Packaging System and Method for Flatware and the Like

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

FIELD OF THE INVENTION

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

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's flatware set. However, since the cost of flatware was high, few families replaced entire sets until or unless it became absolutely necessary.

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.

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.

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.

Currently, flatware sets are packaged in boxes that typically include a display window through which one of each of the set'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.

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.

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.

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.

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

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.

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.

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.

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.

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

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:

FIG. 1 is an exploded isometric illustration of one embodiment of the packaging system and method of the present invention;

FIG. 2 is an illustration of an embodiment of an insert tray constructed in accordance with the teaching of embodiments in the present invention;

FIG. 3 is a side view illustration of the insert tray of FIG. 2;

FIG. 4 is a bottom view illustration of the insert tray of FIG. 2;

FIG. 5 is an end view illustration of an alternate embodiment of the packaging system of the present invention;

FIG. 6 is a top view illustration of the embodiment of FIG. 5;

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;

FIG. 8 is an isometric illustration of the retainer structure used with the embodiment illustrated in FIG. 5;

FIG. 9 is a top view illustration of the insert tray of the embodiment of FIG. 5;

FIG. 10 is an end view illustration of the insert tray of FIG. 9; and

FIG. 11 is a side view illustration of the insert tray of FIG. 9.

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

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.

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.

The insert tray 106 houses the individual pieces 112A-112D 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.

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.

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.

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 122A, 122B, and one vertical retainer receiving slot 122C as viewed in the orientation of this figure. The multiple retainer receiving slots 122A-122C 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.

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 118C 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.

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.

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 128A, 128B are not received in nesting receiving locations, but instead are received in the retainer receiving slots 122A, 122B respectively, when stacked one on top of the other.

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.

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.

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 132A, the back surface 134, the other side surface 132B 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.

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.

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.

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.

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.

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.

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.

Claims

1. A packaging system comprising: an insert tray including a pair of end walls, at least two sidewalls longitudinally between the end walls and extending between a top surface of the insert tray and a bottom surface defining at least one receiving location, the insert tray including at least one retainer receiving slot oriented across at least one receiving location, the at least one retainer receiving slot defined by a plurality of recesses extending from the top surface towards the bottom surface, individual recesses being formed in one of the end walls or sidewalls; anda retainer including, at least, a retention member receivable in the at least one retainer receiving slot, the retention member extending across the at least one receiving location when received in the at least one receiving slot, forming a gap between a bottom surface of the retention member and the bottom surface of the at least one receiving location.

2. The packaging system of claim 1, further comprising a box sized to receive the insert tray while the retention member is received in the at least one retainer receiving slot, the box maintaining the retention member in the retainer receiving slot.

3. The packaging system of claim 1, wherein the retainer further includes a planar portion that extends across at least a portion of the top surface of the insert tray while the retention member is received in the retainer receiving slot.

4. The packaging system of claim 3, wherein: the retainer includes a second retention member spaced apart from the first retention member, the planar portion being interposed between and connecting the first and second retention members; andthe insert tray includes a second retainer receiving slot extending across at least one receiving location, the first and second retainer receiving slots spaced apart and each of the first and second retainer receiving slots sized to receive at least one of the first and second retention members.

5. The packaging system of claim 1, wherein the at least one retainer receiving slot is provided by a plurality of generally aligned recesses in adjacent ones of the plurality of sidewalls, the receiving slot extending in a first direction being generally transverse to the longitudinally extending direction of the sidewalls.

6. The packaging system of claim 5, wherein a plurality of the sidewalls include indentations extending in the first direction forming stacking guides, the stacking guides aligned longitudinally along the sidewalls proximate the recesses forming the at least one retainer receiving slot, the stacking guides receivable in recesses of another insert tray when stacked thereon.

7. The packaging system of claim 5, wherein one of the at least one retainer receiving slot is provided by a pair of recesses with one recess formed in each end wall, the retainer receiving slots formed by recesses in the sidewalls extending generally transverse to the retainer receiving slot formed by recesses in the end walls; andthe insert tray includes a plurality of receiving locations, individual ones of the receiving locations being formed between the end walls and adjacent sidewalls, the plurality of receiving locations includes at least three receiving locations, each receiving location being elongated, the perimeter of one of the receiving locations is spoon shaped including an elongated handle portion connected to a contoured head portion, the perimeter of one of the receiving locations is generally fork shaped including an elongated handle portion connected to a first side of a contoured head portion, the head portion having a generally flat second side opposite the first side, and the perimeter of another one of the receiving locations is substantially rectangular.

8. The packaging system of claim 1, wherein one of the at least one retainer receiving slot is provided by a pair of recesses with one recess formed in each end wall.

9. The packaging system of claim 1, wherein the top surface includes a plurality of indentations forming a plurality of nesting receiving locations when viewed from a top side of the insert tray, the indentations forming a plurality of nesting keys being negatives, generally, of the nesting receiving locations when viewed from a bottom side of the insert tray, the indentations configured such that the nesting receiving locations may receive corresponding nesting keys of another insert tray when stacked thereon.

10. The packaging system of claim 1, wherein the bottom surface of at least one receiving location includes at least one support hump, the support hump extending toward the top surface.

11. The packaging system of claim 1, wherein: the insert tray is substantially prism shaped generally including a top, a bottom, and four sides extending between the top and bottom, defining a generally rectangular cross-sectional outer periphery defined by the top, bottom and two opposed sides of the four sides;the retainer includes a plurality of surfaces including a back surface, an upper surface, and a pair of spaced apart side surfaces extending between the back surface and upper surface, the plurality of surfaces defining a substantially rectangular opening closely sized to the outer periphery of the insert tray in a closed orientation, the retainer connected to the top surface and extending into the rectangular opening from the top surface; andin the closed orientation the retainer may be mounted to the insert tray to substantially surround the rectangular cross-sectional outer periphery with the retention member of the retainer received in the retainer receiving slot.

12. The packaging system of claim 1, wherein the insert tray includes a plurality of receiving locations, individual ones of the receiving locations being formed between the end walls and adjacent sidewalls.

13. The packaging system of claim 12, wherein the plurality of receiving locations includes at least three receiving locations, each receiving location being elongated, the perimeter of one of the receiving locations is spoon shaped including an elongated handle portion connected to a contoured head portion, the perimeter of one of the receiving locations is generally fork shaped including an elongated handle portion connected to a first side of a contoured head portion, the head portion having a generally flat second side opposite the first side, and the periphery of one of the receiving locations is substantially rectangular.

14. The packaging system of claim 1, wherein the insert tray is made of pulp.

15. The packaging system of claim 14, wherein the pulp includes recycled material.

16. A method of forming a packaging system comprising: forming an insert tray from pulp including recycled material, the insert tray having a plurality of receiving locations and at least one retainer receiving slot extending across the plurality of receiving locations;forming a retainer including at least a retention member sized to insert into the retainer receiving slot;providing a box having an internal cavity closely sized to an outer periphery of the combination of the insert tray with the retainer such that the combination may be received in the box.

17. A method of packaging flatware including: inserting a plurality of flatware pieces into a receiving location of an insert tray;securing the flatware pieces within the receiving location with a retainer; andinserting the flatware pieces, insert tray and retainer into a box.

18. The method of claim 17, wherein securing the flatware pieces includes inserting a retention member of the retainer into a retainer receiving slot of the insert tray such that the retention member extends across at least one receiving location and secures a plurality of flatware pieces between a bottom surface of the receiving location and the retention member.

19. The method of claim 18, further including maintaining the retention member within the at least one retainer receiving slot with the box.

20. The method of claim 18, wherein securing the flatware pieces within the receiving location with the retainer further includes wrapping the retainer around a top, bottom, and two opposed sides of the insert tray.