Beverage container packaging

A beverage container packaging assembly is disclosed. The beverage container packaging assembly includes a bottom tray, center support, and a top tray. The bottom tray includes a plurality of cup-shaped elements each configured to accommodate a bottom portion of a beverage container. Each cup-shaped element includes at least a first deformable element comprising one or more wide portions and one or more thin portions. The center support is disposed between the bottom tray and the top tray. The top tray includes bottle neck accommodating spaces each bounded by a set of vertical posts.

TECHNICAL FIELD

The present invention relates to packaging materials, and particularly to packaging for beverage containers, such as wine bottles, beer bottles, spirits bottles, and the like.

BACKGROUND

Historically, packaging materials for shipment of beverage containers (e.g., wine bottles, beer bottles, spirits bottles, etc.) have included bubble wrap, Styrofoam, popcorn, and other traditional packaging materials. For example, multiple bottles could be wrapped in bubble wrap, positioned in Styrofoam, and/or otherwise secured and placed into a box for transit. More recently, molded paper pulp trays have been used to secure multiple bottles during transit. Typically, a bottom tray accommodates the bottom of a bottle, a top tray accommodates the top of the bottle, and cardboard may be installed between the bottles. Many existing bottom tray designs include ring-shaped crushable elements to absorb impact during shipping. The ring-shaped crushable elements may be ineffective in reducing and/or preventing damage to the bottle when the package is subjected to a large impact and/or multiple large impacts. An improved beverage container packaging would be useful.

DETAILED DESCRIPTION

Exemplary embodiments are discussed in detail below. While specific exemplary embodiments are discussed, it should be understood that this is done for illustration purposes only. In describing and illustrating the exemplary embodiments, specific terminology is employed for the sake of clarity. However, the embodiments are not intended to be limited to the specific terminology so selected. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the embodiments. It is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. The examples and embodiments described herein are non-limiting examples.

All publications and references cited herein are hereby incorporated by reference in their entirety.

As used herein, the term “a” refers to one or more. The terms “including,” “for example,” “such as,” “e.g.,” “may be” and the like, are meant to include, but are not be limited to, the listed examples.

Beverage container packaging is disclosed. The beverage container packaging disclosed herein in various embodiments may include a bottom element (bottom tray, bottom insert), a top element (top tray, top insert), and/or a center support (e.g., center support element). These elements may retain multiple beverage containers, such as wine bottles, beer bottles, spirits bottles, and the like, for shipment in a container, such as a cardboard box, crate, or other container. The beverage containers may vary in size including, for example, 375 ml, 500 ml, 750 ml, or any other size. The term beverage container as used herein may also refer to any container that encloses a fluid, whether or not the fluid is a beverage. Beverage containers may be placed bottom down in the bottom tray. The center support rests on top of the bottom tray and separates the multiple bottles. The center support separates the bottom tray and top tray, thereby providing stacking support. The top tray rests on the center support. And the top element accommodates the top (neck) of the beverage containers. The bottom tray, center support, top tray, and beverage containers are placed in a container, such as a cardboard box, crate, etc., for transit.

In various embodiments, the bottom tray comprises molded paper pulp fabricated from, for example, recycled paper products. The bottom tray may include multiple cup-shaped elements (e.g., cup-shaped cavities) each contoured to encapsulate the bottom of a beverage container, such as a wine bottle, beer bottle, spirits bottles, or the like. In certain cases, the cylindrical cup-shaped element includes an hourglass-shaped deformable element and/or a cross shaped deformable element protruding from the bottom surface of the cup, deformable protrusions on the walls of the cup, and/or other features. These features retain the base of the beverage container in a stationary position during shipment by contacting the base of the container in multiple locations. These features of the cup-shaped element, particularly the hourglass shaped and/or cross-shaped deformable element absorb energy when the container is subjected to impact forces (e.g., when dropped, roughly handled, etc.).

In some embodiments, the top tray comprises molded paper pulp. In certain cases, the top tray may include multiple rectangular cup-shaped elements each contoured to encapsulate the top of a beverage container, such as the neck of a wine bottle, beer bottle, spirits bottle, or other container. The rectangular cup-shaped element may include a cylindrical depression, vertical protrusions on the walls of the cup, and/or other features. These features retain the neck and/or upper portion of the beverage container in a stationary position during shipment by contacting the neck of the container in multiple locations.

In various embodiments, the center support may comprise one or more sheets of cardboard, such as corrugated cardboard. In some cases, the center support may comprise molded paper pulp that is molded to encapsulate beverage containers.

The beverage container packaging assembly disclosed herein in various embodiments provides improved impact energy absorption characteristics in relation to existing packaging solutions. The beverage container packaging disclosed herein may also be cheaper to produce than existing packaging solutions.

FIG. 1depicts a beverage container packaging assembly according to various embodiments. In the example shown, a beverage container packaging assembly100may include a bottom tray110(e.g., bottom element), a top tray120(e.g., a top element), a center support130(e.g., center support element, partition element), and/or other components. The beverage container packaging assembly100is configured to package a plurality of beverage containers140for transit. In the example shown, the beverage container packaging assembly100is configured to package 12 bottles. The base of the beverage container140sits in a cylindrical cup-shaped elements of the bottom tray110. The center support130separates the bottom tray110and top tray120. The top tray120rests on the center support130. The top of the beverage container140is encapsulated in a bottle accommodating space of the top tray120. The center support130prevents the sides of the beverage containers140from contacting during shipping and provides spacing between the bottom tray110and top tray120. In certain cases, the center support130may not be included in the beverage container packaging assembly100.

FIG. 2depicts a bottom tray and center support of a beverage container packaging assembly according to various embodiments. In the example shown, a beverage container140(e.g., wine bottle) is seated in a cup-shaped element112of a bottom tray110. The cup-shaped element112is shaped to retain the beverage container140in a vertical configuration during transit. In the example shown, a center support130is fabricated from molded paper pulp and/or similar materials. The center support130includes exterior support cavities132, interior support cavities134, and/or other elements.

In some embodiments, the center support130does not extend to an outer edge150of the bottom tray110and/or an outer edge of the bottle container packaging assembly (e.g., bottle container packaging assembly100ofFIG. 1). In this case, the center support130is located on an interior portion of the beverage container packaging assembly and does not contact the box. A center support130that does not next extend to an outer edge150of the bottom tray110may require less material than other large center support designs.

As discussed below, other types of center supports, such as corrugated cardboard center supports, may be used. In certain cases, a type of center support may be selected based on shipping requirements, load absorption parameters, customer preferences, and/or any other parameters.

FIG. 3depicts a bottom tray of a beverage container packaging assembly according to some embodiments. As shown, a bottom tray110includes a plurality of cup-shaped elements112. The number of cup-shaped elements112corresponds to a number of beverage containers the bottom tray110is configured to accommodate. In the example shown, the bottom tray110includes twelve cup-shaped elements112—three (3) rows of four (4) cup-shaped elements112. The bottom tray110is thus configured to accommodate 12 beverage containers.FIG. 3depicts one example configuration of cup-shaped elements. The present disclosure, however, is in no way limited to the depicted configuration or number of cup-shaped elements112.

In certain cases, the bottom tray110includes posts114configured to support the center support (not shown). Each of the posts114(six in the example shown) may include a plurality of platforms116(e.g., deformable post elements, protrusions, etc.) that form flat surfaces to contact the center support. The platforms116may be arranged in sets to resemble a cross shape. The platforms116may also be deformable and/or flexible to absorb load applied to the bottom tray110, thereby reducing any load applied to the beverage containers140.

FIG. 4depicts a first view of a bottom tray according to various embodiments. In the example shown, a bottom tray400includes a plurality of cup-shaped elements410(e.g., cup shaped element112ofFIGS. 1-3). In certain cases, each of the cup-shaped elements410is cylindrical and/or substantially cylindrical. The cup-shaped element410may include a bottom portion and multiple side walls forming a cup shape. In certain cases, the side walls may not be vertical but may include draft, such a seven degree draft, to enable the bottom tray400to be easily removed from a mold during fabrication.

Each of multiple cup-shaped elements410may include one or more of deformable elements420on the base (bottom) of the cup-shaped elements410, first deformable elements430on the cup-shaped elements410, second deformable elements440on side(s) of the cup-shaped elements410, thin deformable elements450on sides of the cup-shaped elements410, and/or other components.

The deformable elements420(e.g., base deformable elements) on the base (bottom) of the cup-shaped elements410may be raised (e.g., protrusions) from the bottom surface of the cup-shaped element410. The deformable elements420on the bottom of the cup-shaped element410may resemble a cross, overlapping bowties, and/or other similar shapes. The deformable elements420are configured to absorb impact with the bottom of a beverage container, such as a load applied to a top or bottom of a beverage container when boxes are stacked, a box is dropped, and/or otherwise handled. The cross-shaped deformable element420may be particularly effective in absorbing impact on a bottle with a convex bottom shape, such as certain wine bottles. In certain cases, wider portions422of the cross-shaped deformable element420are configured to contact the outer edges of the bottom of a beverage container, such as a wine bottle. Thinner portions424of the cross-shaped deformable element420allow the element to deform (for example, by bending, crumpling, and/or otherwise deforming) when a load is applied to a beverage container housed in the bottom tray400. The cross-shaped deformable element420deforms to absorb load and reduce damage to a bottle, particularly when a load is applied down from the top on the bottle or when the assembly is dropped.

In some embodiments, deformable elements420on a bottom of the cup-shaped elements410include holes426. The holes426may vent air as the bottom tray400is lowered into a box (not shown). Vent holes426may reduce the vacuum in the box as the bottom tray400is installed in a box, thereby making assembly easier.

In various embodiments, the cup-shaped element410includes multiple vertical deformable elements430,440. The vertical deformable elements430,440are configured to contact the sides of a beverage container (not shown). In certain cases, first vertical elements430and second vertical elements440are configured to contact the outside of a bottle. The vertical deformable elements430,440may be sized, such that a bottle contacts at least a portion of each of the vertical deformable elements430,440when loaded into the cup-shaped element410. The bottle (not shown) and vertical deformable elements430,440may contact one another in an interference fit, such that a force is necessary to push the bottle into the cup-shaped element410and a force is necessary to remove the bottle from the cup-shaped element410. Securing the bottle in the cup-shaped element410in such a manner ensures that the bottle is stationary during transit, thereby reducing any potential damage. In certain cases, the vertical deformable elements430,440can include a protrusions460near the bottom of the cup-shaped element410extending toward a center of the cup-shaped element410. The protrusions460may increase the interference fit between the cup-shaped element410and a bottle.

In certain cases, a first type of vertical deformable elements430are included on the walls between adjacent cup-shaped elements410. The first vertical elements430include a contoured protrusion configured to contact the outside of a bottle.

In some embodiments, a second type of vertical deformable elements440are included on outer walls of the cups-shaped element410(e.g., walls of the cup-shaped elements not adjacent to any other cup-shaped element410). A lower portion of the second vertical deformable elements440may resemble the structure of the first vertical deformable elements430, and an upper portion may include multiple thinner protrusions442. In the example shown, the multiple thin protrusions442may resemble a fork.

According to some embodiments, the cup-shaped element410includes multiple thin deformable elements450. In certain cases, thin deformable elements450may extend from a center of the cup-shaped element up a side of the cup-shaped element410. Thin deformable elements450may include thin protrusions spaced roughly 90 degrees apart from one another. In certain cases, the thin deformable elements450may be spaced roughly 45 degrees from the intersection of the cross-shaped deformable element420. In the example shown, there are four thin deformable elements450in each cup shaped element410. Though in other cases, a cup-shaped element410may include other numbers of first thin deformable elements450.

FIG. 5depicts a second view of a bottom tray according to various embodiments. In the example shown, which may include an opposite side of the bottom tray fromFIG. 4, a bottom tray500includes multiple cup-shaped elements510. The bottom side of the bottom tray500includes non-contoured pulp paper. The bottom side of the cup-shaped elements510may include protrusions520(e.g., four protrusions in the example shown) extending from the bottom of the cup-shaped element510up each side. The protrusions520may absorb impact and reduce loads applied to the beverage containers during, for example, an impact event.

FIG. 6depicts a center support of a beverage container packaging assembly according to various embodiments. In the example shown, a center support600includes a plurality of exterior support cavities610(e.g., beverage container support cavities), interior support cavities620, and/or other elements. The exterior support cavities610and interior support cavities620maintain the bottle upright and to separate each bottle from adjacent bottles. Exterior support cavities610may include a semi-circular shape that follows the contour of a wine bottle. An exterior support cavity610encapsulates a portion of a beverage container (e.g., a body, shoulder, or neck of a bottle). In certain cases, an exterior support cavity610includes walls612including a draft angle of seven degrees and/or another draft angle. The interior support cavities620may include a circular (cylindrical) enclosure. The interior support cavities620may fully encapsulate (surround) a neck, shoulder, body and/or other component of a beverage container. Walls622of the interior support cavities620may include a draft angle of seven degrees and/or another draft angle.

In some embodiments, the center support600includes star shaped cavities630(e.g., cross shaped cavities). The star-shaped cavities630may form the borders of the exterior support cavities610, interior support cavities620, and/or other elements. In certain cases, the posts of a top tray (discussed below) contact the corners632of the star-shaped cavities630when assembled. In certain cases, the corners632of the star-shaped cavities630extend out away from the center far enough to provide cushion between adjacent beverage containers. For example, the corners632of the star-shaped cavities630can extend out away from the center far enough to encapsulate at least half of the circumference of a bottle.

FIG. 7depicts a bottom side of a center support according to various embodiments. In the example shown, a bottom side of center support700(e.g., center support600ofFIG. 6, center support130ofFIGS. 1-2) includes a plurality of exterior support cavities710, interior support cavities720, and/or other elements. The exterior support cavities710and interior support cavities720may be bounded by star-shaped posts730(e.g., star-shaped elements, cross-shaped contoured posts). The star-shaped posts730may include a diamond-shaped inner portion740(e.g., square and/or rectangular shaped inner portion) and star point elements760,770(e.g., star point elements) that extend away from the center of the post730at, for example, ninety degree angles (e.g., orthogonal to one another) to form the rough shape of a star and/or cross. In certain cases, star point elements760extending toward another post may be smaller in size that star point elements770extending towards an edge of the bottle packaging assembly. The larger star point elements770may extend further to encapsulate a portion of the outer surface of a bottle, thereby separating adjacent bottles and preventing adjacent bottles from contacting one another. In certain cases, a center support700includes recessed elements780elements between the posts730. The recessed elements780between posts730allow the posts730to tilt relative to one another and the center support700to flex during use. In certain cases, one or more posts730include a hole750to reduce a vacuum when multiple center supports are stacked (e.g., during manufacture).

In some embodiments, a center support700is placed on a bottom tray (e.g., bottom tray110ofFIGS. 1-3) when, for example, beverage containers are prepared for shipping. In some cases, the star-shape elements730are placed on posts included in a bottom tray (e.g., posts114of bottom tray110ofFIG. 3). During assembly a flat surface of each post730contacts a flat surface of a post on the bottom tray (e.g., posts114or deformable post elements116of bottom tray110ofFIG. 3). The bottom tray110may include six posts to accommodate the six posts730of the center support700.

FIG. 8depicts a top tray of a beverage container packaging assembly according to some embodiments. In the example shown, a top tray800(e.g., top tray120ofFIG. 1) includes multiple vertical posts810. In certain cases, the vertical posts810form the sides (bounds) of bottle neck accommodating spaces820in the top tray800. The bottle neck accommodating spaces are configured to accommodate a neck of a beverage container, such as a wine bottle. The number of bottle neck accommodating spaces820corresponds to a number of beverage containers the top tray800is configured to accommodate. In the example shown, the top tray800includes twelve bottle neck accommodating spaces820—three (3) rows of four (4) bottle neck accommodating spaces—and the top tray800is configured to accommodate twelve beverage containers.

FIG. 9depicts a first view of a top tray according to some embodiments. In the example shown, a top tray900includes multiple vertical posts910that form bottle neck accommodating spaces920. For example, the vertical posts910may include deformable elements912that contact the neck of a bottle and hold it in place during shipping. The deformable elements912may also deform to absorb lateral loads applied to a bottle during transit. In some cases, the vertical posts910may include trapezoidal deformable elements914(e.g., protrusions) on a top of the vertical post910. The trapezoidal elements914may contact portions of the center support structure, such as corners632of the star-shaped cavities630ofFIG. 6.

In certain cases, a top end of the bottle neck accommodating spaces920includes a circular depression930(e.g., circular depressed region). The circular depression930may accommodate the size of wine cork such that the wine bottle rim contacts the top tray but not the cork, for example, when a load is applied down on the top tray900. The circular depression930may include a thin deformable element bisecting the circular depression930.

In some embodiments, the top tray900includes one or more holes940. Similar to the holes discussed with respect to other components of bottle packaging assembly, the holes940reduce vacuum generated when the top tray is placed into a box.

FIG. 10depicts a second view of a top tray according to various embodiments. In the example shown, a top tray1000includes the structure underlying the bottle neck accommodating spaces (e.g., bottle neck accommodating spaces920ofFIG. 9). The top side (on assembly) of the top tray1000includes non-contoured pulp paper. The top side of the bottle neck accommodating spaces may include cross-shaped protrusions1010(e.g., four protrusions meeting at a point in the example shown). The cross-shaped protrusions1010may absorb impact and reduce loads applied to the beverage containers during, for example, an impact event.

FIG. 11depicts a bottom tray and center support of a beverage container packaging assembly according to various embodiments. In the example shown, a beverage container1140is seated in a cup-shaped element of a bottom tray1110. A center support1130is seated upon the lower tray1110. The lower tray1110is similar to bottom tray110ofFIGS. 1-3, bottom tray400ofFIG. 4, and bottom tray500ofFIG. 5. One difference being the bottom tray1010is configured to accommodate fifteen beverage containers—three rows of five containers—as opposed to twelve in the bottom trays110,400,500ofFIGS. 1-5. The center support1030is similar to the center supports130,600,700ofFIGS. 2, 6, and 7, respectively, with the exception that center support1030is configured to accommodate fifteen beverage containers—three rows of five containers—as opposed to twelve.

FIG. 12depicts a bottom tray according to various embodiments. The bottom tray1200depicted is similar to bottom trays to bottom tray110ofFIGS. 1-3, bottom tray400ofFIG. 4, and bottom tray500ofFIG. 5. For the sake of brevity and clarity, the following description will focus primarily on the differences relative to the aforementioned bottom trays110,400, and500. In the example shown, a bottom tray1200includes a plurality of cup-shaped elements1210, posts1230(e.g., eight posts). The cup shaped element1210includes multiple thin deformable elements1212. In certain cases, the thin deformable elements1212extend from a center of the cup-shaped element up a side of the cup-shaped element1210. The thin deformable elements terminate at the bottom of the cup-shaped element1210in a cross shape end214(e.g., cross shape element). The cross-shaped ends1214may assist in absorbing impact from a bottom of bottle when, for example, an assembly is dropped. The cross-shaped ends1214may reduce damage to the end of thin deformable element1212when, for example, the bottom tray1200is bent. The cross-shaped ends1214eliminate a stress concentration point and allow load to be distributed to other elements when the bottom tray1200is bent or otherwise loaded.

In various embodiments, the cup-shaped elements1210elements include rounded corners1220at a base of the cup-shaped elements1210. The rounded corners1220may allow the bottom tray1200to endure more repeated loading. The rounded corners1220also accommodate the shape of the bottom of a bottle.

FIG. 13depicts a center support according to various embodiments. The center support1300shown is similar to the center supports130,600,700ofFIGS. 2, 6, and 7, respectively, with the a difference being the center support1300is configured to accommodate fifteen beverage containers—three rows of five containers—as opposed to twelve.

FIG. 14depicts a top tray according to various embodiments. The top tray1400shown is similar to top trays120,800,900, and1000ofFIGS. 1, 8, 9, and 10. One difference between the top tray1400depicted is configured to accommodate fifteen beverage containers—three rows of five containers—as opposed to twelve as in top trays120,800,900,1000. In certain cases, top tray1400includes a plurality of posts1410each including holes1420in a top flat surface of the posts1410. The holes1420reduce any vacuum effect as the top tray is loaded into a box.

FIG. 15depicts a bottom tray and center support of a beverage container packaging assembly according to various embodiments. In the example shown, a beverage container1540is seated in a cup-shaped element of a lower tray1510. A center support1530is seated upon the bottom tray1510. The bottom tray1510is similar to bottom tray1110,1200ofFIGS. 11 and 12. Center support1530is similar to center support1300ofFIG. 13, with the exception that the center support1530includes bottle enclosure cavities1532that fully encapsulate each beverage container1540.

In various embodiments, the beverage container enclosure cavities1532protect the beverage container1540from side impacts, maintain the beverage container1540upright during transit, and/or provide other benefits. In certain cases, a bottle packaging assembly (e.g., bottom tray1510, center support1530, and top tray1400ofFIG. 14) may be able withstand 15 drops from at least 18 inches, two drops from 36 inches, and/or 10 drops from 30 inches, as required by various shipping companies (e.g., United Parcel Service (UPS), FedEx, and the like).

FIG. 16depicts a center support according to various embodiments. In the example shown, a center support1600includes a plurality of beverage container enclosure cavities1610(e.g., interior support cavities). The enclosure cavities1610function to maintain the bottle upright and to separate each bottle from adjacent bottles. The enclosure cavities1610may include a circular (cylindrical) enclosure. The enclosure cavities1610may fully encapsulate (surround) a neck, shoulder, body and/or other component of a beverage container. Walls1620of the enclosure cavities1610may include a draft angle, such as seven degrees and/or another draft angle.

In some embodiments, the walls1620of the enclosure cavities1610include deformable elements1622. The deformable elements1622are configured to absorb load applied to the side of a beverage container, thereby protecting beverage container from damage during transit. Because the beverage containers are each fully encapsulated by enclosure cavities1610, the center support1600and beverage containers included therein may withstand higher loads and/or more load cycles than center support1300ofFIG. 13.

FIG. 17depicts a bottom view of a center support according to various embodiments. In the example shown, a bottom side of center support1700(e.g., center support1600ofFIG. 16, center support1530ofFIG. 15) includes a plurality of beverage container enclosures1710(e.g., enclosure cavities). The beverage container enclosure cavities1710may be bounded by star-shaped posts1720(e.g., star-shaped elements) and/or partial star-shaped posts1730(e.g., partial star-shaped elements). The star-shaped posts1720may include a diamond-shaped inner portion1740(e.g., square and/or rectangular shaped inner portion) and four outer portions1750(e.g., star point elements, cross arm elements) extend away from the center of the post1720at rough ninety degree angles (e.g., orthogonal to one another) to form the rough shape of a cross. In certain star point elements1750may include different sizes.

In certain cases, a center support1700includes recessed elements1760elements between posts1720. The recessed elements1760between posts1720allow the posts1720to tilt relative to one another and the center support700to flex during use. In certain cases, one or more posts1720include a hole1770to reduce a vacuum when multiple center supports are stacked (e.g., during manufacture).

In some embodiments, a center support1700is placed on a bottom tray element (e.g., bottom tray element1110,1200,1510ofFIGS. 11, 12, and 15) when a beverage container packaging assembly is prepared for shipping. In some cases, the posts1720are placed on posts included in a bottom tray (e.g., posts114and/or platforms116of bottom tray110ofFIG. 3). During assembly a flat surface of each post1720contacts a flat surface of a post on the bottom tray (e.g., posts1230of bottom tray1200ofFIG. 12). The bottom tray1200may include eight posts1230to accommodate the eight internal posts1720of the center support1700.

FIG. 18depicts a beverage container packaging assembly according to various embodiments. In the example shown, a beverage container packaging assembly1800may include a bottom tray1810(e.g., bottom element), a top tray1820(e.g., a top element), a center support1830(e.g., partition element, center support element), and/or other components. The beverage container packaging assembly1800is configured to package a plurality of beverage containers1840for transit. The base of the beverage container1840sits in one of the cylindrical cup-shaped elements of the bottom tray1810. The center support1830separates the bottom tray1810and top tray1820. The top tray1820rests on the center support1830. The top of the beverage container1840is encapsulated in a rectangular cup-shaped element of the top tray1820. The center support1830prevents the sides of the beverage containers1840from contacting during shipping and provides spacing between the bottom tray1810and top tray1820. In certain cases, the center support1830may not be included in the beverage container packaging assembly1800.

FIG. 19depicts a bottom tray and center support of a beverage container packaging assembly according to various embodiments. In the example shown, a beverage container1940(e.g., wine bottle) is seated in a cup-shaped element1912of a lower tray1910. The cup-shaped element1912is shaped to retain the beverage container1940in a vertical configuration during transit. In the example shown, a center support1930includes multiple cardboard elements—two laterally arranged cardboard elements1932,1934and two transversely arranged cardboard elements1936,1938.

FIG. 20depicts a bottom tray of a beverage container packaging assembly according to some embodiments. As shown, a bottom tray2010includes a plurality of cup-shaped elements2012. The number of cup-shaped elements2012corresponds to a number of beverage containers the bottom tray2010is configured to accommodate. In the example shown, the bottom tray2010includes twelve cup-shaped elements2012—three (3) rows of four (4) cup-shaped elements2012—and the bottom tray2010is configured to accommodate 12 beverage containers.FIG. 20depicts one example configuration of cup-shaped elements. The present disclosure, however, is in no way limited to the depicted configuration of cup-shaped elements2012or number of cup-shaped elements2012.

In certain cases, the bottom tray2010includes posts2014configured to support the center support (not shown). Each of the posts2014may include guide elements2016(e.g., protrusions) that form one or more channels to accommodate panels of the center support (not shown).

FIG. 21depicts cup-shaped elements of a bottom tray according to various embodiments. In the example shown, a bottom tray2100(e.g., bottom tray2010ofFIG. 20) may include cup-shaped elements2110(e.g., cup shaped element1912,2012ofFIGS. 19, 20) that are cylindrical and/or substantially cylindrical. The cup-shaped element may include a bottom portion and multiple side walls forming a cup shape. In certain cases, the side walls may not be exactly vertical but may include draft to enable the bottom tray2100to be easily removed from a mold during fabrication.

Each of multiple cup-shaped elements2110includes a first deformable element2112(e.g., an hourglass shaped element, bow-tie shaped element), second deformable elements2116, vertical elements2118,2120,2122,2124, and other elements. The first deformable element2112may be raised (e.g., a protrusion) from the bottom surface of the cup-shaped element2110. The first deformable element2112may resemble an hourglass, bow tie, or other similar shape. The first deformable element2112is configured to absorb impact applied to a top of a beverage container (not shown). The first deformable element2112may be particularly effective in absorbing impact from a bottle with a convex bottom surface, such as a wine bottle. Wider portions2114of the hourglass shaped element2112are configured to contact the outer edges of the bottom of a bottle, such as a wine bottle. Thinner portions2113of the hourglass shaped element2112allow the element to deform (for example, by bending, crumpling, and/or otherwise deforming) when a load is applied to a beverage container housed in the bottom tray2100. The hourglass shaped element2112deforms to absorb load and reduce damage to a bottle, particularly when a load is applied down from the top on the bottle or when the assembly is dropped.

A cup-shaped element2110may include second deformable elements2116. The second deformable elements2116may resemble two adjacent mountain peaks. Similar to the first deformable element2112, the second deformable elements2116are configured to contact the outer edges of the bottom of a bottle, such as a wine bottle. When a load is applied to the top of the wine bottle, when the beverage container packaging is dropped, or when the bottle is otherwise subjected to a force, the second deformable elements2116are configured to absorb the load and/or energy of the load by, for example, crushing, buckling, and/or otherwise deforming.

In various embodiments, the cup-shaped element2110includes multiple vertical deformable elements2118,2120,2122. The vertical deformable elements2118,2120,2122contact the sides of a beverage container (not shown). In certain cases, first vertical elements2118, second vertical elements2120, and third vertical elements2122are configured to contact the outside of a bottle. The first vertical elements2118, second vertical elements2120, and third vertical elements2122may be sized, such that a bottle contacts all of the vertical elements2118,2120,2122when loaded into the cup-shaped element2110. The bottle (not shown) and vertical deformable elements2118,2120,2122may contact one another in an interference fit, such that a force is necessary to push the bottle into the cup-shaped element2110and a force is necessary to remove the bottle from the cup-shaped element2110. Securing the bottle in the cup-shaped element2110in such a manner ensures that the bottle is stationary during transit, thereby reducing any potential damage.

According to some embodiments, the cup-shaped element2110includes multiple thin deformable elements2124,2126. In certain cases, four thin deformable elements2124may extend from a center of the cup-shaped element up a side of the cup-shaped element2110. The four first deformable elements2124may include thin protrusions spaced roughly 90 degrees apart from one another. The thin deformable elements2124may collectively form an X-shape, with each thin deformable element2124extending from the center of the X along the bottom and up a side wall. In certain cases, a portion of a first deformable element2124extending along the wall of the cup-shaped element2110may extend further from the surface than a portion of the thin deformable element spanning the bottom of the cup-shaped element2110. In other words, the portion of the thin deformable element2124spanning the wall may be taller (higher) than the portion spanning the bottom of the cup-shaped element2110. In some embodiments, second thin deformable elements2126may be disposed between vertical elements2118. Similar to the vertical elements, thin deformable elements2124,2126are configured to absorb impact energy and/or loads applied to the sides of the bottle. The thin deformable elements2124,2126prevent damage to the bottom and sides of the bottle.

FIG. 22depicts a bottom tray of a beverage container packaging assembly according to various embodiments. A first cross-section A-A depicts a cross-section of the cup-shaped element2212of the bottom tray in a first direction. The first cross-section A-A is depicted inFIG. 23. A second cross section B-B depicts a cross-section of the cup-shaped element2212in a direction perpendicular to the first direction. The second cross-section B-B is depicted inFIG. 24.

FIG. 23depicts a first cross-section view of a cup-shaped element of a bottom tray according to various embodiments.FIG. 23includes a cross-section view along section A-A as shown inFIG. 22. In the example shown, the cross-section passes through the center of the hourglass shaped deformable element2312. The center of the hourglass shaped deformable element2312includes a thinner portion2313of the hourglass shaped deformable element2312. The wider portion2314of the hourglass shaped deformable element2312is shown in the background. The wider portion2314contacts the outer edges of the bottom of a beverage container. The second deformable elements2316also contact the outer edges of the bottom of the beverage container (not shown). First vertical elements2318contact the sides of the beverage container to retain the container in place. Thin deformable elements2324extend from the center of the cup-shaped element up the sides of the cup-shaped element. In certain cases, a thin deformable element2326may be disposed between the first vertical elements2316.

FIG. 24depicts a second cross-section view of a cup-shaped element of a bottom tray according to various embodiments.FIG. 24includes a cross-section view along section B-B as shown inFIG. 22. In the example shown, the cross-section passes through the center of the hourglass shaped deformable element2412. The thinner portions2413and wider portions2414of the hourglass shaped element2412are raised up from a bottom surface of the cup-shaped element2412. The wider portions of the hourglass shaped element2412contact a beverage container placed into the cup-shaped element2412. When a load is applied to a beverage container with a convex bottom (such as a wine bottle, beer bottle, etc.), the wider portions2414, which contact the bottom of the bottle, are configured to deform and absorb the energy of the load. The second deformable portion2416(shown in the background of the cross-section) is similarly configured to deform and absorb a load applied to a beverage container.

FIG. 25depicts a top tray of a beverage container packaging assembly according to some embodiments. In the example shown, a top tray2520includes rectangular cup-shaped elements2522, vertical posts2524, and/or other elements. The rectangular cup-shaped elements2522are configured to accommodate a neck of a beverage container, such as a wine bottle. The number of cup-shaped elements2522corresponds to a number of beverage containers the top tray2520is configured to accommodate. In the example shown, the top tray2520includes twelve rectangular cup-shaped elements2522—three (3) rows of four (4) cup-shaped elements2522—and the bottom tray is configured to accommodate twelve beverage containers.FIG. 25depicts one example configuration of rectangular cup-shaped elements, and the present disclosure is in no way limited to the depicted configuration.

FIG. 26depicts a top tray of a beverage container packaging assembly according to some embodiments. In the example shown, a top tray2620includes rectangular cup-shaped elements2622, vertical posts2624, and/or other elements. The rectangular cup-shaped elements2622include four walls forming roughly the shape of a rectangular enclosure. The vertical posts2624include vertical deformable elements2626(on each of the four surrounding vertical posts2624). A neck of bottle may, for example, be in contact with four vertical deformable elements2626. The vertical deformable elements2626in contact with the neck of the bottle restrain the bottle from movement during shipment. The vertical deformable elements2626may also absorb loads applied to a side of the bottle.

In various embodiments, a bottom portion of the rectangular cup-shaped element2622includes a cylindrical depression2628. The cylindrical depression2628may be sized to accommodate a top of a bottle (not shown) and to restrain the top of the bottle from movement during transit.

FIG. 27depicts a bottom tray and center support of a beverage container packaging assembly according to some embodiments. In the example shown, a center support2730rests on a lower tray2710(e.g., lower tray1810ofFIG. 18). The center support2730may be an alternative design relative to center support1830,1930ofFIGS. 18 and 19. The center support2730includes two cardboard elements2732,2734. The cardboard elements2732,2734may include corrugated cardboard or any other type of cardboard. The cardboard elements2732,2734may be L-shaped and/or include a bend. A first cardboard element2732may include cutouts (e.g., notches) that align with cutouts in the second cardboard element2734. When installed, the first cardboard element2732and second cardboard element2734may interlock to form a rectangular section2736. The rectangular section2736may span (e.g., surround, enclose) two securement chambers of the lower tray1810.

FIG. 28depicts a beverage container packaging assembly including a lower tray and center support according to some embodiments. In the example shown, a center support2830rests on a lower tray2810(e.g., lower tray1810ofFIG. 18). The center support2830may be an alternative design relative to center support1830,1930ofFIGS. 18 and 19and the center support2730ofFIG. 27. The center support2830includes two cardboard elements2832,2834. Each of the cardboard elements2832,2834includes two corrugated sections. In other words, the cardboard elements2832,2834include double-walled corrugated cardboard including two layers of corrugation. For example, the two layers of corrugation may resemble double-layered sandwich.

In various embodiments, the center support2830, the center support2730ofFIG. 27, center support1830ofFIG. 18, center support600ofFIG. 6, center support700ofFIG. 7, center support1300ofFIG. 13, center support1600ofFIG. 16, and center support1700ofFIG. 17include several example center support configurations contemplated by the present disclosure. In some embodiments (not shown), the center support may include triple-walled corrugated and/or any other number of stacked corrugated sections. Alternatively, the center support may include cardboard without any corrugation. For example, the center support may include a stack of multiple sheets of cardboard with no corrugation. The present disclosure, however, is not limited to these configurations and is intended to encompass a wide variety of center support designs.

In various embodiments, assembly of a beverage container packaging assembly2800is depicted. A lower tray2810may be placed into a container2850, such as a cardboard box, crate, and/or other container. A center support (e.g., center support600,700,1300,1600,1700,1830,2730,2830, and/or any other center support) is placed onto the lower tray2810. Beverage containers (not shown) are loaded into cup-shaped elements of the lower tray2810. An upper tray (not shown) is placed on the top of the center support. The container2850is sealed by, for example, closing the flaps of the box and/or applying tape. The container2850may be then be shipped to its recipient. And upon receipt, a recipient may perform the inverse (opposite) of these steps to unpack the beverage container packaging assembly2800.

In various embodiments, these and other steps to assemble and disassemble a container packaging assembly2800may be performed in other sequences to achieve similar results.