, preferably with the more shock sensitive parts such as bulbs in the inner volume. On unpacking the sub units, the sub units can be reversed to form the lamp shading.

Another application can be for extra packaging protection, known as an alternative to “packaging chips” or “foam peanuts” made of expanded polystyrene.

In the case of pre-assemblies, such as the sub units as strips shown in FIG. 3B, or as a more complete assembled package unit shown in FIG. 3C, the sub units can be attached in many ways, such as by their bodies using the same material as in the bodies, preferably using living joints. This allows for production of continuous strips of sub units. Sub units can then easily be filled with contents and sealed in place with lids before the sub units are cut to length and assembled into a packaging system.

Sub units also can be attached to each other using the lid, typically a foil. This allows for mix and match of various types of sub units, filling sub units with contents and then sealing the contents and simultaneously connecting sub units using these lids. In a variation, the sealing and connecting stages are separate, allowing freedom in the ordering of sealing and connecting processes.

By using a separate material for the sub units and the connecting parts between the sub units, transforming strips shown in FIG. 3B into more complete pre-assemblies as shown in FIG. 3C is facilitated. Hybrid solutions with any combinations of separate sub units and pre-assembled sub units, and attachments using lids or separate connecting stages in the inventive packaging system, is also possible.

The invention according to the application finds use in compact and robust packaging, transport and unpacking of goods.

Claims

1. A packaging system comprising at least one packaging unit, the at least one packaging unit including a plurality of sub units having a tapered structure towards a narrow end from a first opposing surface at an end opposite the narrow end, wherein the sub units are configured to be positioned so that the first opposing surfaces form an outside of the at least one packaging unit.

2. The packaging system according to claim 1, further comprising at least two packaging units, the first opposing surface of the sub units being positioned against an inner wall of a housing, resulting in complementing the inside of the housing.

3. The packaging system according to claim 1, wherein at least one sub unit is formed with a tapered body having sidewalls towards a narrow end from a first opposing or outer surface at an end opposite the narrow end.

4. The packaging system according to claim 3, wherein the narrow end is a frustum.

5. The packaging system according to claim 3, wherein the body comprises at least one partition wall, dividing a volume within the body into a plurality of volumes.

6. The packaging system according to claim 3, wherein the sidewalls taper inwards inwardly at 45 degrees.

7. The packaging system according to claim 3, wherein the first opposing or outer surface is provided with a lid.

8. The packaging system according to claim 3, wherein at least one of the sidewalls is provided with a lid.

9. The packaging system according to claim 2, wherein at least one of said sub units is formed with a tapered body having sidewalls towards a narrow end from a first opposing or outer surface at an end opposite the narrow end.

10. The packaging system according to claim 9, wherein the narrow end is a frustum.

11. The packaging system according to claim 4, wherein the body comprises at least one partition wall, dividing a volume within the body into a plurality of volumes.

12. The packaging system according to claim 9, wherein the body comprises at least one partition wall, dividing a volume within the body into a plurality of volumes.

13. The packaging system according to claim 10, wherein the body comprises at least one partition wall, dividing a volume within the body into a plurality of volumes.

14. The packaging system according to claim 9, wherein the sidewalls taper inwardly at 45 degrees.

15. The packaging system according to claim 9, wherein the first or opposing outer surface is provided with a lid.

16. The packaging system according to claim 9, wherein at least one of the sidewalls is provided with a lid.

17. A packaging system comprising a plurality of packaging units, the packaging units including a plurality of sub units having a tapered body having sidewalls towards a narrow end from a first opposing or outer surface at an end opposite the narrow end; the sub units being configured to be positioned so that the first opposing surfaces form an outside of the packaging units;the first opposing surface of the sub units being positioned against an inner wall of a housing, resulting in complementing an inside of the housing; andthe body including at least one partition wall, dividing a volume within the body into a plurality of volumes.

18. The packaging system according to claim 17, wherein the narrow end is a frustum.

19. The packaging system according to claim 18, wherein the sidewalls taper inwardly at 45 degrees.

20. The packaging system according to claim 19, wherein each sidewall is provided with a lid.