Packaging system

Abstract

A packaging system includes a base box with a plurality of walls and a tray with a primary panel and a plurality of flaps extending therefrom. The primary panel includes a recess that extends at least partially into an interior space of the base box. The plurality of flaps are attached to exterior surfaces of the plurality of walls.

1 . A packaging system comprising:
 a base box having a plurality of walls defining an interior space, the plurality of walls having exterior surfaces; and   a tray attached to the base box, the tray comprising:
 a primary panel with a recess that extends at least partially into the interior space of the base box; and 
 a plurality of flaps extending from the primary panel and attached to the exterior surfaces of the plurality of walls. 
   
     
     
         2 . The packaging system of  claim 1 , wherein the tray comprises an underside, the underside having a groove formed therein between the primary panel and each of the plurality of flaps. 
     
     
         3 . The packaging system of  claim 2 , wherein each groove comprises opposing walls that are angled relative to one another. 
     
     
         4 . The packaging system of  claim 3 , wherein the opposing walls are angled relative to one another at an angle that enables the plurality of flaps to be folded to a predetermined angle relative to the primary panel. 
     
     
         5 . The packaging system of  claim 1 , wherein opposing ends of each of the plurality of flaps comprises a chamfer. 
     
     
         6 . The packaging system of  claim 5 , wherein the chamfers are angled to enable the ends of adjacent flaps to form a seam such that the adjacent flaps are oriented at a predetermined angle relative to one another. 
     
     
         7 . The packaging system of  claim 1 , wherein the tray is a monolithic component. 
     
     
         8 . The packaging system of  claim 1 , wherein the tray is formed of a moldable material. 
     
     
         9 . The packaging system of  claim 1 , wherein the each of the plurality of flaps has a dimension that is substantially equal to a dimension of the plurality of walls. 
     
     
         10 . The packaging system of  claim 9 , wherein the dimension of the flaps is a distance between a groove formed in the tray and an outer edge of the flap and the dimension of the wall is a height of the exterior surface of the wall. 
     
     
         11 . The packaging system of  claim 1 , wherein the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels. 
     
     
         12 . A packaging system comprising:
 a base box assembly, comprising:
 a base box having a plurality of walls defining an interior space, each of the plurality of walls has an exterior surface and an upper edge; and 
 a monolithic molded tray attached to the base box, the tray comprising:
 a primary panel comprising:
 a planar portion that rests on the upper edges of the plurality of walls of the base box; and 
 a recess that extends at least partially into the interior space of the base box; 
 
 a plurality of flaps extending from the primary panel and attached to the exterior surfaces of the plurality of walls; and 
 a plurality of folds formed between the primary panel and the plurality of flaps; and 
 
 a lid having a top panel and a plurality of wall panels that cooperate to form and interior space, the interior space of the lid being configured to receive the base box assembly at least partially therein. 
   
     
     
         13 . The packaging system of  claim 12 , wherein the tray comprises a groove formed therein between the primary panel and each of the plurality of flaps. 
     
     
         14 . The packaging system of  claim 13 , wherein the grooves facilitate forming the plurality of folds. 
     
     
         15 . The packaging system of  claim 12 , wherein the recess is configured to receive a product therein for packaging within the packaging system. 
     
     
         16 . The packaging system of  claim 12 , wherein the plurality of flaps cover an entirety or a substantial portion of the exterior surfaces of the plurality of wall panels. 
     
     
         17 . A method for forming a packaging system comprising:
 providing a base box having a plurality of walls that define an interior space and have exterior surfaces;   providing a tray having a primary panel and a plurality of flaps extending from the primary panel, the primary panel having a recess; and   attaching the tray to the base box so that the protruding portion extends at least partially into the interior space and the plurality of flaps are attached to the exterior surfaces.   
     
     
         18 . The method of  claim 17 , further comprising forming a plurality of grooves in the tray between the primary panel and the plurality of flaps. 
     
     
         19 . The method of  claim 17 , further comprising forming chamfers on opposing ends of each of the plurality of flaps. 
     
     
         20 . The method of  claim 17 , wherein providing the tray comprising forming the tray with a moldable material and a molding process.