U.S. patent application number 16/675270 was filed with the patent office on 2021-05-06 for bottle shipping packaging.
This patent application is currently assigned to Western Pulp Products Company. The applicant listed for this patent is Western Pulp Products Company. Invention is credited to Richard B. Hurley, Thomas J. Taylor.
Application Number | 20210130059 16/675270 |
Document ID | / |
Family ID | 1000004484005 |
Filed Date | 2021-05-06 |
United States Patent
Application |
20210130059 |
Kind Code |
A1 |
Hurley; Richard B. ; et
al. |
May 6, 2021 |
BOTTLE SHIPPING PACKAGING
Abstract
Packaging systems for shipping bottles of varying sizes are
disclosed. In embodiments, the packaging system includes a top
packaging piece and bottom packaging piece, each formed as a molded
piece. The top packaging piece includes a plurality of tapered
cavities, each sized to receive the neck of one of the bottles. The
bottom packaging piece includes a corresponding plurality of
tapered cavities, each sized to receive the bottom of one of the
bottles. The center packaging piece is formed from a single sheet
of flat material such as cardboard, and is folded in upon itself to
form a spacer between the top and bottom packaging pieces. The
center packaging piece includes a plurality of apertures
corresponding to the cavities in the top and bottom packaging
pieces to pass through each bottle from the top to bottom packaging
pieces.
Inventors: |
Hurley; Richard B.;
(Corvallis, OR) ; Taylor; Thomas J.; (Corvallis,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Western Pulp Products Company |
Corvallis |
OR |
US |
|
|
Assignee: |
Western Pulp Products
Company
Corvallis
OR
|
Family ID: |
1000004484005 |
Appl. No.: |
16/675270 |
Filed: |
November 6, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 71/46 20130101;
B65D 81/022 20130101; B65D 71/70 20130101; B65D 71/403
20130101 |
International
Class: |
B65D 71/40 20060101
B65D071/40; B65D 71/70 20060101 B65D071/70; B65D 71/46 20060101
B65D071/46; B65D 81/02 20060101 B65D081/02 |
Claims
1. A packaging system for a plurality of bottles, comprising: a top
packaging piece comprised of a plurality of cavities and a
plurality of shock absorbing features; a bottom packaging piece
comprised of a plurality of cavities and a plurality of shock
absorbing features; and a center packaging piece comprising a
plurality of apertures, disposed between the top packaging piece
and the bottom packaging piece, wherein: each cavity in the top
packaging piece is tapered and sized to receive the neck of one of
the plurality of bottles, each cavity in the bottom packaging piece
is tapered and sized to receive the bottom of the one of the
plurality of bottles, each aperture in the center packaging piece
is sized to receive the one of the plurality of bottles, and the
center packaging piece is formed from a flat sheet of material that
is folded in upon itself.
2. The packaging system of claim 1, wherein each of the plurality
of bottles is a wine bottle.
3. The packaging system of claim 1, wherein the top packaging piece
and bottom packaging piece are each formed from molded paper
fiber.
4. The packaging system of claim 3, wherein the center packaging
piece is formed from cardboard.
5. The packaging system of claim 4, wherein at least one aperture
of the center packaging piece is comprised of a top hole and a
bottom hole, the bottom hole having a larger diameter than the top
hole.
6. The packaging system of claim 4, wherein each aperture of the
center packaging piece has a plurality of protrusions directed
radially inward from a rim of the aperture.
7. The packaging system of claim 4, wherein the center packaging
piece is formed by folding the cardboard upon itself in a plurality
of ninety-degree bends, to form a plurality of vertical
sidewalls.
8. The packaging system of claim 7, wherein of each of the
plurality of vertical sidewalls is of a common height selected to
result in an overall height of the packaging system approximately
equal with an inner height of a box to enclose the packaging
system.
9. The packaging system of claim 7, wherein the vertical sidewalls
define a first plane having the plurality of apertures, and a
plurality of second planes disposed distally from the first plane,
each of the second planes having a subset of the plurality of
apertures.
10. The packaging system of claim 9, wherein the first plane is
disposed upon the top packaging piece when the packaging system is
assembled.
11. The packaging system of claim 9, wherein the first plane is
disposed upon the bottom packaging piece when the packaging system
is assembled.
12. A packaging piece, comprising a substantially flat sheet,
wherein: the flat sheet defines a first region, a second region, a
third region, and a fourth region; the first region defines a first
plurality of apertures; the third region defines a second plurality
of apertures that correspond to at least a subset of the first
plurality of apertures; and wherein, when a portion of the fourth
region is secured to the first region, the second and fourth
regions define sidewalls that are bounded by the first and third
regions.
13. The packaging piece of claim 12, wherein: the substantially
flat sheet comprises corrugated cardboard, the corrugated cardboard
comprises a plurality of ribs that define a strength axis, and the
strength axis is oriented to run along the second and fourth
regions between the first and third regions.
14. The packaging piece of claim 13, wherein each of the first,
second, third, and fourth regions are defined by a score line that
runs across the strength axis.
15. The packaging piece of claim 12, wherein the first plurality of
apertures are smaller in diameter than the second plurality of
apertures.
16. The packaging piece of claim 12, wherein the first plurality of
apertures are larger in diameter than the second plurality of
apertures.
17. The packaging piece of claim 12, wherein each of the first
plurality of apertures is defined by a rim, and each of the first
plurality of apertures further comprises a plurality of protrusions
disposed on the rim and projecting radially inward into the
aperture.
18. The packaging piece of claim 12, wherein: the first region
further comprises a plurality of slots; the fourth region comprises
an edge with a plurality of protrusions, and wherein each of the
plurality of protrusions is sized and disposed to fit within a
corresponding one of the plurality of slots, and wherein the
portion of the fourth region is secured to the first region by
insertion of each of the plurality of protrusions into its
corresponding one of the plurality of slots.
Description
TECHNICAL FIELD
[0001] Disclosed embodiments are generally related to packaging for
shipping purposes. Specifically, packaging systems for shipping
glass bottles, e.g., bottles of varying sizes for wine or another
type of beverage, are disclosed.
BACKGROUND
[0002] Shipping goods, regardless of whether the method of
transport is via U.S. Mail, FedEx, UPS, a private or local courier,
or even personally transporting purchased goods, presents a high
likelihood that the goods will be subject to impact and/or shock,
despite reasonable care being taken during transport. Depending on
the severity of the impact or shock and the nature of the goods,
damage may result. For example, goods at least partially made from
glass may fracture or shatter if subjected to a sufficiently severe
impact, resulting in loss of product. Other damage, such as denting
the capsule (the hood on top of the bottle neck that covers the
cork or stopper, found on most wine bottles) or scuffing of the
bottle label, while cosmetic in nature may render the product
difficult to sell, and so is also undesirable. To guard against
damage in the likely event of a shock, shock-absorbent packaging
materials are typically employed to protect the goods and reduce or
minimize any impact or shock.
[0003] The background description provided herein is for the
purpose of generally presenting the context of the disclosure.
Unless otherwise indicated herein, the materials described in this
section are not prior art to the claims in this application and are
not admitted to be prior art by inclusion in this section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Embodiments will be readily understood by the following
detailed description in conjunction with the accompanying drawings.
To facilitate this description, like reference numerals designate
like structural elements. Embodiments are illustrated by way of
example, and not by way of limitation, in the figures of the
accompanying drawings.
[0005] FIG. 1 depicts an exploded view of an example packaging
system, illustrating its components, according to various
embodiments.
[0006] FIG. 2A depicts a perspective view of the example packaging
system depicted in FIG. 1, according to various embodiments.
[0007] FIG. 2B depicts an end elevation view of the example
packaging system depicted in FIG. 1, according to various
embodiments.
[0008] FIG. 3 depicts various views of a first example top
packaging piece that may be used with the example packaging
depicted in FIG. 1, according to various embodiments.
[0009] FIG. 4 depicts various views of an example bottom packaging
piece that may be used with the example packaging depicted in FIG.
1, according to various embodiments.
[0010] FIG. 5 depicts various views of a first example center
packaging piece in a folded configuration that may be used with the
example packaging depicted in FIG. 1, according to various
embodiments.
[0011] FIG. 6 depicts a top elevation view of the center packaging
piece depicted in FIG. 5 in an unfolded configuration, according to
various embodiments.
[0012] FIG. 7 depicts various views of a second example center
packaging piece that may be used with the example packaging
depicted in FIG. 1, according to various embodiments.
[0013] FIG. 8 depicts various views of a third example center
packaging piece that may be used with the example packaging
depicted in FIG. 1, according to various embodiments.
[0014] FIG. 9 depicts various views of a fourth example center
packaging piece that may be used with the example packaging
depicted in FIG. 1, according to various embodiments.
[0015] FIG. 10 depicts various views of a fifth example center
packaging piece that may be used with the example packaging
depicted in FIG. 1, according to various embodiments.
[0016] FIG. 11 depicts various views of a second example top
packaging piece that may be used with the example packaging
depicted in FIG. 1, according to various embodiments.
DETAILED DESCRIPTION
[0017] In the following detailed description, reference is made to
the accompanying drawings which form a part hereof wherein like
numerals designate like parts throughout, and in which is shown by
way of illustration embodiments that may be practiced. It is to be
understood that other embodiments may be utilized and structural or
logical changes may be made without departing from the scope of the
present disclosure. Therefore, the following detailed description
is not to be taken in a limiting sense, and the scope of
embodiments is defined by the appended claims and their
equivalents.
[0018] Aspects of the disclosure are disclosed in the accompanying
description. Alternate embodiments of the present disclosure and
their equivalents may be devised without parting from the spirit or
scope of the present disclosure. It should be noted that like
elements disclosed below are indicated by like reference numbers in
the drawings.
[0019] Various operations may be described as multiple discrete
actions or operations in turn, in a manner that is most helpful in
understanding the claimed subject matter. However, the order of
description should not be construed as to imply that these
operations are necessarily order dependent. In particular, these
operations may not be performed in the order of presentation.
Operations described may be performed in a different order than the
described embodiment. Various additional operations may be
performed and/or described operations may be omitted in additional
embodiments.
[0020] For the purposes of the present disclosure, the phrase "A
and/or B" means (A), (B), or (A and B). For the purposes of the
present disclosure, the phrase "A, B, and/or C" means (A), (B),
(C), (A and B), (A and C), (B and C), or (A, B and C).
[0021] The description may use the phrases "in an embodiment," or
"in embodiments," which may each refer to one or more of the same
or different embodiments. Furthermore, the terms "comprising,"
"including," "having," and the like, as used with respect to
embodiments of the present disclosure, are synonymous.
[0022] Bottles are typically damaged in transport when subjected to
an impact or handled roughly. If a bottle is allowed too much
freedom of movement in an enclosing container and/or the enclosing
container allows force from an impact or shock to be transmitted to
the enclosed bottles, damage may occur. The damage may result from
the impact force causing direct damage to the bottle. Alternatively
or additionally, the bottle may be damaged from coming into contact
with adjacent bottles also enclosed in the package, which may
result from an impact or from rough handling that allows the bottle
to build up sufficient momentum, particularly where the packaging
does not sufficiently constrain the bottle's range of movement. For
effective protection of a glass bottle, then, the packaging holds
the bottle within a constrained area, not allowing the bottle to
move enough to impact other bottles. The packaging can also be
configured to absorb the force of impacts, such as with structures
that are designed to sacrificially deform and absorb at least
enough impact energy to prevent bottle damage.
[0023] Glass bottles for containing liquids come in a variety of
sizes and configurations. For example, the shape of a wine bottle
of a typical size, e.g. 750 ml, will often vary, reflective of the
region from which the wine originates, the type of wine, trade
dress considerations of a wine maker, and/or other considerations.
Where multiple units of a single bottle type are to be shipped,
packaging can be designed to specifically fit the shape of the
chosen bottle type. In contrast, where multiple units of differing
bottle types are to be shipped in a single container, the packaging
must be designed to accommodate the various possible bottle designs
that may be placed within the packaging, and still hold each bottle
securely, without excessive movement.
[0024] Simultaneously accommodating a plurality of bottles of
potentially varying lengths and profiles may be accomplished by
using multiple packaging pieces. In one possible implementation,
the packaging may include a piece configured to surround the bottom
of each bottle, and a piece configured to surround the top of each
bottle. The bottom and top of each bottle is respectively inserted
into each piece. For a given bottle size, e.g. 750 ml, a wider
diameter bottle will typically have a shorter length. By
configuring the bottom, top or both pieces with tapered portions
that narrow or constrict moving away from the bottle, bottles of
varying diameters can be snugly supported by the packaging. A wider
diameter bottle, being shorter, will sit higher in the bottom piece
due to the taper, while a narrower but taller bottle will sit
lower. As a result bottles of varying sizes and/or configurations
(albeit typically of approximately equal volume) may be inserted
and supported by the packaging, and sit at a height that still
prevents excessive movement.
[0025] In addition to top and bottom packaging pieces, a center
packaging piece or space may be fitted around and between the
bottles, between the top and bottom packaging pieces, which can
provide support. Without a center packaging piece, the top and
bottom packaging pieces may not be in contact, but instead be
spaced apart by the inserted bottles. In such a configuration, a
load placed on either the top or bottom piece parallel to the
longitudinal axis of each bottle will cause the load to compress,
shift, or possibly collapse the packaging. Consequently, the load
could be transferred to one or more of the bottles, further
imposing stress on each bottle that could lead to damage or
breakage. The center packaging piece, contacting the top and bottom
pieces, can instead act to transfer load between the top and bottom
pieces, substantially relieving any load from the bottles, and in
some embodiments, absorb at least some of the load. Moreover, a
center packaging piece can allow the packaging to still be employed
with only one or a few bottles, where the packaging may have empty
bottle slots that would otherwise negate the packaging
effectiveness without a center packaging piece. Still further, the
center packaging piece can aid in restricting bottle movement to
prevent bottle to bottle contact, particularly where the top and/or
bottom packaging pieces would otherwise permit excessive
movement.
[0026] In addition to the top and bottom packaging pieces,
packaging for containing and shipping bottles typically will
include at least a box sized to snugly or closely fit the packaging
pieces and bottles contained therein. The boxes can be stored
unfolded in a substantially flat configuration, allowing many boxes
to be stored in a relatively small amount of space. The top and
bottom packaging pieces are typically reminiscent of a large egg
carton, with multiple rows of cups to accept either the top and
neck, or bottom of each bottle, respectively. In contrast to the
boxes, which are typically die-cut cardboard, the various packaging
pieces are typically formed by molding materials into
three-dimensional structures with a substantial height. The height
of these pieces thus consumes considerably more space than the
boxes, which can be packed flat. In some configurations, the top
and bottom pieces may be able to nest together, saving some space,
although even nested a given number of top and bottom packaging
pieces will typically consume more space than the same number of
boxes. If a molded center packaging piece is also included,
additional space is consumed. In some such implementations, the
center packaging piece, due to its configuration to fit between and
around the bottles, may not be suitable for nesting within the top
and bottom pieces. Where the center piece cannot be nested,
substantial additional space may be consumed by the packaging.
[0027] For a given warehouse, it is generally preferable to
maximize the amount of space devoted to product to be sold, and
minimize the amount of space required by packaging. Furthermore, as
warehouses typically are located some distance from where the
packaging is produced, the packaging must be shipped to the
warehouse. Shipping costs are often determined by the amount of
space consumed or by full truck load (FTL), without regard to the
quantity of goods being shipped. Thus, the less space consumed by
the shipped goods, the more goods that can be shipped in a given
shipment. Reducing the size consumed by a given unit of packaging
(comprising the top, center, and bottom packaging pieces) allows
more units of packaging to be shipped in a given load, reducing the
cost of shipping for each packaging unit.
[0028] One approach to minimizing the space consumed by packaging
is to reduce the number of molded packaging pieces, such as the top
and bottom pieces, in favor of pieces that can be stored in a
flattened configuration, such as the boxes. Disclosed embodiments
include a packaging configuration that uses a folded center
packaging piece that can be stored unfolded as a single sheet, such
as a die-cut cardboard sheet. The center packaging piece can
further be quickly folded into a configuration for use.
[0029] FIGS. 1, 2A and 2B illustrate the components of an example
packaging system 100, according to various embodiments. System 100
includes a top packaging piece 102, a bottom packaging piece 104,
and a center packaging piece 106. The system 100 can contain a
plurality of bottles, such as bottles 108a, 108b (generically,
bottle 108). As seen in FIGS. 2A and 2B, the bottles 108a and 108b
are enclosed within the packaging, with the top and neck of each
bottle 108 inserting into a corresponding cavity 110 in the top
packaging piece 102, and the bottom of each bottle inserting into a
corresponding cavity 112 in the bottom packaging piece 104. Each
bottle passes through center packaging piece 106. When assembled,
the packaging system 100 forms a sandwich-like structure that
encapsulates each bottle 108, thus holding each bottle 108 securely
and restricting possible movement, minimizing the likelihood of
damage. The assembled system 100 may be inserted into a box (not
shown) that has an internal cavity sized to closely match the
exterior dimensions of the system 100.
[0030] In the depicted embodiment, packaging system 100 is
configured to accept up to twelve bottles. Other embodiments may be
configured to accept a greater or fewer number of bottles. Some
embodiments may be configured to accept a single bottle. With the
presence of center packaging piece 106, packaging system 100 need
not be completely filled with bottles to maintain its integrity in
shipping. Packaging system 100 may be shipped with anywhere from
zero to the maximum number of bottles for which packaging system
100 is configured.
[0031] FIG. 3 depicts the various structures and configurations of
an example embodiment of top packaging piece 102. View 3A depicts
the structures from a top elevation, looking down upon the top
packaging piece 102. From this view, the bottles 108 would be
beneath the top packaging piece 102. View 3B depicts the structures
from a bottom perspective view, with the underside of top packaging
piece 102 visible. From this view, bottles 108 would be upside-down
if inserted into top packaging piece 102. View 3C depicts the
structures from a side elevation view, with a section A-A depicting
the arrangement of various shock absorbing structures (described
below) that interleave with cavities 110a-110f (collectively or
generically, cavity 110).
[0032] In the example embodiment, top packaging piece 102 is
configured to accept twelve bottles 108, and so has twelve cavities
110 (including cavities 110a-110f). The cavities 110 are configured
in a three by four array, e.g. three rows, each accepting four
bottles 108, with the cavities 110 arrayed in a grid pattern. A
greater or lesser number of bottles 108 may be accommodated by
changing the dimensions, e.g. providing more or fewer rows and/or
configuring the rows to accept a greater or fewer number of bottles
108. Examples of other possible configurations will be discussed
below with respect to various embodiments of the center packaging
piece 106.
[0033] Each top packaging piece 102 includes a number of shock
absorbing structures. The shock absorbing structures may include
corner absorbers 202a, 202b, 202c, and 202d (collectively or
generically, corner absorber 202), center absorbers 204a and 204b
(collectively or generically, center absorber 204), and edge
absorbers 206a, 206b, 206c, and 206d (collectively or generically,
edge absorber 206). It will be observed that not every center
absorber 204 or edge absorber 206 is numbered in FIG. 3, although
each such structure is identical, regardless of whether numbered.
Some embodiments of top packaging piece 102 may include additional
types of shock absorbing structures, and/or may omit one or more of
the corner absorbers 202, center absorbers 204, and/or edge
absorbers 206. The selection, type, number, and layout of the
various shock absorbing structures may vary depending upon the
needs of a given implementation. An example of one possible
alternative embodiment is depicted in FIG. 11, where the corner
absorbers are configured differently, with a reduced height.
[0034] Top packaging piece 102 defines a plane, from which all
absorbers and cavities 110 extend in a common direction. As can be
seen in FIG. 1, each bottle 108 inserts through the plane of top
packaging piece 102 into a corresponding cavity 110. Top packaging
piece 102 may be molded using pulp, e.g. paper fiber, styrofoam,
plastic, or another suitable material that meets the requirements
of a given implementation, and/or may be manufactured using any
suitable technique that meets the requirements of a given
implementation. In various embodiments, materials that can deform
under stress are selected, to allow the packaging system 100 to
sacrificially deform and absorb energy from a shock or impact while
minimizing the amount of force or load imparted to bottles 108
contained within packaging system 100.
[0035] Each of the cavities 110, corner absorbers 202, center
absorbers 204, and edge absorbers 206 is substantially conical in
shape, tapering narrower as it protrudes from plane of top
packaging piece 102. In the depicted implementation, the end of
each cavity 110, most distal from the plane of top packaging piece
102, includes one or more shock absorbing features 208. When
enclosing a bottle 108, the neck of bottle 108 will protrude into
its cavity 110. Depending upon the configuration of bottle 108, a
portion of the neck may meet the sidewall of cavity 110 due to the
decreasing radius of cavity 110 and, for some types of bottle 108,
the increasing radius of the neck of bottle 108. When so inserted,
the top of bottle 108 may not come into contact with the end of
cavity 110, with the tapered sidewall serving to limit the movement
of bottle 108. The remaining space between the top of bottle 108
and the end of cavity 110 provides a shock absorbing cushion, with
the sides of cavity 110 capable of deforming, in various
embodiments, to prevent the neck of bottle 108 from receiving a
substantial impact. If the taper of cavity 110 and/or of the neck
of bottle 108 is insufficient to stop the insertion of bottle 108
prior to reaching the end of cavity 110, shock absorbing feature
208 will nevertheless provide the cushion, deforming to prevent
transfer of a substantial shock to the neck of bottle 108. In
embodiments, the diameter of each cavity 110, even if the neck of
bottle 108 does not contact the sidewall of cavity 110, is still
sized to prevent excessive movement of bottle 108, e.g. movement
that would allow a portion of bottle 108 to contact an adjacent
bottle 108.
[0036] In the depicted embodiment (see view 3A), shock absorbing
feature 208 is implemented as a series of shelves protruding into
the interior of cavity 110. Other embodiments may implement shock
absorbing feature 208 as a different structure, or may omit shock
absorbing feature 208 altogether, particularly where other shock
absorbing features (e.g. 202, 204, 206) provide sufficient
protection for the neck of bottle 108.
[0037] Top packaging piece 102 may be configured with sufficient
depth to receive a portion of the neck of each bottle 108 so as to
prevent the possibility that the neck of one bottle 108 is able to
come into contact with any portion of any adjoining bottle 108.
Such an arrangement may be accomplished in conjunction with the
configuration of the bottom packaging piece 104 and/or center
packaging piece 106.
[0038] Center absorbers 204, in the depicted embodiment, interleave
with the various cavities 110. As can be seen, center absorbers 204
are essentially frusto-conical in shape. In addition to potentially
absorbing any energy from an impact by deforming, center absorbers
204 help to transfer any load directed down upon package system
100, e.g. applied to the ends of the structures of top packaging
piece 102 in the direction of the plane of top packaging piece 102,
to the other components of packaging system 100. For example, if
the top of a box enclosing packaging system 100 is impacted, the
load would be absorbed at least partially by center absorbers 204,
which in turn may transfer at least a portion of the absorbed load
to center packaging piece 106, and further in turn to bottom
packaging piece 104, potentially to any enclosing box. This
distribution of load can help increase the amount of impact that
can be absorbed beyond what center absorbers 204 alone could
receive. The amount of load transferred (if any) may depend upon
the degree of impact severity as well as the specific configuration
of the center absorbers 204.
[0039] Corner absorbers 202 and edge absorbers 206 run around the
perimeter of top packaging piece 102, and help to at least
partially absorb any loads (by deformation), such as from a lateral
impact, that may be applied to the side or top corner of packaging
system 100. Such an impact would include an impact vector directed
at least partially orthogonally to the longitudinal axis of each
bottle 108. Corner absorbers 202 can provide rigidity and stability
to the corners of packaging system 100, absorbing at least part of
any impact applied to the corner or corner edge of packaging system
100. As with center absorbers 204, corner absorbers 202 transfer
load from top packaging piece 102 applied to the top corners of top
packaging piece 102 to the other components of packaging system
100. In the depicted embodiment, and similar to center absorbers
204, corner absorbers are roughly frusto-conical in shape, albeit
with a smaller radius.
[0040] Edge absorbers 206, in addition to providing similar energy
absorption via deformation as corner absorbers 202 and center
absorbers 204, likewise provide load transfer to the other
components of packaging system 100. Each edge absorber may include
one or more protrusions or similar features, depicted as slots that
face outward from the center of top packaging piece 102. The
protrusions can, in some embodiments, help to improve edge rigidity
and integrity of packaging system 100. Like corner absorbers 202
and center absorbers 204, in the depicted embodiment, edge
absorbers 206 are roughly frusto-conical in shape.
[0041] It can also be seen in the embodiment depicted in FIG. 3
that each of the cavities 110, corner absorbers 202, center
absorbers 204, and edge absorbers 206 all terminate distal from the
plane of top packaging piece 102 in a second plane. This second
plane allows each of the structures to fit closely or abut the
surface of any enclosing box or other container, to help minimize
any movement of packaging system 100 within the enclosing
container, and maximize rigidity of the package.
[0042] Turning to FIG. 4 a possible configuration for bottom
packaging piece 104 according to one embodiment is depicted. View
4A depicts the structures from a top elevation, looking down upon
the bottom packaging piece 104. From this view, the bottles 108
would be sitting within bottom packaging piece 104. View 4B depicts
the structures from a top perspective view, revealing some of the
side structures of bottom packaging piece 104. View 4C depicts the
structures from a side elevation view, with a section A-A depicting
the arrangement of various shock absorbing structures (described
below) that interleave with cavities 112a-112e (collectively or
generically, cavity 112).
[0043] Each bottom packaging piece 104 includes a number of shock
absorbing structures. The shock absorbing structures may include
center absorbers 402a and 402b (collectively or generically, center
absorber 402) and corner absorbers 406a, 406b, 406c, and 406d
(collectively or generically, corner absorber 406). It will be
observed that not every center absorber 402 is numbered in FIG. 4,
although each such structure is identical, regardless of whether
numbered. As with top packaging piece 102, some embodiments of
bottom packaging piece 104 may include additional types of shock
absorbing structures, and/or may omit one or more of the center
absorbers 402 and/or corner absorbers 406. The selection, type,
number, and layout of the various shock absorbing structures may
vary depending upon the needs of a given implementation, and may,
in some embodiments, be configured to correspond to the shock
absorbing structures of top packaging piece 102 and/or center
packaging piece 106, if any.
[0044] Similar to top packaging piece 102, bottom packaging piece
104 defines a plane, from which all absorbers and cavities 112
extend in a common direction. As can be seen in FIG. 1, each bottle
108 inserts through the plane of bottom packaging piece 104 into a
corresponding cavity 112. Each of the cavities 112 further
terminate distal from the plane around a second plane, which allows
the bottom of packaging system 100 to sit substantially flush with
the interior wall of any containing box or other container, helping
to minimize the movement of packaging system 100 inside the
container and aid container rigidity.
[0045] Bottom packaging piece 104 may be constructed from the same
or similar materials as top packaging piece 102, or may be
constructed from different materials, depending upon the needs of a
given implementation. As with top packaging piece 102, bottom
packaging piece 104 may be molded or formed using pulp, e.g. paper
fiber, styrofoam, plastic, or another suitable material that meets
the requirements of a given implementation, and/or may be
manufactured using any suitable technique that meets the
requirements of a given implementation. In various embodiments,
materials for bottom packaging piece 104 that can deform under
stress are selected, to allow the packaging system 100 to
sacrificially deform and absorb energy from a shock or impact while
minimizing the amount of force or load imparted to bottles 108
contained within packaging system 100.
[0046] Each cavity 112 in the depicted embodiment, similar to
cavity 110, is roughly frusto-conical in shape, tapering as it
extends away from the plane of bottom packaging piece 104. At the
bottom of each cavity 112, proximate to the second plane defined by
cavities 112 and the shock absorbers, is formed a plurality of
shock absorbing structures 410. Similar to cavity 110, the
sidewalls of each cavity 112 are tapered, narrowing in radius
distally from the plane of bottom packaging piece 104. This
tapering can be seen on section 404, forming a concave edge on each
center absorber 402, and on internal sidewall portion 408, formed
into the outer perimeter of bottom packaging piece 104. It is best
seen in cross-section A-A of view 4C. Where the base of bottle 108
is larger than the diameter of each cavity 112, the taper of the
sidewalls will act to limit the distance that bottle 108 can insert
into cavity 112. As a result, the neck of such a bottle 108 may
protrude further into its corresponding cavity 110 of the top
packaging piece 102, depending upon the configuration of the bottle
108. This increased protrusion may help further to limit the
movement of bottle 108. As with the neck of each bottle 108 into
cavity 110, space between the bottom of cavity 112 and bottle 108
provides a measure of shock protection, as the sidewalls of each
cavity 112 can deform in response an impact. Where the base of
bottle 108 is small enough to allow bottle 108 to reach the bottom
of cavity 112, shock absorbing structures 410 can deform to absorb
at least some of any impact, thus at least reducing the load
transferred to bottle 108.
[0047] In the depicted embodiment, center absorbers 402, in
contrast to center absorbers 204 of top packaging piece 102, are
essentially formed as the interleaving structures that result from
formation of the cavities 112. Center absorbers 402 thus form and
define a platform coincident with the plane of bottom packaging
piece 104, upon which a portion of center packaging piece 106 can
sit. In this configuration, the center absorbers 402 can receive at
least a portion of any load or impact imparted upon top packaging
piece 102 that is transferred via center packaging piece 106, thus
allowing packaging system 100 to be rigid and stackable. Further,
as center absorbers 402 may be constructed to be deformable, the
transfer of impact or load can be at least partially absorbed by
center absorbers 402. As mentioned above, center absorbers 402
include four concave tapered sections 404 that effectively form the
edges of each center absorber 402, as well as a portion of the
tapered sides of each cavity 112.
[0048] Corner absorbers 406, in depicted embodiment and similar to
corner absorbers 202 of top packaging piece 102, are formed to the
corners of bottom packaging piece 104, and are disposed upon
adjacent cavities 112 (e.g. cavities 112a and 112c). As can be seen
with corner absorbers 406a and 406b in view 4B, each corner
absorber in the depicted embodiment opens into its adjacent cavity
112. Corner absorbers help add rigidity to bottom packaging piece
104, and further enhance protection for bottles 108 placed into
cavities 112 proximate to the edges of packaging system 100 from
edge- and corner-directed impacts.
[0049] In FIG. 5, an embodiment of a center packaging piece 106 in
an assembled configuration is depicted. View 5A depicts the center
packaging piece 106 from a top elevation. From this view, the
bottles 108 would be passing through the various apertures of
center packaging piece 106. View 5B depicts the center packaging
piece 106 from a top perspective view, revealing the openings that
comprise each aperture. View 5C depicts the center packaging piece
106 from a side elevation view, showing how center packaging piece
is constructed in a cross-section. View 5D depicts the center
packaging piece 106 from a side elevation view 90 degrees from view
5C.
[0050] Center packaging piece 106 includes apertures that
correspond in number and layout to cavities 110 on top packaging
piece 102 and cavities 112 on bottom packaging piece 104. The
center of bottles 108 placed within packaging system 100 thus are
passed through center packaging piece 106, as depicted in FIGS. 1,
2A, and 2B. Center packaging piece 106, as discussed above, acts to
pass loads between top packaging piece 102 and bottom packaging
piece 104, and so is constructed with sufficient rigidity to work
in cooperation with the other packaging pieces to provide at least
a desired level of protection for bottles 108 contained within
packaging system 100. In some embodiments, center packaging piece
106 may be configured to deform or otherwise absorb some or all of
a received load, such as from an impact, in addition or alternative
to transferring some portion of the load to top packaging piece 102
and/or bottom packaging piece 104.
[0051] In some embodiments, center packaging piece 106 is
constructed from cardboard, such as corrugated cardboard,
fiberboard, or a similar sheet-like material. Other materials may
be used depending upon the needs of a given embodiment. The
material may be selected with regard to its ability to transfer
and/or absorb impacts imparted to either the top packaging piece
102 or bottom packaging piece 104. Center packaging piece 106 may
be formed from a sheet material via stamping, die cutting, laser
cutting, embossing, and/or any other suitable manufacturing
technique.
[0052] Each aperture in center packaging piece 106 is formed from a
top opening 502a, 502b, 502c, and 502d, that aligns with a
corresponding bottom opening 504a, 504b, 504c, and 504d,
respectively (collectively or generically, top opening 502 and
bottom opening 504). The top openings 502 and/or bottom openings
504 may be sized to constrain movement of each inserted bottle 108,
to prevent it from coming into contact with adjacent bottles 108.
In the embodiments depicted in FIGS. 5, 6, 9, and 10, the top
openings 502 and bottom openings 504 are each approximately the
same size. The size is typically selected to accommodate the widest
diameter bottle that is intended to be used with packaging system
100. However, the sizes of the top openings 502 may be of a
different size from the bottom openings 504, as will be discussed
below with respect to FIGS. 7 and 8. Moreover, the openings need
not be circular; other shapes may be employed in some embodiments
for one or both of the top openings 502 and bottom openings 504, as
will be discussed below with respect to FIG. 8.
[0053] As will be discussed further below, center packaging piece
106 is formed by folding the unassembled sheet in upon itself with
a series of approximately ninety degree bends, which aligns each
top opening 502 with its bottom opening 504 to form the aperture.
This further results in the formation of a plurality of vertical
walls 508 (four, in the depicted embodiment). Center packaging
piece 106 is retained upon itself by insertion of tabs (described
below) into a plurality of corresponding slots 506a and 506b. As
with top packaging piece 102 and bottom packaging piece 104, not
all top and bottom openings or slots are numbered. The height of
all vertical walls 508 in the disclosed embodiment are equal.
[0054] The height of the vertical walls 508 may be selected to
achieve a target height for packaging system 100 when assembled
with top packaging piece 102 and bottom packaging piece 104
surrounding center packaging piece 106. As will be understood by a
person skilled in the art, the desired target height may depend
upon the height of the bottles 108 to be inserted into packaging
system 100. Moreover, the overall height of packaging system 100,
and thus the height of bottles 108 to be inserted into packaging
system 100, may be adjusted for a given combination of top
packaging piece 102 and bottom packaging piece 104 by selection of
different center packaging pieces 106 that have different heights
of vertical walls 508. Thus, packaging system 100 may be used with
bottles 108 of a wide variety of different heights by swapping
between different center packaging pieces 106 with vertical walls
508 of an appropriate height.
[0055] As mentioned above, center packaging piece 106 may be
constructed from cardboard. This cardboard may be of a multi-ply
corrugated configuration, where a rippled sheet of paper is glued
and sandwiched between a top and bottom sheet of paper. This
configuration can be seen in detailed view from view 5D, which
shows a cross-section of a corrugated cardboard wall. As seen, the
center rippled sheet of paper essentially forms a plurality of ribs
510 that run in one direction. As will be understood by a person
skilled in the relevant art, such an arrangement creates a strength
axis that runs along the longitudinal axis of each of the ribs.
Thus, the corrugated cardboard resists bending across the
ribs/strength axis, but will more readily bend parallel to the
strength axis/ribs. With respect to the center packaging piece 106,
in the embodiment depicted in FIG. 5, the strength axis 512 is
oriented to run perpendicular to the folds made to assemble the
center packaging piece 106. Thus, the strength axis runs vertically
on each of the plurality of vertical walls 508. In this
orientation, each of the vertical walls 508 is strengthened against
bending, and so is better able to transmit loads between the top
packaging piece 102 and the bottom packaging piece 104.
[0056] FIG. 6 depicts center packaging piece 106 in an unassembled
state. When unassembled, center packaging piece 106 is essentially
a flat board, such as a flat cardboard sheet, and so takes up
minimal space in shipping and/or storage. The various top openings
502 and bottom openings 504 are depicted, along with tabs 602a,
602b, 602c (generically or collectively, tab 602; not all tabs are
numbered), that insert into corresponding slots 604a, 604b, 604c
(generically or collectively, slot 604; not all slots are
numbered). In the depicted embodiment, the number of tabs 602 equal
the number of slots 604. Each tab 602 and slot 604 are sized and
shaped so that tab 602 inserts relatively snugly into slot 604.
Also depicted are fold or score lines 606a, 606b, 606c, 606d, 606e,
and 606f (collectively or generically, fold line 606). As can be
seen, the strength axis 512 (defined as the longitudinal axis of
the corrugated ribs) is oriented perpendicular to the score lines
606. Each of the score lines 606, in such an embodiment, is die-cut
or stamped across the ribs. As a result, in assembly the center
packaging piece 106 will tend to "snap" as each fold is made, as
the weakened ribs are overcome. Furthermore, by cutting or stamping
across the ribs, each score line 606 helps ensure that folds are
confined to the score lines 606, and do not otherwise inadvertently
fold or otherwise compromise the integrity of the center packaging
piece 106.
[0057] As will be understood, and with reference to FIGS. 5 and 6,
the depicted embodiment of center packaging piece 106 is assembled
from a flat configuration by folding the sheet in upon itself on
each fold line ninety degrees to form the vertical walls 508,
depicted in view 5C. Each tab 602 is inserted into slot 604 to
secure the center packaging piece 106 in its assembled
configuration. It will also be observed, from views 58 and 5C, that
the middle row of apertures only is formed from a top opening 502,
with no corresponding bottom opening 504.
[0058] As discussed above, the presence of a center packaging piece
106 helps allow packaging system 100 to be usable for shipping
without requiring that all spaces within the packaging be filled.
Although packaging system 100 is configured to accept twelve
bottles 108, it should also be understood that packaging system 100
may be configured to accept any arbitrary number of bottles, such
as by changing the dimensions, e.g. providing more or fewer rows
that accept more or fewer bottles 108. In various embodiments, top
packaging piece 102 and bottom packaging piece 104 are configured
so that a given bottle 108 of a fixed size and similar type, e.g. a
750 ml wine bottle, will fit within packaging system 100 such that
each packaging layer 102, 104, and 106 are each in contact with its
adjoining piece (as depicted in FIGS. 2A and 2B), and each inserted
bottle 108 is held with limited movement within packaging system
100, so as to prevent each bottle 108 from contacting adjacent
bottles 108. Each bottle 108 may be of a relatively different
configuration, e.g. the bottle bottom may vary in diameter along
with neck height and diameter, shoulder, etc., and so may vary in
vertical position in response to interaction with the taper of the
cavities 110 and 112 in the top and bottom packaging pieces 102,
104, respectively.
[0059] FIG. 7 depicts another possible embodiment of a center
packaging piece 700, with differing hole sizes. Specifically, top
hole 702 is of a narrower diameter than bottom hole 704. The
narrower top hole 702 helps to constrain movement of bottles 108
that may have relatively slender necks, and would otherwise
experience excessive movement with configurations where the top
hole is identical in size to the bottom hole. Such a configuration,
with a smaller top hole 702 and larger bottom hole 704, may be
useful where the corresponding top packaging piece 102 is not sized
or configured to sufficiently restrict the movement of each bottle
108, as center packaging piece 700 can provide the necessary
restriction. In assembly of a packaging system 100 employing center
packaging piece 700, bottles 108 would first be inserted into the
bottom packaging piece 104, the center packaging piece 700 would
next be placed over all bottles 108, followed by the top packaging
piece 102. Thus, in such a configuration the bottom hole 704 is
sized to accommodate a wider base and/or body of each bottle 108,
while the top hole 702 is sized to accommodate a narrower neck or
shoulder of each bottle 108. Center packaging piece 700 is
otherwise constructed and assembled identically to center packaging
piece 106.
[0060] FIG. 8 depicts a third possible embodiment of a center
packaging piece 800, with holes configured with a star shape,
rather than round. As can be seen in the depicted embodiment, top
hole 802 and bottom hole 804 are essentially round, but with four
inward-protruding flaps 806. The inward-protruding flaps 806 can
bend upon insertion of a bottle 108 to roughly conform to the
contours of the inserted bottle 108. These flaps thus can help
further restrict movement of an inserted bottle 108, as well as
help absorb energy from being transferred to each bottle 108 in the
event of an impact. In some embodiments of center packaging piece
800, the overall diameter of each top hole 802 and bottom hole 804
is sized to accommodate the base or other largest portion of a
bottle 108, with the flaps 806 helping to provide a centered and
relatively snug fit for portions of bottles 108 that are of a
smaller diameter. Thus, center packaging piece 800 may
substantially offer the movement restricting benefits of the
smaller top hole 702 of center packaging piece 700 (and its
commensurate use with a variety of different embodiments of top
packaging piece 102), with the flexibility to accommodate a mix of
narrower- and wider-necked bottles 108 that would not otherwise be
accommodated by a center packaging piece 700 with a fixed smaller
top hole 702. As with center packaging piece 700, center packaging
piece 800 is otherwise constructed and assembled identically to
center packaging piece 106.
[0061] FIGS. 9 and 10 depict two example possible alternative
implementations of center packaging piece 106, as mentioned above.
Specifically, FIG. 9 depicts a 2x4 configuration. As can be seen,
the vertical walls in the center of the center packaging piece
essentially abut, rather than being spaced apart as in the
depiction of center packaging piece 106 in FIGS. 5 and 6. FIG. 10
depicts an alternative arrangement of the 3x4 configuration of
center packaging piece 106, where the vertical walls are formed
along each end column of three holes, rather than each outer row of
four holes. In this arrangement, as can be seen, the inner vertical
walls are spaced apart by two columns of three holes, rather than a
single row of four holes.
[0062] FIG. 11 depicts an example alternative embodiment for top
packaging piece 102. As may be seen, the corner absorbers 202 are
shorter in height relative to the cavities, rather than being
approximately equal in height. The reduced height may allow some
degree of shock absorbing by an enclosing box before the shock
forces are transferred to the contained packaging pieces.
[0063] It will be apparent to those skilled in the art that various
modifications and variations can be made in the disclosed
embodiments of the disclosed device and associated methods without
departing from the spirit or scope of the disclosure. Thus, it is
intended that the present disclosure covers the modifications and
variations of the embodiments disclosed above provided that the
modifications and variations come within the scope of any claims
and their equivalents.
* * * * *