Molded fiber packaging system for toilets

Abstract

A molded fiber packaging system for a toilet includes a first molded fiber tray comprising a toilet bowl cavity molded to receive a top portion of a toilet bowl, a first outer edge comprising an overhang that is configured to extend over a nose of the toilet bowl along an outer surface of the bowl toward a base of the bowl, a first tank cavity molded to fit a back portion of a toilet tank, a first tank lid cavity molded to fit a back edge of a toilet tank lid, and one or more protrusions positioned between the first toilet tank cavity from the first lid cavity. The system includes a second molded fiber tray comprising a second tank cavity molded to fit a front portion of the toilet tank and a second lid cavity molded to fit a front edge of the toilet tank lid.

1 . A molded fiber packaging system for a toilet, the system comprising:
 a first molded fiber tray comprising:
 a toilet bowl cavity rounded in shape and molded to receive a top portion of a toilet bowl, 
 a first outer edge comprising an overhang that is configured to extend over a nose of the toilet bowl along an outer surface of the toilet bowl toward a base of the toilet bowl, 
 a first toilet tank cavity rectangular in shape and molded to fit a back portion of a toilet tank, 
 a first toilet tank lid cavity rectangular in shape and molded to fit a back edge of a toilet tank lid, and 
 one or more protrusions positioned between the first toilet tank cavity from the first toilet lid cavity; and 
   a second molded fiber tray comprising:
 a second toilet tank cavity rectangular in shape and molded to fit a front portion of the toilet tank, and 
 a second toilet lid cavity rectangular in shape and molded to fit a front edge of the toilet tank lid. 
   
     
     
         2 . The system of  claim 1 , wherein the toilet bowl cavity is formed in a first surface of the first molded fiber tray and the first toilet tank cavity and the first toilet tank lid cavity are formed in a second surface of the first molded fiber tray that is opposite to the first surface. 
     
     
         3 . The system of  claim 2 , wherein the first surface of the first molded fiber tray comprises one or more ribs disposed between the toilet bowl cavity and a second outer edge that is opposite the first outer edge. 
     
     
         4 . The system of  claim 1 , wherein the first toilet tank cavity comprises one or more cushioning bumps that protrude upward from a bottom surface of the toilet tank cavity. 
     
     
         5 . The system of  claim 4 , wherein the one or more cushioning bumps comprise at least five cushioning bumps. 
     
     
         6 . The system of  claim 1 , wherein the first toilet tank lid cavity comprises one or more cushioning bumps that protrude upward from a bottom surface of the toilet lid cavity. 
     
     
         7 . The system of  claim 6 , wherein the one or more cushioning bumps comprises at least three cushioning bumps. 
     
     
         8 . The system of  claim 1 , wherein the one or more protrusions positioned between the first toilet tank cavity from the first toilet lid cavity comprise at least three protrusions. 
     
     
         9 . The system of  claim 1 , wherein the second molded fiber tray comprises one or more protrusions positioned between the second toilet tank cavity from the second toilet tank lid cavity. 
     
     
         10 . The system of  claim 9 , wherein the one or more protrusions positioned between the second toilet tank cavity from the second toilet tank lid cavity comprise at least three protrusions. 
     
     
         11 . The system of  claim 1 , wherein the second toilet tank cavity comprises at least one flush lever cavity. 
     
     
         12 . The system of  claim 11 , wherein the at least one flush lever cavity is configured to surround but not come into contact with a flush lever on the front surface of the toilet tank when the toilet tank is positioned within the second toilet tank cavity. 
     
     
         13 . The system of  claim 11 , wherein the second toilet tank cavity comprises two flush lever cavities. 
     
     
         14 . The system of  claim 1 , wherein the first molded fiber tray comprises a hardware cavity configured to contain one or more boxes of toilet hardware. 
     
     
         15 . The system of  claim 1 , wherein the overhang extends over the nose of the toilet bowl by at least 5 mm. 
     
     
         16 . The system of  claim 1 , wherein the overhang is at least 3 mm thick at its thickest point. 
     
     
         17 . The system of  claim 1 , wherein the first molded fiber tray comprises one or more strap channels configured to receive one or more straps for securing the first molded fiber tray to the second molded fiber tray. 
     
     
         18 . The system of  claim 17 , wherein the one or more strap channels comprise two strap channels. 
     
     
         19 . A molded fiber packaging system for a toilet, the system comprising:
 a first molded fiber tray comprising:
 a toilet bowl cavity rounded in shape and molded to fit a top portion of a toilet bowl, 
 a first outer edge comprising an overhang that is configured to extend over a nose of the toilet bowl along an outer surface of the toilet bowl toward a base of the toilet bowl, 
 a first toilet tank cavity rectangular in shape and molded to fit a back portion of a toilet tank, 
 a first toilet tank lid cavity rectangular in shape and molded to fit a back edge of a toilet tank lid; and 
   a second molded fiber tray comprising:
 a second toilet tank cavity rectangular in shape and molded to fit a front portion of the toilet tank, and 
 a second toilet lid cavity rectangular in shape and molded to fit a front edge of the toilet tank lid. 
   
     
     
         20 . A molded fiber packaging system for a toilet, the system comprising:
 a first molded fiber tray comprising:
 a toilet bowl cavity rounded in shape and molded to fit a top portion of a toilet bowl, 
 a first toilet tank cavity rectangular in shape and molded to fit a back portion of a toilet tank, 
 a first toilet tank lid cavity rectangular in shape and molded to fit a back edge of a toilet tank lid, and 
 one or more protrusions positioned between the first toilet tank cavity from the first toilet lid cavity; and 
   a second molded fiber tray comprising:
 a second toilet tank cavity rectangular in shape and molded to fit a front portion of the toilet tank, and 
 a second toilet lid cavity rectangular in shape and molded to fit a front edge of the toilet tank lid.