Abstract:
A system and method for packaging consumer products that include a number of individual pieces is provided. A pulp insert tray that includes a number of form fitting receiving locations to receive the individual pieces of the set separates and protects the individual pieces from damage resulting from uncontained packaging. A retainer may be used in association with the insert tray to provide additional support of the individual pieces, and assist in the final assembly of the packaged set. The use of pulp as the insert tray material provides significant ecological benefit.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
       [0001]    This patent application claims the benefit of U.S. Provisional Patent Application No. 60/887,660, filed Feb. 1, 2007, the disclosure and teachings of which are incorporated herein, in their entireties, by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to consumer product packaging systems and methods, and more particularly to a packaging system and method utilizing pre-formed insert trays for multiple component consumer products and the like. 
       BACKGROUND OF THE INVENTION 
       [0003]    In the past, typical families would have one set of flatware, i.e., dinner knives, forks, spoons, and various serving pieces. Among more affluent families, a second set of flatware, often made of silver, would be kept and used only on special occasions. Often the flatware sets were acquired through promotional programs from banks or grocery stores or by saving savers coupons and redeeming them for various pieces of flatware to add to or replace pieces for a family set. A gift of flatware would often be received as a wedding present, and many families kept and used that same set of flatware indefinitely. As pieces were lost, other single pieces might be acquired, often resulting in various different types of pieces, particularly spoons, in a family&#39;s flatware set. However, since the cost of flatware was high, few families replaced entire sets until or unless it became absolutely necessary. 
         [0004]    Recently, however, the cost of flatware has come down significantly. This is due, in part, to the production of flatware in countries with lower cost of labor and manufacturing. Different compositions of the flatware and coating processes have also lowered the cost while at the same time increased the durability of flatware pieces. At the same time, many flatware manufacturers have hired designers to create many different styles of design for the flatware pieces. Such styles now often include seasonal designs, designs for particular holiday seasons, festivals, picnicking, summer garden parties, etc. 
         [0005]    As a result of the lower cost and increased number of styles available on the market, many families now regularly purchase many different flatware sets to compliment their dining and hosting experiences. Indeed, not only do many families now have more than the traditional daily set of flatware and special occasion good silver flatware, but they also include different sets of flatware to match different place settings, fun sets for hosting parties, etc. Further, with the cost and varied styles of flatware available, families are now more likely to replace entire sets when pieces are broken or lost than buying matched or mismatched single pieces, e.g., spoons, to keep the current set running. 
         [0006]    While such changing habits have created great opportunities for flatware manufacturers, current systems and methods of packaging and shipping such flatware sets have experienced significant problems that have detracted from the full potential of consumer acceptance and desire of such flatware sets. 
         [0007]    Currently, flatware sets are packaged in boxes that typically include a display window through which one of each of the set&#39;s pieces is displayed for the consumer to see. Often these windows are open so that the consumers may feel the quality of such pieces in addition to merely reviewing the style. For example, a typical 20 piece set, serving for 4, includes a salad fork, a dinner fork, a dinner knife, a soup spoon, and a teaspoon displayed in the window so that the consumer may view, and possibly feel, the style of each of the different pieces included within the set. The remaining pieces in the set are then packaged within the interior of the box enclosure. 
         [0008]    Typically, each of the different types of flatware pieces are rubber-banded together with the other like pieces and simply placed within the box enclosure. As a result, these rubber-banded groupings of flatware pieces are free to move about within the enclosure as the package is shipped, placed on shelves, and handled by consumers. The result of this packaging method is that the pieces are allowed to rattle around on the interior of the box. Such often results in damage to the flatware pieces caused by scratching against other pieces within the set. Damage also occurs to the interior of the packaging often resulting in punctures, tears, or other damage that lessens the appeal of the particular set, as well as giving it an overall “cheapness” feeling that is left with consumers as the pieces in the set are allowed to rattle around in the box. Further, and particularly with larger sets of flatware, pieces may be missing because there is no way to tell if the person placing the various pieces in the box has missed an item other than doing a physical removal of the bundles of flatware pieces strewn in the box. 
         [0009]    With such a situation with the packaging of the flatware pieces, the flatware manufacturers have had to increase the rigidity of the boxes in which the flatware is contained. This “sturdier” packaging is used in an attempt to prevent much of the damage to the packaging itself caused by the flatware pieces rattling around inside the box and caused by damage from outside forces during the shipping and handling of the boxes through the entire distribution and retail chain. This has increased the overall cost to the manufacturers as thicker and more robust materials made to minimize the number of returns of flatware sets due to damaged packaging. 
         [0010]    There exists, therefore, a need in the art for a new packaging system and method for flatware and other consumer set products that overcome these and other problems existing in the art. 
         [0011]    These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein. 
       BRIEF SUMMARY OF THE INVENTION 
       [0012]    Embodiments of the present invention provide a new and improved packaging systems and methods for use with consumer products. More particularly, embodiments of the present invention provide a new and improved packaging system and method that may be used with flatware and other consumer products that include multiple pieces in a set. 
         [0013]    In one embodiment of the present invention a packaging system and method is provided that prevents the individual pieces in a set from rattling around in its overall packaging, thereby reducing the possibility of damage to the individual pieces caused by contact with different pieces in the set. Such a packaging system and method also reduces the likelihood of damage to the outside box because the individual pieces are contained in a single location and are unable to rattle around in the box causing damage thereto. In an embodiment of the present invention, the packaging system and method also provides structural integrity to the overall packaging of the consumer product, thereby allowing a reduced weight packaging material to be used for the overall packaging as structural integrity is now provided by an embodiment of the present invention. In a further embodiment, the packaging system and method provides a quality control mechanism that quickly reveals the proper composition of the set of consumer products to ensure that each of the various pieces are included and that none are forgotten or duplicated. 
         [0014]    In one embodiment of the present invention the packaging system and method utilizes a preformed insert tray having a number of separate pockets into which the different pieces of the set are held. Each individual receiving location is sized to receive a particular type of item in the set to minimize interaction or contact between the different types of pieces. The individual receiving location and the types of pieces received in those locations are arranged in one embodiment to distribute the weight of the overall set more evenly throughout the overall package to provide a solid, high quality feel to the overall packaging of the set. In one embodiment retention members or bars are utilized in association with the pre-formed insert trays to minimize the amount of movement of the various pieces of the set within the packaging to reduce the overall “rattle” that exists with current packaging systems and methods. Utilizing embodiments of the present invention, workers at the manufacturing facility can ensure proper set-loading through a cursory visual examination to ensure that each of the individual receiving locations contain a grouping of pieces. 
         [0015]    In a preferred embodiment of the present invention, the insert trays are made from pulp. In one embodiment the pulp is made from newspaper and/or recycled corrugated and water. As such, a preferred embodiment of the present invention is 100% recyclable and may contain as much recycled/post-consumer content as the manufacturer wishes. Such pulp insert trays may also be kept by the consumer as a convenient location for storing the different sets of flatware or other consumer set products while different flatware sets are used. Alternate embodiments may utilize other materials for the insert trays such as, for example, expanded polystyrene, vacuum formed PVC, plastic, etc. However, the pulp of the preferred embodiment provides a much smaller environmental footprint than these other materials. 
         [0016]    Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings: 
           [0018]      FIG. 1  is an exploded isometric illustration of one embodiment of the packaging system and method of the present invention; 
           [0019]      FIG. 2  is an illustration of an embodiment of an insert tray constructed in accordance with the teaching of embodiments in the present invention; 
           [0020]      FIG. 3  is a side view illustration of the insert tray of  FIG. 2 ; 
           [0021]      FIG. 4  is a bottom view illustration of the insert tray of  FIG. 2 ; 
           [0022]      FIG. 5  is an end view illustration of an alternate embodiment of the packaging system of the present invention; 
           [0023]      FIG. 6  is a top view illustration of the embodiment of  FIG. 5 ; 
           [0024]      FIG. 7  is a top view illustration of the embodiment of  FIG. 5  with the retainer open to show an alternate embodiment of a insert tray used therewith; 
           [0025]      FIG. 8  is an isometric illustration of the retainer structure used with the embodiment illustrated in  FIG. 5 ; 
           [0026]      FIG. 9  is a top view illustration of the insert tray of the embodiment of  FIG. 5 ; 
           [0027]      FIG. 10  is an end view illustration of the insert tray of  FIG. 9 ; and 
           [0028]      FIG. 11  is a side view illustration of the insert tray of  FIG. 9 . 
       
    
    
       [0029]    While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    Turning now to the drawings, there is illustrated in  FIG. 1  an embodiment of a packaging system  100  constructed in accordance with the teachings of the present invention. While the packaging system  100  illustrated in  FIG. 1  is designed for sets of flatware, those skilled in the art will recognize from the foregoing and following discussion that embodiments of the present invention may be particularly configured to package other consumer product sets. Therefore, while the following description will describe an embodiment to the present invention particularly suited to flatware packaging, such description is provided for illustration only and should not be taken as being limiting on the scope of the present invention. 
         [0031]    In the embodiment illustrated in  FIG. 1 , the packaging system  100  includes a box  102  that houses a window display board  104 , and insert tray  106 , and, in a preferred embodiment, a retainer  108 . The window display board  104  includes a display set  110  of the individual pieces in the serving set packaged within box  102 . This window display board  104  and display set  110  may be open to a consumer so that the weight and surface finish of the display set  110  may be readily accessed by the consumer. In alternate embodiments, the box  102  includes a clear window through which the display set  110  and display board  104  may be viewed, but access to the display set is prohibited. In still other embodiments, the box  102  does not include a window and no window display board  104  or display set  110  is used. 
         [0032]    The insert tray  106  houses the individual pieces  112 A- 112 D of the flatware set packaged therein. As may be seen from  FIG. 1 , the individual flatware pieces are individually packaged and grouped with an appropriate number of each individual pieces by a fastener, such as a rubber band. The individual coverings minimize the amount of damage that each of the pieces will sustain as a result of contact with other pieces in the set. 
         [0033]    In one embodiment of the present invention, a retainer  108  is used in conjunction with the insert tray  106  to secure the individual pieces  112  of the set in the tray  106  and prevent unnecessary movement thereof while in the packaging system  100 . In the illustrated embodiment, the retainer  108  includes two retention members or bars  114  connected by a planar surface  116 . As will be described more fully below, the retention members  114  are received in a retainer receiving slot  122  formed in the insert tray  106 . These retention members or bars  114  secure the individual pieces  112  in their respective receiving location so that they do not rattle in the box  102  as was problematic with prior packaging methods. Planar surface  116  is provided mainly for assembly expediency, and may be dispensed with in other embodiments of the present invention. 
         [0034]    Details of the insert tray  106  of the present embodiment may be best understood with reference to  FIGS. 2-4 . Turning first to  FIG. 2 , a top view illustration of the insert tray  106  of  FIG. 1  is provided. As may be seen, each of the individual pieces of the set is received in an individual receiving location  118 . Preferably, the individual receiving locations  118  are configured to closely correspond to the outline shape of each of the individual pieces of the set. This minimizes lateral movement of the pieces. This minimizes both noise, wear and tear on the packaging, and potential scratches or other damage to the individual pieces. 
         [0035]    The individual receiving locations  118  are separated from the outside and from one another by walls  120 . In the illustrated embodiment, the individual walls  120  each include a retainer receiving slot  122  that traverses the packaging from one side to the other. In the illustrated embodiment, there are two horizontal retainer receiving slots  122 A,  122 B, and one vertical retainer receiving slot  122 C as viewed in the orientation of this figure. The multiple retainer receiving slots  122 A- 122 C allow for various embodiments of a retainer to be used therewith based on the manufacturers preference or packaging type. Further, while the retainer receiving slots  122  are illustrated as traversing the entire length or width of the insert tray  106 , those skilled in the art will recognize that this need not be the case in other embodiments that utilize shorter retention members. 
         [0036]    Many of the pieces in a serving set of flatware are curved such that they do not lie in a single plane. Such individual pieces are easily removed from the insert tray  106 . However, other pieces in a serving set of flatware may not include any curves such that they do lie generally in a single plane, e.g., dinner knives. As such, one embodiment of the present invention utilizes piece support humps  124  which support the flatter serving pieces, provide for ease of removal from the insert tray  106  and properly position the pieces for proper retention when packaged. In other words, since the knives do not stack as high as, for example, the dinner forks, the piece support humps  124  raise the location of the knives in the receiving slot  118 C so that the retention member  114  may properly hold the knives in position to minimize the amount of movement in the z-axis. This greatly reduces the amount of movement that such flat pieces would otherwise be capable of moving, thereby reducing the wear and tear of the packaging, the rattle associated with such movement, and the associated wear and tear on the individual pieces. 
         [0037]    In an embodiment of the insert tray  106  of the present invention, nesting receiving locations  126  are provided to aid in the overall assembly process of the packaged set. That is, in the manufacturing environment the individual insert trays  106  may be stacked one upon the other at the worker location where final assembly of the set is to occur. To simplify the process of unstacking the insert trays  106  as needed, the nesting receiving locations  126  are included to provide a slight separation between trays for ease of unstacking. These nesting receiving locations  126  also provide additional structural rigidity of the insert tray  106 , which thereby allows for a lighter grade material to be used for the box  102 . 
         [0038]    As may be seen from the side view illustration of  FIG. 3 , the illustrated embodiment of the insert tray  106  also includes stacking guides  128  that function similar to the nesting receiving locations  126 . However, the stacking guides  128 A,  128 B are not received in nesting receiving locations, but instead are received in the retainer receiving slots  122 A,  122 B respectively, when stacked one on top of the other. 
         [0039]    As may be seen from the bottom view illustration of the insert tray  106 , the underside of the nesting receiving locations form nesting keys  130  that are received by the top surface nesting receiving locations  126  when stacked one on top of the other at the manufacturing facility. As may also be seen from the bottom view illustration of  FIG. 4 , in one embodiment of the present invention only the top surface of the insert tray  106  is “finished”. That is, in the illustrated embodiment wherein the insert tray  106  is made of pulp, the bottom surface is allowed to remain in its natural, textured form. 
         [0040]      FIG. 5  illustrates an alternate embodiment of an insert tray  106 ′ and retainer  108 ′ of the packaging system of the present invention. As illustrated in the end view of  FIG. 5 , the retainer  108 ′ provides the retention member  114 ′ and the planar surface  116 ′, but also includes two retainer side surfaces  132  and a back surface  134  that form an enclosure around the insert tray  106 ′. As may be seen from the top view illustration of this embodiment in  FIG. 6 , the exterior of the assembled insert tray and retainer simply presents a planar surface  116 ′ to the box in which it is contained. Once the retainer  108 ′ is opened, as illustrated in  FIG. 7 , the relationship between the retainer  108 ′ and the insert tray  106 ′ may be seen. In this embodiment, the retention member  114 ′ is vertically oriented and received in the retainer receiving slot  122 ′C. This is appropriate in this embodiment because the height of the stacked pieces for both spoons and forks are very close to the overall height of the insert tray  106 ′ such that the planar surface  116 ′ sufficiently retains the pieces in their respective receiving locations without the retention member being positioned thereacross. The knives, however, are not of a sufficient height, and therefore are aided by the retention member  114 ′ being positioned in retainer receiving slot  122 ′C. 
         [0041]    The retainer  108 ′ is illustrated in  FIG. 8 . As may be seen from this opened orientation of the retainer  108 ′, appropriate folds are positioned to form a portion of the planar surface  116 ′A, the side wall  132 A, the back surface  134 , the other side surface  132 B and the other portion of the planar surface  116 ′B. In the illustrated embodiment, the retention member  114 ′ is formed by four bends of the same material (although other embodiments may form the retention member  114 ′ with more or fewer folds as desired). This greatly reduces the manufacturing time and expense as it allows the entire retainer  108 ′ to be constructed from a single sheet of corrugated or other appropriate material. Depending on the number of pieces in the set, the retainer  108 ′ illustrated in  FIG. 8  may also be used with the earlier described embodiment of the insert tray  106  with appropriate resizing. 
         [0042]    The details of this embodiment of the insert tray  106 ′ may best be seen by an examination of  FIGS. 9-11 , wherein like elements are provided with like numerals. With the present embodiment  106 ′ only a single horizontal and vertical retainer receiving slot  122  is provided. As with the previous embodiment, the present embodiment of the insert tray  106 ′ also includes nesting receiving locations  126  and stacking guides  128  similar to the previously described embodiment to ease the unstacking of the insert trays  106 ′ during the assembly process. 
         [0043]    As will now be apparent to those of ordinary skill in the art, the individual pieces of flatware, e.g., knives, forks, spoons, etc., are divided into separate receiving locations or pockets so that the entire weight of the product in the retail box, which is often substantial, does not move as a unit, thereby preventing damage to the outer box  102 . Instead, the weight of the individual pieces in the set is distributed more evenly, which results in a more structurally sound arrangement of the overall product. In a preferred embodiment of the present invention, the insert tray is made of pulp which, by virtue of its structural design, supports the outer box and makes it stronger and less able to be crushed during the shipping and handling process. This insert tray in which the individual pieces are organized enhances proper set-loading and lends ease to the visual inspection of piece counts in the assembly and manufacturing operations. This presentation of the finished product to the consumer is more organized and aesthetically more appealing, thereby suggesting to the consumer a very high quality product. 
         [0044]    In the preferred embodiment where the insert trays are made of pulp, there are several ecological benefits provided as well. Since the pulp insert trays of the preferred embodiment are comprised of newspaper and/or recycled corrugated and water, they are 100% recyclable. The contents can include as much recycled/post-consumer content as the manufacturer wishes. The method of producing the pulp insert trays are also environment-friendly. The production process does not involve the use of extreme heat or toxic chemicals. This results in a much smaller environmental footprint than the use of, for example, expanded polystyrene or vacuum-formed PVC to organize flatware. 
         [0045]    All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein. 
         [0046]    The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0047]    Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.