Bottle shipping system

Abstract

Disclosed are systems and methods for an improved bottle packaging system and shipping container, and more particularly to a container wherein a plurality of inserts are employed to stabilize the bottle(s) and to provide impact resistant cushioning during shipment of liquids and the like. For a 4-bottle (quad) pack embodiment the improved insert design includes a folding bottle separator or insert to receive and secure a bottle bottom, along with a top insert to receive and restrain a bottle shoulder and neck region (bottle top). The inserts, in combination with a two-layer cardboard box may be used to provide a re-usable and recyclable shipping container or package for chemicals and the like.

1 . A bottle packaging system, comprising:
 a carton having paper board panels defining a space, the panels meeting to define a plurality of interior corners; and   at least one folding insert, said folding insert including
 a bottom surface receiving a bottom of the bottle and supporting the bottle in a spaced-apart and padded relationship with respect to the bottom, sides and interior corners of the carton, 
 a plurality of ribbed sides receiving and contacting the outer diameter of the sides of the bottle and supporting the bottle in a spaced-apart and padded relationship with at least the sides of the carton, and 
 a top insert for maintaining the position of the bottle neck and cap in relation to the carton. 
   
     
     
         2 . The packaging system according to  claim 1 , wherein said carton is of a generally rectangular cross section. 
     
     
         3 . The packaging system of  claim 2 , wherein said carton holds multiple bottles therein and where the plurality of ribbed sides support the bottles in a spaced-apart and padded relationship with one another. 
     
     
         4 . The packaging system according to  claim 1  wherein said folding and top inserts are made of a recyclable material selected from the group consisting of: cellulose, paper pulp, sugar cane, palm waste, and expanded starches. 
     
     
         5 . The packaging system according to  claim 1  wherein said inserts are made from re-cycled fibrous material consisting of recycled paper products. 
     
     
         6 . The packaging system according to  claim 1 , wherein said folding inserts each define at least a portion of a cell for receiving a bottle, said cell comprising a plurality of ribbed walls providing a spacing between the adjacent carton walls and other bottles in the carton. 
     
     
         7 . The packaging system according to  claim 1 , wherein said folding inserts include a base portion for contact with and support for the bottom of a bottle placed therein. 
     
     
         8 . The packaging system according to  claim 7 , wherein said folding inserts further include a plurality of reinforced tabs on the face of at least two sections folded into alignment with one another, said tabs providing reinforcement to the base to protect the bottle. 
     
     
         9 . The packaging system according to  claim 7 , wherein said folding inserts further include a plurality of reinforced portions on a rear surface of at least one of the sections, said reinforced portions aligning with similar structure on an adjacent insert in said carton to prevent contact between bottle sides. 
     
     
         10 . A folding packaging insert to protect fragile cylindrical items in a carton, comprising:
 a bottom surface receiving a bottom of the bottle and supporting the bottle in a spaced-apart and padded relationship with the bottom, sides and interior corners of the carton, and   a plurality of ribbed sides receiving and contacting the outer diameter of the sides of a bottle and supporting the bottle in a spaced-apart and padded relationship with the sides, other bottles (if present) and interior corners of the carton.   
     
     
         11 . The A folding packaging insert according to  claim 10 , wherein said folding inserts each define at least a portion of a cell for receiving a bottle, said cell comprising a plurality of ribbed walls providing a spacing between the adjacent carton walls and other bottles in the carton. 
     
     
         12 . A method for packaging a plurality of bottles, comprising:
 folding and positioning at least two folding inserts, having at least one bottle-receiving cell therein, within a carton;   inserting the bottles into the carton such that the bottoms and sides thereof are in contact with the folding inserts and at least a portion of the bottle necks extend above the inserts;   placing a top insert within the top of the carton, fitting over the necks of the bottles, to secure the bottles in the carton.   
     
     
         13 . The method according to  claim 12  wherein each of said folding inserts are of a common design. 
     
     
         14 . The method according to  claim 12 , further including producing each of said inserts using a slurry molding process. 
     
     
         15 . The method according to  claim 14 , wherein said folding and top inserts are produced using a fibrous material deposited on a mold. 
     
     
         16 . The method according to  claim 12 , wherein said folding and top inserts are produced using a fibrous material.