Molded paperboard packaging and methods of making the same

Abstract

Paperboard packaging is provided that includes a paperboard tray and a tray cover. The paperboard tray includes a base configured to receive and hold one or more products therein and a planar lip that extends from and around the base to define a boundary of the paperboard tray. The tray cover is coupled to the planar lip of the paperboard tray over the products to trap the products therebetween.

1 . A paperboard package comprising:
 a formed paperboard tray comprising a one or a plurality of formed pockets or depressions having varying depths from a base surface depth level.   
     
     
         2 . The paperboard package of  claim 1 , wherein at least one formed pocket or depression included in the plurality of formed pockets or depressions is wholly contained within another formed pocket or depression. 
     
     
         3 . The paperboard package of  claim 1 , further comprising at least one cut-out opening or window disposed in one or a plurality of the formed pockets or depressions. 
     
     
         4 . The paperboard package of  claim 1 , comprising a first pocket of a first depth and a second pocket of a second depth, wherein the second pocket is within the first pocket. 
     
     
         5 . The paperboard package of  claim 1 , wherein deeper pockets or depressions included in the plurality of formed pockets or depressions are disposed within shallower pockets. 
     
     
         6 . The paperboard package of  claim 1 , further comprising a panel adapted to fit on or be adhered to a top portion of the formed paperboard tray thereby forming packaging in which products may be contained and stored within the plurality of formed pockets or depressions. 
     
     
         7 . The paperboard package of  claim 1 , wherein the formed paperboard tray is formed from a paperboard blank having one or more creases configured to aid in forming the paperboard blank into the formed paperboard tray when pressed in a press. 
     
     
         8 . A formed paperboard tray product comprising:
 a paperboard tray including a paperboard base that defines a first pocket having a first depth measured from a surface of an unformed part of the paperboard base to a bottom surface of the first pocket, and a second pocket having a second depth measured from the surface of the unformed part of the paperboard base to a bottom surface of the second pocket, wherein the first and second depths are different.   
     
     
         9 . The formed paperboard tray product of  claim 8 , further comprising at least one window disposed within at least one of the first or second pockets. 
     
     
         10 . The formed paperboard tray product of  claim 8 , wherein the second pocket is partially disposed within the first pocket. 
     
     
         11 . The formed paperboard tray of  claim 10 , wherein the paperboard base defines a third pocket having a third depth measured from the surface of the unformed part of the paperboard base to a bottom surface of the third pocket, and wherein the first and second depths are different from the third depth. 
     
     
         12 . The formed paperboard tray product of  claim 11 , wherein the third pocket is partially or completely disposed within the second pocket. 
     
     
         13 . The formed paperboard tray product of  claim 8 , further comprising a panel adapted to fit on or be adhered to the unformed part of the paperboard base of the paperboard tray thereby forming packaging in which products may be contained and stored within the pockets or depressions. 
     
     
         14 . The formed paperboard tray product of  claim 13 , wherein the panel comprises paperboard. 
     
     
         15 . The formed paperboard tray product of  claim 14 , wherein the panel comprises a plurality of pockets of varying depths. 
     
     
         16 . The formed paperboard tray product of  claim 8 , wherein the paperboard tray is formed from a paperboard blank having one or more creases configured to aid in forming the paperboard blank into the paperboard tray when pressed in a press. 
     
     
         17 . A method of assembling a package with one or more products therein, the method comprising:
 providing a paperboard blank with predetermined dimensions based on the one or more products to be packaged,   applying one or more creases to the paperboard blank at predetermined locations to aid in forming a formed paperboard tray from the paperboard blank,   arranging the paperboard blank with the one or more creases applied thereto in a press,   pressing the paperboard blank in the press at least once while applying heat to the paperboard blank to provide the formed paperboard tray including a base that defines a plurality of pockets or depressions and a planar lip that extends from and around the base to define a boundary of the formed paperboard tray,   arranging the one or more products in the plurality of pockets or depressions of the formed paperboard tray,   providing a tray cover with predetermined dimensions based on the formed paperboard tray, and   coupling the tray cover to the tray lip of the formed paperboard tray after arranging the one or more products in the plurality of pockets or depressions to trap the one or more products therebetween.   
     
     
         18 . The method of  claim 17 , wherein pressing the paperboard blank in the press includes multiple pressing steps while applying heat to the paperboard blank to provide the formed paperboard tray. 
     
     
         19 . The method of  claim 17 , further comprising applying a printed label to the paperboard blank. 
     
     
         20 . The method of  claim 17 , further comprising cutting out one or more windows from the paperboard blank.