U.S. patent application number 12/796263 was filed with the patent office on 2011-02-03 for bottle shipping system.
This patent application is currently assigned to Fibercel Packaging, LLC. Invention is credited to James W. Gilfert.
Application Number | 20110024318 12/796263 |
Document ID | / |
Family ID | 43525990 |
Filed Date | 2011-02-03 |
United States Patent
Application |
20110024318 |
Kind Code |
A1 |
Gilfert; James W. |
February 3, 2011 |
BOTTLE SHIPPING SYSTEM
Abstract
Disclosed are systems and methods for an improved bottle
packaging system and shipping container, and more particularly to a
container wherein a plurality of inserts are employed to stabilize
the bottle(s) and to provide impact resistant cushioning during
shipment of liquids and the like. For a 4-bottle (quad) pack
embodiment the improved insert design includes a folding bottle
separator or insert to receive and secure a bottle bottom, along
with a top insert to receive and restrain a bottle shoulder and
neck region (bottle top). The inserts, in combination with a
two-layer cardboard box may be used to provide a re-usable and
recyclable shipping container or package for chemicals and the
like.
Inventors: |
Gilfert; James W.; (Eldred,
PA) |
Correspondence
Address: |
BASCH & NICKERSON LLP
1777 PENFIELD ROAD
PENFIELD
NY
14526
US
|
Assignee: |
Fibercel Packaging, LLC
Portville
NY
|
Family ID: |
43525990 |
Appl. No.: |
12/796263 |
Filed: |
June 8, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61230656 |
Jul 31, 2009 |
|
|
|
Current U.S.
Class: |
206/433 ;
206/590; 53/458 |
Current CPC
Class: |
B65D 5/503 20130101;
B65D 2565/385 20130101; B65D 81/133 20130101; Y02W 30/807 20150501;
Y02W 30/80 20150501; B65B 61/22 20130101; B65B 61/207 20130101;
B65D 5/5028 20130101; B65B 21/02 20130101 |
Class at
Publication: |
206/433 ;
206/590; 53/458 |
International
Class: |
B65D 85/30 20060101
B65D085/30; B65D 77/26 20060101 B65D077/26; B65B 5/02 20060101
B65B005/02 |
Claims
1. A bottle packaging system, comprising: a carton having paper
board panels defining a space, the panels meeting to define a
plurality of interior corners; and at least one folding insert,
said folding insert including a bottom surface receiving a bottom
of the bottle and supporting the bottle in a spaced-apart and
padded relationship with respect to the bottom, sides and interior
corners of the carton, a plurality of ribbed sides receiving and
contacting the outer diameter of the sides of the bottle and
supporting the bottle in a spaced-apart and padded relationship
with at least the sides of the carton, and a top insert for
maintaining the position of the bottle neck and cap in relation to
the carton.
2. The packaging system according to claim 1, wherein said carton
is of a generally rectangular cross section.
3. The packaging system of claim 2, wherein said carton holds
multiple bottles therein and where the plurality of ribbed sides
support the bottles in a spaced-apart and padded relationship with
one another.
4. The packaging system according to claim 1 wherein said folding
and top inserts are made of a recyclable material selected from the
group consisting of: cellulose, paper pulp, sugar cane, palm waste,
and expanded starches.
5. The packaging system according to claim 1 wherein said inserts
are made from re-cycled fibrous material consisting of recycled
paper products.
6. The packaging system according to claim 1, wherein said folding
inserts each define at least a portion of a cell for receiving a
bottle, said cell comprising a plurality of ribbed walls providing
a spacing between the adjacent carton walls and other bottles in
the carton.
7. The packaging system according to claim 1, wherein said folding
inserts include a base portion for contact with and support for the
bottom of a bottle placed therein.
8. The packaging system according to claim 7, wherein said folding
inserts further include a plurality of reinforced tabs on the face
of at least two sections folded into alignment with one another,
said tabs providing reinforcement to the base to protect the
bottle.
9. The packaging system according to claim 7, wherein said folding
inserts further include a plurality of reinforced portions on a
rear surface of at least one of the sections, said reinforced
portions aligning with similar structure on an adjacent insert in
said carton to prevent contact between bottle sides.
10. A folding packaging insert to protect fragile cylindrical items
in a carton, comprising: a bottom surface receiving a bottom of the
bottle and supporting the bottle in a spaced-apart and padded
relationship with the bottom, sides and interior corners of the
carton, and a plurality of ribbed sides receiving and contacting
the outer diameter of the sides of a bottle and supporting the
bottle in a spaced-apart and padded relationship with the sides,
other bottles (if present) and interior corners of the carton.
11. The A folding packaging insert according to claim 10, wherein
said folding inserts each define at least a portion of a cell for
receiving a bottle, said cell comprising a plurality of ribbed
walls providing a spacing between the adjacent carton walls and
other bottles in the carton.
12. A method for packaging a plurality of bottles, comprising:
folding and positioning at least two folding inserts, having at
least one bottle-receiving cell therein, within a carton; inserting
the bottles into the carton such that the bottoms and sides thereof
are in contact with the folding inserts and at least a portion of
the bottle necks extend above the inserts; placing a top insert
within the top of the carton, fitting over the necks of the
bottles, to secure the bottles in the carton.
13. The method according to claim 12 wherein each of said folding
inserts are of a common design.
14. The method according to claim 12, further including producing
each of said inserts using a slurry molding process.
15. The method according to claim 14, wherein said folding and top
inserts are produced using a fibrous material deposited on a
mold.
16. The method according to claim 12, wherein said folding and top
inserts are produced using a fibrous material.
Description
[0001] Priority is claimed from U.S. Provisional Patent Application
61/230,656 for a "BOTTLE SHIPPING SYSTEM" filed Jul. 31, 2009 by
James W. Gilfert, and cross-reference is made to co-pending Design
Patent Applications 29/341,240 for a "BOTTLE SHIPPING TOP CAP
INSERT," filed Jul. 31, 2009 and 29/341,241 for a "BOTTLE SHIPPING
FOLDING BOTTLE SEPARATOR," filed Jul. 31, 2009 by James Gilfert,
all of which are also hereby incorporated by reference in their
entirety.
[0002] The disclosed packaging system is directed to an improved
bottle shipping container, and more particularly to a container
wherein a plurality of inserts are employed to stabilize the
bottle(s) and to provide impact resistant cushioning during
shipment of liquids and the like. For a 4-bottle (quad) pack
embodiment the improved insert design includes a folding bottle
separator to receive and secure the bottle bottoms and sides, along
with a top insert to receive and restrain a bottle cap and neck
region (bottle top) of each bottle. The inserts, in combination
with a two-layer cardboard box may be used for shipping bottled
chemicals and the like.
BACKGROUND AND SUMMARY
[0003] Glass bottles and similar containers are used for shipment
of liquid products that may, for one reason or another, not be
storable or shippable in plastic containers (e.g., made from
polystyrene, polypropylene or polyvinyl chloride). For example,
chemical products that must retain a high level of purity are
shipped in glass bottles because of the adverse reactions with
plastic containers. However, glass bottles are fragile and prone to
shattering on impact with surfaces or one another. Therefore, it is
necessary to cushion glass bottles containing chemical products to
prevent breakage during shipping and storage. This is necessary,
not only to protect the product itself, but also because these
products are frequently solvents or other chemicals that present an
environmental hazard if leaked or spilled.
[0004] Disposing of packaging material is an additional burden on
those who receive bottles and who are already burdened with
disposing of not only chemical waste but also of the bottles and
packaging materials themselves. Any arrangement that can reduce the
disposal burden on an end user of chemical products shipped and
stored in bottles is of substantial importance. Moreover, it is
desirable that such packaging materials be recyclable and made from
recycled, or at a minimum, biodegradable materials.
[0005] Currently, it is generally known to package bottles of
chemicals in expanded foam polystyrene (EPS) packing material,
which is placed around the bottles within a corrugated paper board
container. A drawback of using EPS is that solvents in or on the
bottles can dissolve the EPS, thus reducing or eliminating its
cushioning purpose. Moreover, once the package is opened there are
two discreet material groups which must be disposed of--the
corrugated paper board as well as the expanded polystyrene.
Polystyrene foam also has environmental impacts itself, both
because the gases that it releases as it decomposes and because of
its exaggerated physical presence resulting from its rigid expanded
cell structure that consumes a great deal of volume in landfills.
Restricting the use of foamed polystyrene packaging is a priority
of many solid waste and environmental organizations as well as
governments. For example, a number of US cities have banned
polystyrene food packaging.
[0006] In view of these considerations, there is a continuing need
for an economical replacement of polystyrene with a packing system
that eliminates the dual waste streams, and that uses a
biodegradable packing material for which there are established,
environment-friendly waste management processes in place. One such
solution is a packaging system and method described in pending U.S.
patent application Ser. No. 12/025,419 (US 2008/0302691 A1) for a
"BOTTLE SHIPPING SYSTEM WITH MULTIPURPOSE INSERT," by James
Gilfert.
[0007] In light of the above-noted problems, the packaging system
disclosed herein provides an improved package with one or more
molded, foldable inserts using a common design, in conjunction with
a top insert fitting over and retaining the tops of bottles (bottle
necks and caps) in the package. More specifically, the system
provides both impact protection and cushioning for the bottle(s),
and also assures the ease of use and re-use of such a system by
employing a common insert design for cushioning the bottoms and
sides of the bottle(s) therein. Furthermore the inserts are
preferably manufactured from molded paper or pulp materials that
may include recycled content and are similarly recyclable or
biodegradable.
[0008] Disclosed herein is a bottle packaging system, comprising: a
carton having paper board panels defining a space, the panels
meeting to define a plurality of interior corners; and at least one
folding insert, said folding insert including a bottom surface
receiving a bottom of the bottle and supporting the bottle in a
spaced-apart and padded relationship with the bottom, sides and
interior corners of the carton, a plurality of ribbed sides
receiving and contacting the outer diameter of the sides of a
bottle and supporting the bottle in a spaced-apart and padded
relationship with the sides, other bottles (if present) and
interior corners of the carton, and a top insert for maintaining
the position of the bottle neck and cap in relation to the carton
and other bottles (if present).
[0009] Further disclosed in embodiments herein is a folding
packaging insert to protect bottles (or other fragile cylindrical
items) in a shipping container or package, comprising: a bottom
surface receiving a bottom of the bottle and supporting the bottle
in a spaced-apart and padded relationship with the bottom, sides
and interior corners of the carton, and a plurality of ribbed sides
receiving and contacting the outer diameter of the sides of a
bottle and supporting the bottle in a spaced-apart and padded
relationship with the sides, other bottles (if present) and
interior corners of the carton.
[0010] Also disclosed herein is a method for packaging a plurality
of bottles, comprising: folding and positioning at least two
folding inserts, having at least one bottle-receiving cell therein,
within a carton; inserting the bottles into the carton such that
the bottoms and sides thereof are in contact with the folding
inserts and at least a portion of the bottle necks extend above the
inserts; placing a top insert within the carton fitting over the
necks of the bottles and securing a top surface of the carton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective assembly view of a folding bottle
separator having been folded and being placed into a shipping
package;
[0012] FIG. 2 is a perspective view of an interior region of the
shipping package of FIG. 1 having a plurality of folding bottle
separators therein into which bottles are being inserted;
[0013] FIG. 3 is a perspective view of the top, front and right
sides of a folding bottle separator;
[0014] FIG. 4 is a front elevation view of the folding bottle
separator;
[0015] FIG. 5 is a right side elevation view of the folding bottle
separator;
[0016] FIG. 6 is a rear elevation view of the folding bottle
separator;
[0017] FIG. 7 is a left side elevation view of the folding bottle
separator;
[0018] FIG. 8 is a top plan view of the folding bottle
separator;
[0019] FIG. 9 is a bottom plan view of the folding bottle
separator;
[0020] FIG. 10 is a perspective view of a top cap insert for
assembly with a bottle shipping package;
[0021] FIG. 11 is a perspective view of the top, front and right
sides of a top cap insert shown in a typical use configuration;
[0022] FIG. 12 is a front elevation view of the top cap insert;
[0023] FIG. 13 is a right side elevation view of the top cap
insert;
[0024] FIG. 14 is a rear elevation view of the top cap insert;
[0025] FIG. 15 is a left side elevation view of the top cap
insert;
[0026] FIG. 16 is a top plan view of the top cap insert;
[0027] FIG. 17 is a bottom plan view of the top cap insert;
[0028] FIG. 18 is a cutaway view of the package of FIG. 10
incorporating the top cap insert; and
[0029] FIGS. 19 and 20 are, respectively, illustrative
representations of a formed screen employed to mold the folded
insert and top cap insert.
[0030] The various embodiments described herein are not intended to
limit the invention to those embodiments described. On the
contrary, the intent is to cover all alternatives, modifications,
and equivalents as may be included within the spirit and scope of
the appended claims.
DETAILED DESCRIPTION
[0031] As more particularly set forth below, the disclosed system
and methods are for assembling an improved bottle shipping
container, specifically a container wherein a folding insert(s) or
separator(s) is employed, in conjunction with a top cap insert to
stabilize the bottle(s) and to provide padding during shipment and
handling. As used herein the term bottle is intended to cover both
a conventional glass bottle having a base, sides, shoulder, neck
and re-sealable top, as well as other types of containers used for
the storage and shipment of liquids and the like. The various
embodiments described herein disclose several configurations for
the shipping containers, and it is further contemplated that the
shipping systems may also be used to ship containers other than
traditional bottles. Accordingly, the use of the term bottles is
not intended to limit the disclosure or claims to conventional
bottles or bottle designs. The improved insert designs and
associated packaging system permits stabilization of the necked
bottle(s) used for shipping chemicals and the like. Although
generally described relative to a 4-bottle (quad) pack, it will be
appreciated that the disclosed inserts may be employed in packaging
for any number of bottles (e.g., a single, double, triple, quad and
six-pack configuration). Moreover, various sizes and types of
bottles may be packaged using the disclosed insert, or
modifications thereof.
[0032] FIG. 1 is a perspective assembly view of a folding bottle
separator having been folded and being placed into a shipping
package, and FIG. 2 is a perspective view of an interior cutaway
region of the shipping package or container of FIG. 2 having a
plurality of folding bottle separators therein into which bottles
are being inserted. Referring to FIGS. 1 and 2, an insert component
of a 4-pack packaging embodiment is illustrated from a top
perspective view. The 4-pack folding inserts 100 are folded and
placed within a carton 130 or similar enclosed space and each
generally define two cells 110 into which bottles 200 are placed.
Thus, two inserts 100 used concurrently provide a total of four
cells in the embodiment depicted (e.g. FIG. 2). Each cell comprises
a generally square region (other shapes are possible) defined by a
ribbed wall 112 on at least two sides--wherein the folding inserts
each define at least a portion of a cell for receiving a bottle.
The ribs in walls 112 provide spacing between the adjacent carton
walls and/or other bottles. The bottom of the cell, at the base of
wall 112, includes a support surface 114 extending over at least
one-half the bottom of the bottle to cushion and support the bottom
of the bottle relative to the bottom of the shipping box or
container 130.
[0033] The bottle packaging system, as depicted in FIGS. 1 and 2,
may include a carton 130 having paper board panels (e.g., top,
bottom, sides) defining a space, the panels meeting to define a
plurality of interior corners as with conventional shipping boxes.
The system further includes at least one folding insert 100, said
folding insert including a bottom surface 114 receiving a bottom of
the bottle and supporting the bottle in a spaced-apart and padded
relationship with the bottom, sides and interior corners of the
carton, and a plurality of ribbed sides 112 receiving and
contacting the outer diameter of the sides of a bottle and
supporting the bottle in a spaced-apart and padded relationship
with the sides, other bottles (if present) and interior corners of
the carton.
[0034] Referring also to FIGS. 3-9, depicted therein are further
details of the inserts 100. The folding inserts 100 of the
packaging system may further include a plurality of reinforced tabs
144 on the face of at least the two folding sections to provide
further reinforcement to the base to protect the bottle should the
package be dropped. And, another feature of the folding inserts is
a surface on the exterior (see corresponding interior recess 480 in
FIGS. 3-4; reinforced portions 484 in FIG. 6) wherein the
reinforced portions on a rear surface of at least one of the
sections 414, aligns with a similar structure on an adjacent insert
to prevent contact in the center of the package between bottle
sides, should the package be dropped.
[0035] Referring to FIG. 10, the partial assembly view illustrates
the packaging of a plurality of bottles in a double-walled
cardboard box as depicted in FIGS. 1 and 2, but where a top cap
insert 150 is employed to receive the tops/caps and necks of one or
more bottles therein. Referring also to FIGS. 11-18, top cap insert
150 includes a plurality of recesses 154 into which the top of each
bottle is received, along with corresponding, concentric shoulders
156, which serve to contact the top or cap of the bottle and to
stabilize it during shipping and or in the event the carton or box
is dropped. An additional concentric, downward-protruding, shoulder
160 is further included for each aperture, and is employed to make
contact with the "trigger" or finger-loop 162 of each bottle, and
to further limit the movement of the bottle once the top cap insert
is applied and the carton is closed and sealed. Various other
ridges 170, ribs 172 and similar structures are employed in the top
cap insert in order to provide the insert with rigidity and permit
reinforcement and to prevent collapse or complete failure of the
insert in the event the carton is dropped during shipment. FIG. 18,
for example, is cut-away bottom view with the top cap insert 150
installed on the top of the packaging system.
[0036] The packaging system described herein may further include
the top cap insert 150 for maintaining the position of the bottle
neck and cap in relation to the carton 130 and other bottles (if
present). As an alternative, the present disclosure contemplates
the separate use of either the folding inserts 100 or the top cap
insert 150 as separate pieces employed with various alternatives to
the depicted packaging systems.
[0037] Referring next to FIG. 3, depicted therein is an as-molded
or unfolded insert 100, where the three sections 410, 412 and 414
are each depicted. In use, section 414 is folded along line 420, by
about 180-degrees (arrow 422) so that the face of section 414 is
abutting section 412 and they form a 4-sided compartment or cell as
described above. Similarly, cell 410 is slightly folded (approx.
45-degrees; arrow 424) relative to cell 412 (along line 430), so as
to fit within a carton or container as depicted in FIGS. 1 and 2,
for example. It will be further appreciated that the size and
arrangement of the ribs along sidewalls 112 of insert 100 may be
modified or adjusted to accommodate different bottle sizes and
carton configurations, as well as to provide for additional
cushioning and support for the bottles. And, it is also possible to
control the density or amount of material deposited on the molds
(see below) to further control the firmness or energy absorbing
characteristics of both of the inserts disclosed.
[0038] Referring also to FIGS. 4-9, these drawings illustrate the
relative sizes and proportions of the various rib structured, tabs,
recesses, etc. of the folded separator. As indicated in the figures
it is contemplated that two such separators would be used to
separate or divide a corrugated box or similar container into four
cells or areas into which bottles may be inserted (see e.g., FIGS.
1 and 2). As noted above, in one embodiment, the folding separator
may be employed with a top cap insert 150 in order to provide a
complete packaging system for shipment of bottles. And, while
depicted as a quad or 4-bottle embodiment, it will be appreciated
that various of the design features of the inserts may be employed
for other bottle/package configurations.
[0039] As illustrated in FIGS. 1, 2, 10 and 18, the packaging
system employs a carton 130 of a generally rectangular cross
section having a top, bottom and sides, wherein the top and bottom
may be formed of several flaps that are aligned or overlap for
taping or sealing. Alternative shapes and sizes would be
contemplated based upon the size of the bottles or other items
being shipped. In order to assure the recyclability of the
packaging, in one embodiment, the folded (100) and top (150)
inserts are made of a recyclable material selected from the group
consisting of: cellulose, paper pulp, sugar cane, palm waste, and
expanded starches. The packaging system inserts may be made from
re-cycled fibrous material consisting of recycled paper
products.
[0040] As has been described herein, one aspect of the system is a
folding packaging insert 100 to protect bottles (or other fragile
cylindrical items) in a shipping container or package, where the
folding insert 100 includes a bottom surface 114 receiving a bottom
of a bottle and supporting the bottle in a spaced-apart and padded
relationship with the bottom, sides and interior corners of the
carton into which the insert is placed. The insert also includes a
plurality (at least two in each cell) of ribbed sides for receiving
and contacting the outer diameter of the sides of a bottle and
supporting the bottle in a spaced-apart and padded relationship
with the sides, other bottles (if present) and interior corners of
the carton.
[0041] Depicted in FIGS. 12-17 are various alternative views of the
top cap 150 insert as described above. Again, it will be
appreciated that the dimensions, orientation and sizes of the
insert and respective recesses/shoulders may be adjusted in
accordance with the configuration and design of the bottles or
other elements being retained by the insert. It will be further
appreciated that the design of the insert is intended for
production in a fiber molding operation and accordingly includes
drafts and angled portions to permit easy molding and removal of
the insert from a mold.
[0042] The following figures are provided for further illustration
of the various aspects and features of the two inserts. In
particular, FIG. 11 provides a perspective view of the top, front
and right sides of a top cap insert 150 shown in a typical
configuration; FIG. 12 is a front elevation view of the top cap
insert; FIG. 13 is a right side elevation view of the top cap
insert; FIG. 14 is a rear elevation view of the top cap insert;
FIG. 15 is a left side elevation view of the top cap insert; FIG.
16 is a top plan view of the top cap insert. FIG. 17 is a bottom
plan view of the top cap insert and it will be noted that the
various features are illustrated in dashed lines as an indication
of the variable nature of such features when the top cap is
produced as a molded fiber insert where only one side is
molded.
[0043] Similarly, FIG. 3 is a perspective view of the top, front
and right sides of the folding bottle separator 100; FIG. 4 is a
front elevation view of the folding bottle separator; FIG. 5 is a
right side elevation view of the folding bottle separator; FIG. 6
is a rear elevation view of the folding bottle separator; FIG. 7 is
a left side elevation view of the folding bottle separator; FIG. 8
is a top plan view of the folding bottle separator; FIG. 9 is a
bottom plan view of the folding bottle separator, again with the
dashed lines representing portions on the side opposite the molding
surface.
[0044] Having described the general aspects and features of the two
inserts and associated packaging, attention is turned to FIGS. 19
and 20, which illustrate, respectively, representations of a formed
screen mold employed in molding the folded insert and top cap
insert. In one embodiment, a method for packaging a plurality of
bottles, includes folding and positioning at least two folding
inserts, having at least one bottle-receiving cell therein, within
a carton; inserting the bottles into the carton such that the
bottoms and sides thereof are in contact with the folding inserts
and at least a portion of the bottle necks extend above the
inserts; placing a top insert within the carton fitting over the
necks of the bottles; and securing a top surface of the carton.
[0045] As will be appreciated from an examination of FIGS. 19 and
20, the inserts may be produced using a fibrous material in a
slurry molding process. FIG. 19 depicts the mold 1910 for insert
100 whereas FIG. 20 illustrates a two-piece mold 2010 for insert
150. It will be appreciated that various mold configurations
similar to those depicted may be employed, and that certain mold
elements may need to be altered or customized in accordance with
the method of manufacture and the materials employed. In one
embodiment the inserts 100 and 150 may be made by FIBERCEL
PACKAGING, LLC using the molds depicted, and a fiber material. The
fiber material may be made from recycled cellulose or other fibrous
or pulp materials mixed with water or other carrier and deposited
on the surface of the mold (fiber is attracted to screen-like mold
surface by selectively pumping water from the reverse side of the
mold).
[0046] In one embodiment, the fiber may include at least 50% Kraft
paper material and less than 50% newsprint, and more particularly,
about 60% Kraft paper and about 40% newsprint. It is however,
possible to use varying compositions, even compositions that are at
or about 100% Kraft paper material, or at or about 100% newsprint,
as well as compositions that utilize alternative types of
pulp/fiber materials as noted herein. One source of such materials
may be recycled paper products such as cardboard, newsprint,
etc.
[0047] One process involves creating a vacuum formed plastic mold
(e.g., 1910, 2010) representative of the insert shape depicted in
the embodiments described above. This mold or "tooling" is mounted
on a plate, which is subsequently mounted in pans of pulp molding
machines. These machines include a tank that is continuously
supplied with slurry of corrugated Kraft and newsprint pulp. The
pans are attached to a rotating wheel and as the wheel revolves,
the pans are submerged in the pulp tank. The molds are connected to
a vacuum, which draws the pulp solids onto the mold surface and
removes water. At the end of a rotation of the wheel, the
individual pan reaches the unload station where an air blast blows
the semi-solid pulp insert off of the mold and onto a negative
fixture for support. The insert is then transferred directly to a
belt for drying, possibly using a large, zoned drying oven (e.g.
gas-fired), which removes most of the remaining moisture from the
molded material. At the end of the oven, the inserts may be packed
for shipment.
[0048] As briefly mentioned above various alternative materials may
also be used, including various pulps, cellulose, sugar cane waste,
palm waste, expanded starches, and foams (EPS). Preferably the
materials employed in making the insert are recycled and/or
recyclable. It is also contemplated that various handling tools and
techniques may be employed to assist in the removal of the molded
fiber inserts prior to and/or during a drying process (e.g. before
stiffness and dryness of the insert achieves a desired level).
[0049] The packaging system employing the disclosed inserts not
only provides for inexpensive packaging, it further provides a
solution that is resistant to bottle breakage or damage. The
disclosed packaging comprising inserts 100 and 150, bottles 200 and
container 130, meet the requirements for packaging as tested in
accordance with one or more standardized tests (e.g., ASTM D5276,
ASTM D4577, ASTM D999 and ISO 535). Furthermore, use of the common
design for the folding inserts in the disclosed packaging system,
permits the efficient use, reuse and re-packaging of such
materials--thereby reducing the cost of handling and shipping
liquids in various bottle configurations. Molded pulp packaging, in
accordance with one embodiment of the insert, protects the product
and can safely cushion even the most delicate contents such as a
bottle(s). A lightweight and cost-effective alternative to most
conventional types of packaging, the product is made from 100%
recycled materials and is 100% biodegradable.
[0050] Although described herein relative to a fiber-based insert,
the disclosed system may indeed be suitable for use with
alternative packaging materials, including biodegradable or other
plastics, starch compounds, etc. Another possible manufacturing
process may involve a vacuum-formed plastic having insert shape
depicted in the embodiments. It will be appreciated that other
techniques such as blow-molding and the like may also be used to
manufacture the inserts. It should be further appreciated that
various alternative materials may also be used, including various
pulps, cellulose, sugar cane waste, palm waste, expanded starches,
and foams (EPS). The materials employed in making the insert are
preferably recycled, recyclable, or in the alternative
biodegradable.
[0051] It will be appreciated that variations of the
above-disclosed embodiments and other features and functions, or
alternatives thereof, may be desirably combined into many other
different systems or applications. Also, various presently
unforeseen or unanticipated alternatives, modifications, variations
or improvements therein may be subsequently made by those skilled
in the art which are also intended to be encompassed by the
following claims.
* * * * *