Abstract:
A method and system for packaging a plurality of bottles in an efficient, compact package that maximizes the useable space in the storage and shipping of materials, such as beverages. Each pair of bottles in the package may be arranged in a mated configuration to form a space-conserving block. A holding sleeve may be used to maintain the pair of bottles in the mated configuration, while securing the blocks of the package together. The blocks are arranged and maintained together in an outer housing (e.g., a box) in a manner substantially free of dead space.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims the benefit of U.S. Provisional Application Ser. No. 60/752,314 filed on Dec. 19, 2005. The entire disclosure of U.S. Provisional Application Ser. No. 60/752,314 is incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates generally to packaging, and, more particularly, to a system and method for packaging a plurality of bottles.  
       BACKGROUND OF THE INVENTION  
       [0003]     Two of the most persistent and overarching challenges facing the packaging industry are space management and breakage concerns. Specifically, the packaging and storage of multiple bottles, such as water and/or wine bottles, in conventional lots, known as cases, often waste valuable space due to the inefficient geometry and arrangement of the bottles. This wasted, or “dead” space is commonly found around the curved surfaces of conventional bottles, such as, for example, the cylindrical neck and rounded base of a conventional water or wine bottle.  
         [0004]     This dead space creates two significant problems. First, it provides the bottles with room to shift during movement and/or shipping, resulting in unwanted contact between the bottles and, ultimately, to breakage. Second, this dead space is unused, creating significant inefficiencies in space management. For example, in a-typical case (e.g., twelve bottles arranged in a box), the bottles fill approximately  60 % of the space available, leaving the rest of the space empty.  
         [0005]     Many residual expenses flow from the breakage or damage of bottles, including re-shipping costs, replacement costs, clean up costs, loss of labels, ancillary damage or loss of packaging materials, contamination of other bottles in the same shipment, loss of product, and failure to meet business obligations. For example, employees must be paid to separate the broken bottles out of a shipment, clean up spilled product, clean off other bottles in the case, and remove and replace stained labels. This process increases costs and decreases productivity.  
         [0006]      FIG. 1  shows an exemplary prior art packaging arrangement of conventional bottles. For illustration purposes, only two bottles are depicted. As shown in  FIG. 1 , there are a number of dead space pockets or areas inherently formed by arranging conventional wine bottles having a rounded neck and rounded base adjacent to one another. This failure to use significant portions of space leads to higher shipping costs. In addition, when taken in the aggregate, a significant amount of space in warehouses, distribution centers, transportation means is ultimately wasted by the dead space between conventional bottles.  
         [0007]     Accordingly, a need exists for an efficient method and system for packaging bottles, such as water or wine bottles.  
       SUMMARY OF THE INVENTION  
       [0008]     Embodiments of the present invention satisfy these and other needs by providing a compact, re-enforced, and space-conserving packaging system. According to an embodiment of the present invention, the packaging system includes a plurality of bottles, such as water or wine bottles, having a geometry which allows for two like bottles to “mate” when arranged in a mated configuration (i.e., with opposing ends together).  
         [0009]     Specifically, two bottles are arranged in the mated configuration by fitting a neck of a first bottle into a corresponding groove in the base of a second bottle. The pair of mated bottles form a block having substantially flat side surfaces, which may be arranged in a substantially flush manner with adjacent block(s) and/or side walls of an outer housing (e.g., a box). Due to the geometry of the bottles, the blocks are formed and arranged together with little to no dead space in the package.  
         [0010]     According to an embodiment of the invention, the packaging system may include a holding sleeve which secures and maintains the pairs of bottles in the mated configuration (i.e., the individual blocks), while, additionally holding the plurality of blocks together in a rigid, re-enforced fashion within the housing of the packaging system.  
         [0011]     The compact packaging provided by the present invention reduces the amount of dead space, particularly the space typically present around the cylindrical necks of conventional bottles arranged in a package. Advantageously, breakage complications that stem from movement beyond the inherent tolerance of the packaged arrangement are also reduced. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The present invention will be more readily understood from the detailed description of exemplary embodiments presented below considered in conjunction with the attached drawings, of which:  
         [0013]      FIG. 1  is an illustration of a prior art package including two conventional bottles;  
         [0014]      FIG. 2  is an illustration of an exemplary bottle, according to an embodiment of the present invention;  
         [0015]      FIG. 2A  illustrates exemplary shapes for a neck of a bottle, according to an embodiment of the present invention;  
         [0016]      FIG. 3  illustrates a pair of exemplary bottles arranged in a mated configuration, according to an embodiment of the present invention;  
         [0017]      FIG. 4  shows a plurality of blocks forming a exemplary package, according to an embodiment of the present invention;  
         [0018]      FIG. 5  illustrates an exemplary holding sleeve, according to an embodiment of the present invention;  
         [0019]      FIG. 6  illustrates an exemplary segment of a holding sleeve, according to an embodiment of the present invention;  
         [0020]      FIG. 7  illustrates an exemplary housing, according to an embodiment of the present invention;  
         [0021]      FIG. 7A  illustrates an exemplary packaging system, according to an embodiment of the present invention; and  
         [0022]      FIGS. 8A-8D  shows an exemplary packaging system at various stages of the packaging process, according to an embodiment of the present invention 
     
    
       [0023]     It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention and may not be to scale, and are not intended to be limiting in terms of the range of possible shapes, proportions, and/or number of bottles.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     The present invention relates to a method and system for packaging a plurality of bottles in a rigid, compact arrangement. The bottles of the package each have a geometry that enables two like bottles to “mate” or fit together into a block that includes significantly less dead space as compared to conventional packaging. Advantageously, the mated bottle pairs, or blocks, each require a footprint approximately equivalent to that of a single bottle, resulting in significant space conservation.  
         [0025]     According to an embodiment of the present invention, a holding sleeve is provided that secures each pair of bottles in the mated configuration. In addition, the holding sleeve and housing combine to maintain the plurality of blocks in a compact arrangement.  
         [0026]     According to an embodiment of the present invention, the packaging system, as shown in  FIG. 8D , comprises a plurality of bottles  10 , a holding sleeve  20 , and a housing  30 . The plurality of bottles  10 , or package  1 , may include any number of bottles, such as, for example, twelve or twenty-four bottles. According to an embodiment of the present invention, the bottle  10  may be adapted to contain any liquid, solid, or gaseous material. One having ordinary skill in the art will appreciate that the bottle  10  may be composed of any suitable material, including, but not limited to, plastic, glass, ceramic, cardboard, and/or a composite material. The bottle  10  may be adapted to contain any suitably sized amount or volume of material. In a preferred embodiment, the bottle  10  is composed of glass or plastic and is adapted to hold water, wine, or other beverage having a volume of approximately 187 mL, approximately 1.5 L, or other conventional water and/or wine bottle volume.  
         [0027]     According to an embodiment of the invention, each pair of the plurality of bottles  10  may be arranged in a “mated configuration,” wherein two like bottles mate or interact to form a block having a plurality of substantially flat side surfaces. The mated configuration is described in further detail below.  
         [0028]      FIG. 2  illustrates an exemplary bottle  10  according to an embodiment of the present invention. As shown, the bottle  10  includes a neck  12  and a base  14 . The neck  12  is shaped to include at least one substantially flat (i.e., substantially non-cylindrical) side  12   s . For example, the bottle  10  depicted in  FIG. 2  includes a neck  12  having two substantially flat sides  12   s.    
         [0029]     According to an embodiment of the present invention, the base  14  is geometrically configured to include at least one substantially flat side surface and a groove  15  adapted to accept or mate with the neck  12  of a corresponding bottle  10 , when arranged in the mated configuration. One having ordinary skill in the art will appreciate that the base  14  may be any suitable shape, including, but not limited to, a rectangular, a triangular, a square, and any other geometrically similar or derivative shape.  
         [0030]     The neck  12  functions similarly to a neck of a convention bottle, in that it acts as a pouring channel or spout and includes an open top end that may be closed or capped using any suitable means, such as, for example, a cork, screw-top, threaded or crimped cap, pull tab, etc. As shown in  FIGS. 2 and 3 , the neck  12  extends from the base  14  in an offset manner (i.e., from the side or corner of the base  14  opposing the groove  15 ). Unlike a conventional bottle, the neck  12  does not extend from the center of the base  14 . According to a preferred embodiment of the present invention, the bottle  10  includes a square or rectangularly shaped base and a square or rectangularly shaped neck  12  extending from the base  14  in an offset manner (i.e., from a comer or side of the base  14 , not the center). Preferably, the neck  12  extends from a comer of the substantially square or rectangular base  14  diagonally opposed to the groove  15 , as shown in  FIG. 2 .  
         [0031]     According to an embodiment of the present invention, the neck  12  and the base  14  are shaped and sized such that when a pair of bottles  10  are arranged in the mated configuration, the neck  12  of each bottle  10  fits within the groove  15  of the corresponding bottle. Preferably, the groove  15  and the neck  12  are substantially the same length.  
         [0032]     The neck  12  may be any suitable shape so long as one or more sides of the neck  12  come into contact with and fit the contour of the respective groove  15  of a corresponding bottle  10 , when two bottles  10  are arranged in the mated configuration.  
         [0033]      FIG. 2A  shows a top view of exemplary shapes of the neck  12  of bottle  10 . One having ordinary skill in the art will appreciate any geometric shape having at least one substantially flat side may be used in accordance with the present invention, including shapes not shown in  FIG. 2A .  
         [0034]      FIG. 3  illustrates a pair of bottles, a first bottle  10 A and a second bottle  10 B, arranged in the mated configuration. As shown, the first bottle  10 A and the second bottle  10 B are in reverse orientation relative to one another (i.e., with reverse polarity), such that the neck  12 A of the bottle  10 A is fitted or mated with groove  15 B of base  14 B. Likewise, neck  12 B of bottle  10 B is fitted or mated with groove  15 A of base  14 A. As shown in  FIG. 3 , the first bottle  10 A and the second bottle  10 B in the mated configuration form a block  50 .  
         [0035]      FIG. 4  illustrates a number of blocks  50 A- 50 F arranged together to form a package  1 , according to an embodiment of the present invention. As shown, each block  50 A- 50 F has a plurality of substantially flat, non-cylindrical sides to allow adjacent blocks and/or the housing  30  (not shown in  FIG. 4 ) to abut the block in a flush manner, such that there is no significant dead space therebetween. For example, block  50 A has four substantially flat side surfaces, two of which are abutted by blocks  50 B and  50 D respectively, and two that are abutted by the side walls of the housing  30  when arranged therein. This secure arrangement provides for a reduction in movement of the bottles  10  and/or blocks  50 , and reduces the amount and likelihood of damage and/or breakage of bottles  10  composed of breakable material, such as glass.  
         [0036]      FIG. 5  illustrates an embodiment of the present invention wherein a plurality of bottles  10  and blocks  50  of a package  1  are held together in a substantially dead space-free manner by a holding sleeve  20 . As shown in  FIG. 5 , the holding sleeve  20  includes a number of holding sleeve segments  25  corresponding to the number of blocks  50  of the package  1 . The holding sleeve  20  may be a monolithic piece including integrally connected or attached holding sleeve segments  25 . One having ordinary skill in the art will appreciate that the holding sleeve  20  may be composed of any suitable material, including, but not limited to, plastic, glass, cardboard, wood, foam, or composite material.  
         [0037]     As shown in  FIG. 6 , the holding sleeve segment  25  may include an aperture  26  and a carved-out portion  27 . The aperture  26  is shaped and sized to accept and secure a neck (e.g., neck  12 A shown in  FIG. 3 ). The carved-out portion  27  of the holding sleeve segment  25  is provided in the corner of the holding sleeve segment  25  diagonally opposing the aperture  26  such that a side edge of an adjacent holding sleeve segment or a side wall of the housing  30  couple with the carved-out portion  27  to form or define a slot to secure a neck (e.g., the neck of bottle  10 B of  FIG. 3 ). The aperture  26  and the carved-out portion  27  each provide an opening adapted to surround and secure a portion of the necks of the bottles arranged in the mated configuration. One having ordinary skill in the art will appreciate that the holding sleeve segments  25  of the holding sleeve  20  are shaped and sized to correspond with the base  14  of the bottles in the package  1 . For example, the holding sleeve segments  25  may be shaped like a square, rectangle or triangle. Optionally, the holding sleeve segments  25  may be individually attached and/or detached from one another to form an adjustably sized holding sleeve  20  that may be adapted to fit various sized packages.  
         [0038]     Optionally, according to an embodiment of the present invention, the outer side surface (i.e., the outer perimeter) of the holding sleeve  20  may include one or more notches  21  (shown in  FIGS. 4 and 5 ), which, upon proper alignment, fit into a corresponding holes  31  (shown in  FIG. 7 ) in a side wall of the housing  30 , to provide a more secure fit therein. One having ordinary skill in the art will appreciate that any alternative arrangement may be used to secure the holding sleeve  20  within the housing  30 . In addition, it is to be appreciated by one having ordinary skill in the art that the holes  31  need not extend through the entire side wall of the housing  30 , but only need be of sufficient depth to accept and securely fit the notches  21 .  
         [0039]     According to an embodiment of the present invention, the packaging system includes a housing  30  within which the package  1  is arranged. As described above and shown in  FIG. 7 , the housing  30  may include one or more holes  31  adapted to align with the corresponding number of notches arranged along the outer side surface (i.e., outer perimeter) of the sleeve  20 . The housing  30  may be composed of any suitable material, such as, for example, cardboard. The housing  30  may be any shape, with the important consideration being that the interior cavity of the housing be sufficiently shaped and sized to securely enclose the package  1  with the minimal amount of dead space provided therein.  
         [0040]     One having ordinary skill in the art will appreciate that the housing  30  may be any size or shape, including, but not limited to, a size adapted for storage and/or placement in a small space such as, for example, a refrigerator (e.g., “fridge pack” sized).  FIG. 7A  illustrates an embodiment of the present invention wherein the packaging system includes a number of blocks  50 , preferably composed of smaller sized bottles  10  (e.g., approximately 187 L bottles), in a horizontally stacked arrangement within the housing  30 . As shown in  FIG. 7A , the housing  30  includes an end which allows access to, and the removal of, the bottles  10  therein. One having ordinary skill in the art will appreciate that this access point may be a movable or removable piece. For example,  FIG. 7A  shows the access point with the ‘door’ or cover removed, such that the bottles may be accessed by a user. Alternatively, the access point may comprise a moveable door which is lifted or otherwise moved to allow for access to the bottles. One having ordinary skill in the art will appreciate that the access point may be arranged at any location on the housing, such as, for example, the top, side, back, or front of the housing.  
         [0041]     Although  FIG. 7A  depicts a two-by-two arrangement of blocks  50 A- 50 D, one having ordinary skill in the art will appreciate that the bottles may be arranged in a number of alternative ways, and may include any number of rows and/or columns, such as, for example, a single vertical column arrangement.  
         [0042]     Referring to  FIG. 7A , bottle  10 A may be removed via the opening in housing  30 . Removing bottle  10 A bifurcates block  50 A, thus freeing up bottle  10 B for removal. Once block  50 A is removed, blocks  50 B and  50 C are in position for removal.  
         [0043]     One having ordinary skill in the art will appreciate that in this embodiment, the packaging system does not include a holding sleeve  20 , thus allowing the next block (e.g., block  50 B in  FIG. 7A ) to fall into position for removal from the housing  30  (i.e., into alignment with the access panel  35 ). Advantageously, the packaging system illustrated in  FIG. 7A  may be arranged in a refrigerator or other limited space.  
         [0044]      FIGS. 8A-8D  illustrate a packaging system at various stages of the packaging process, according to an embodiment of the present invention. As shown in  FIG. 8A , a first load of bottles is placed base-side  14  down into the housing  30 . For illustration purposes, the housing  30  is depicted as having transparent (i.e., cut-away) sides so that the interior enclosure of the housing  30  may be seen. One having ordinary skill in the art will appreciate that the housing  30  may or may not be composed of a transparent material.  
         [0045]     As shown in  FIG. 8B , the holding sleeve  20  is mounted over the first load of bottles such that each neck  12  of the first load is aligned with and passes through a corresponding aperture  26  of the holding sleeve segment  25 , as described in detail above. As indicated above, the holding sleeve  50  is an optional feature of the packaging system, and need not be included. Because each holding sleeve segment  25  is shaped and sized to match the base of the bottles  10 , the holding sleeve  20  may form a friction or snap fit with the bottles  10  when mounted thereon. As described above, the notches  21  formed on the perimeter of the holding sleeve  20  fit into the corresponding holes  31  (not shown in  FIG. 8B ) of the housing  30  upon proper alignment of same.  
         [0046]     Next, a second load of bottles is arranged into the mated configuration with the first load of bottles, as shown in  FIG. 8C . The bottles of the second load are introduced in the housing such that each neck of the second load is aligned with and passes through a corresponding carved-out portion  27  of the holding sleeve segment  25 . When properly aligned, the first and second loads are secured in place within the housing  30  in the mated configuration by the holding sleeve  20 . Each corresponding pair of bottles of the first and second loads are coupled together in the mated configuration by the holding sleeve  20 , thereby forming a substantially rigid package  1 . In this arrangement, the side walls of the housing  30  provide additional support to the package  1 , while the holding sleeve  20  provides both exterior and interior support to the package  1 , as shown in  FIG. 8D .  
         [0047]     One having ordinary skill in the art will appreciate that the above described steps do not have to be performed in the order presented above. For example, the second load of bottles  10  may be introduced into the housing  30  with the holding sleeve  20  mounted thereon, such that the holding sleeve  20  is mounted over the first load when the second load is arranged into the mated configuration with the first load.  
         [0048]     One having ordinary skill in the art will appreciate that the blocks  50  of the package  1  may be arranged within the housing  30  with a vertical orientation (i.e., standing upright as shown in  FIG. 8D ), with a horizontal orientation (i.e., with the blocks  50  lying side down as shown in  FIG. 7A ), or a combination of the two arrangements.  
         [0049]     It is to be understood that the exemplary embodiments are merely illustrative of the invention and that many variations of the above-described embodiments can be devised by one skilled in the art without departing from the scope of the invention. It is therefore intended that all such variations be included within the scope of the above description.