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

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 ...

AI Technical Summary

Benefits of technology

[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.

Problems solved by technology

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.

However, the pulp of the preferred embodiment provides a much smaller environmental footprint than these other materials.

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