Molded Fiber Packaging System for Toilets

This application claims the benefit of U.S. Provisional Application No. 63/656,735, filed Jun. 6, 2024, the entire contents of which are incorporated herein by reference.

The present disclosure relates generally to packaging for toilets, in particular to molded fiber packaging for toilets.

Molded fiber packaging formed from fibrous material such as recycled paper is a cheap, sustainable alternative to other types of packaging such as Styrofoam packaging. Typically, molded fiber packaging for an object can be manufactured by forming fiber pieces (e.g., fiber trays) to the shape of the object. In the case of a toilet, however, simple fiber molds of the major components of the toilet (the bowl, the tank, etc.) fail to adequately cushion fragile regions of the toilet and frequently include multiple weak areas that prevent the toilet from being packed in a space-efficient manner.

Described is a molded fiber packaging system for a toilet that includes cushioning for the toilet's fragile regions and reinforcements in areas subject to large forces. The provided molded fiber packaging system may allow the toilet to be packed in a space-efficient manner and can be used with multiple distinct toilet designs.

The molded fiber packaging system disclosed herein may include a first molded fiber tray and a second molded fiber tray. The first molded fiber tray may be configured to protect a top surface of a toilet bowl as well as to contain a toilet tank and a toilet tank lid. A front edge of the first molded fiber tray may be equipped with an overhang that can the delicate “nose” portion of a toilet bowl from damage. The second molded fiber tray may be configured to protect a front surface of a toilet tank and a front edge of a toilet tank lid. In particular, the second molded fiber tray may be configured to shield a flush lever on the toilet tank from contact with other components of the toilet and from the packaging.

In some embodiments, a molded fiber packaging system for a toilet comprises a first molded fiber tray and a second molded fiber tray. The first molded fiber tray can include 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. The second molded fiber tray can include 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.

The toilet bowl cavity may be formed in a first surface of the first molded fiber tray and the first toilet tank cavity and the first toilet tank lid cavity may be formed in a second surface of the first molded fiber tray that is opposite to the first surface. The first surface of the first molded fiber tray can include one or more ribs disposed between the toilet bowl cavity and a second outer edge that is opposite the first outer edge.

The first toilet tank cavity can include one or more cushioning bumps that protrude upward from a bottom surface of the toilet tank cavity. In some embodiments, the first toilet tank cavity includes at least five cushioning bumps. The first toilet tank lid cavity can include one or more cushioning bumps that protrude upward from a bottom surface of the toilet lid cavity. In some embodiments, the first toilet tank lid cavity includes at least three cushioning bumps.

The one or more protrusions positioned between the first toilet tank cavity from the first toilet lid cavity can include at least three protrusions. The second molded fiber tray can include one or more protrusions positioned between the second toilet tank cavity from the second toilet tank lid cavity. The one or more protrusions positioned between the second toilet tank cavity from the second toilet tank lid cavity can include at least three protrusions.

The second toilet tank cavity can include at least one flush lever cavity. The at least one flush lever cavity may be 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. In some embodiments, the second toilet tank cavity includes two flush lever cavities.

The first molded fiber tray can include a hardware cavity configured to contain one or more boxes of toilet hardware.

The overhang may extend over the nose of the toilet bowl by at least 5 mm. The overhang may be at least 3 mm thick at its thickest point.

The first molded fiber tray can include 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. In some embodiments, the first molded fiber tray includes two strap channels.

In other embodiments, a molded fiber packaging system for a toilet comprises 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.

In other embodiments, a molded fiber packaging system for a toilet comprises 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.

Provided herein is a molded fiber packaging system for a toilet that includes cushioning for the toilet's fragile regions (including, e.g., the front “nose” portion of the toilet bowl) and reinforcements in areas subject to large forces. Cushioning for the toilet's fragile regions is provided, as described herein, by various specific geometric features of the molded fiber trays that form the overall packaging system. The described molded fiber packaging system may allow the toilet to be packed in a space-efficient manner and can be used with multiple distinct toilet designs, while providing adequate cushioning for safe storage and transportation and maintaining a low cost of manufacture for the packaging.

Any of the systems, methods, techniques, and/or features disclosed herein may be combined, in whole or in part, with any other systems, methods, techniques, and/or features disclosed herein.

As used herein, the singular forms “a”, “an”, and “the” include the plural reference unless the context clearly dictates otherwise.

Reference to “about” or “approximately” a value or parameter herein includes (and describes) variations of that value or parameter per se. For example, description referring to “approximately X” or “about X” includes description of “X” as well as variations of “X”.

When a range of values or values is provided, it is to be understood that each intervening value between the upper and lower limit of that range, and any other stated or intervening value in that stated range, is encompassed within the scope of the present disclosure. Where the stated range includes upper or lower limits, ranges excluding either of those included limits are also included in the present disclosure.

Exemplary toilets that may be packaged using the provided molded fiber packaging systems are shown in. A toilet may include a toilet bowland a toilet tank, which may be detachable from one another for shipping/storage and may be attached to one another (in the assembled position shown in) when assembled. The noseof toilet bowlmay be a portion of toilet bowl that is distal from toilet tank. As used herein, the term “toilet bowl” may be used to refer to the monolithic toilet component comprising the basin portion of the bowl, the pedestal portion that supports the basin portion of the bowl, and the trapway assembly portion located behind the pedestal portion and configured for assembly beneath a toilet tank. The baseof toilet bowlmay be a surface of toilet bowlthat mounts to a floor (e.g., a bathroom floor) when the toilet is installed. The top surfaceof toilet bowlmay be a surface of toilet bowlthat includes the opening to the bowl. A toilet bowl lidmay be configured to cover a toilet seat, and the toilet seatmay be configured to cover top surfaceof toilet bowlas shown inand. Toilet tankmay have a front surfaceand a back surface. The front surfaceof toilet tankmay be approximately normal to a direction in which the noseof toilet bowlpoints when the toilet is fully assembled. The back surfaceof toilet tankmay face in the opposite direction as the noseof toilet bowlwhen the toilet is fully assembled. Toilet tankmay be covered by a toilet tank lid, which may have a front edgethat faces the same direction as the front surfaceof toilet tankand a back edgethat faces the same direction as the back surfaceof toilet tankwhen the toilet is fully assembled.

show perspective views of a toilet being packed using a molded fiber packaging system. A first molded fiber traymay be placed on the top surface (e.g., top surfaceshown in) of toilet bowl. Toilet tankand toilet tank lidmay then be placed within appropriate cavities in first molded fiber tray. To ensure the toilet is packed compactly and to minimize risk of breakage, tankmay be laid on its back surface (e.g., back surfaceshown in) and toilet tank lidmay be laid on its back edge (e.g., back edgeshown in). A second molded fiber traymay be fitted over the front surface (e.g., front surfaceshown in) of toilet tankand the front edge (e.g., front edgeshown in) of toilet tank lid. The toilet bowl lidmay be packaged alongside toilet bowl, and toilet tank lidmay be supported by the first molded fiber trayand the second molded fiber trayas shown in. The toilet and the molded fiber trays, arranged in the packaged arrangement described above, may be placed in a box (e.g., a cardboard box of a suitable size) for storage and/or shipping.

In some embodiments, a third molded fiber tray may be provided beneath the toilet bowl base. This third molded fiber tray may support the toilet bowl baseand/or the laterally positioned toilet bowl lid. In some embodiments, the first, second, and/or third molded fiber trays may be made from a material including recycled corrugate carton fibers and recycled newspaper. The fiber tray material may include 70-90% carton fibers and 10%-30% recycled newspaper. In some embodiments, the fiber tray material may include less than or equal to 72%, 74%, 76%, 78%, 80%, 82%, 84%, 86%, 88%, or 90% carton fibers. In some embodiments, the fiber tray material may include greater than or equal to 70%, 72%, 74%, 76%, 78%, 80%, 82%, 84%, 86%, or 88% carton fibers. In some embodiments, the fiber tray material may include 70-75% carton fibers, 75-80% carton fibers, 80-85% carton fibers, or 85-90% carton fibers. In some embodiments, the fiber tray material may include less than or equal to 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, or 30% recycled newspaper. In some embodiments, the fiber tray material may include greater than or equal to 10%, 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, or 28% recycled newspaper. In some embodiments, the fiber tray material may include 10-15% recycled newspaper, 15-20% recycled newspaper, 20-25% recycled newspaper, or 25-30% recycled newspaper. In some embodiments, the walls making up the first, second, and/or third molded fiber trays may have a thickness of 2.5 mm-3.5 mm, or approximately 3 mm.

provide diagrams of various surfaces and edges of an exemplary first molded fiber tray. As shown in, first molded fiber traymay be configured to protect a top surface of a toilet bowl and to contain a toilet tank and a toilet tank lid. Accordingly, a bottom surfaceof first molded fiber traymay include a toilet bowl cavitythat is molded to the shape of a top surface of a toilet bowl (e.g., top surfaceof toilet bowlshown in). Bottom surfacemay also include a toilet bowl lid cavitythat is configured to receive an edge portion of a toilet bowl lid (e.g., toilet bowl lidshown in) when the toilet bowl lid is placed alongside the toilet bowl as shown in. A top surfaceof first molded fiber traymay include a toilet tank cavitythat is molded to the shape of a back surface of a toilet tank (e.g., back surfaceof toilet tankshown in) and a toilet tank lid cavitythat is molded to the shape of a back edge of a toilet tank lid (e.g., back edgeof toilet tank lidshown in). The packing arrangement of the toilet tankin the toilet tank cavityand the toilet tank lidin the toilet tank lid cavityis shown in.

When first molded fiber trayis used to package a toilet, traymay be oriented such that a front edgeof trayis proximal to a nose of the toilet bowl (e.g., noseof toilet bowlshown in) and a rear edgeof trayis distal from the nose of the toilet bowl. Side edgesof first molded fiber traymay be oriented approximately parallel to the sides of the toilet bowl. In this orientation, the top surface of the toilet bowl may be inserted into toilet bowl cavityin bottom surface. Once toilet bowl cavityis fitted over the top surface of the toilet bowl, the toilet tank may be placed on its back surface within toilet tank cavityand the toilet tank lid may be placed on its back edge within toilet tank lid cavity.

Top surfaceof first molded fiber traymay include one or more protrusionsbetween toilet tank cavityand toilet tank lid cavitythat are configured to prevent the collisions between the toilet tank lid and the toilet tank during packing and/or movement of the toilet. In some embodiments, top surfaceincludes between two and ten protrusions, between 3 and 9 protrusions, between four and eight protrusions, or between five and seven protrusions. In other embodiments, top surfaceincludes at least 11 protrusions. Protrusionscan be cylindrical, pyramidal, or prism-shaped (e.g., rectangular prism-shaped, trapezoidal prism-shaped, etc.). In some embodiments, each protrusionhas the same shape; in other embodiments, protrusionsinclude at least two protrusions having different shapes.

A plurality of cushioning bumpsmay be provided within toilet tank cavityof the first molded fiber tray, as shown in. Cushioning bumpsmay prevent first molded fiber trayfrom bending or otherwise deforming when a toilet tank is placed within tank cavity. Additionally, cushioning bumpsmay protect the back surface of the toilet tank and the top surface of the toilet bowl from damage by absorbing forces resulting from movement (e.g., bouncing) of the toilet tank in toilet tank cavity. Cushioning bumpsmay have a height that is less than the height of tank cavity, such that they do not extend above the top of tank cavity.

In some embodiments, toilet tank cavityincludes at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 cushioning bumps. A cushioning bump may protrude from the surface of toilet tank cavityby between 2 and 20 mm, between 3 and 18 mm, between 4 and 17 mm, between 5 and 16 mm, between 6 and 15 mm, between 7 and 14 mm, between 8 and 13 mm, between 9 and 12 mm, or between 10 and 11 mm. For example, a cushioning bump may protrude from the surface of toilet tank cavityby about 10 mm, about 10.5 mm, about 11 mm, about 11.5 mm, about 12 mm, or about 12.5 mm. In some embodiments, each cushioning bump has the same shape and/or the same orientation relative to the other cushioning bumps. In other embodiments, one or more cushioning bumps may have different shapes or different relative orientations. Perspective and close-up views of example cushioning bumpsin a toilet tank cavityof a molded fiber trayare shown in.

Tank lid cavitymay include a plurality of cushioning bumps. Just as cushioning bumpsmay prevent first molded fiber trayfrom bending or otherwise deforming when a toilet tank is placed within tank cavity, cushioning bumpsin tank lid cavitymay prevent first molded fiber trayfrom bending or otherwise deforming when a toilet tank lid is placed within tank lid cavity. Cushioning bumpsmay also protect the back edge of the toilet tank lid and the top surface of the toilet bowl from damage by absorbing forces resulting from movement (e.g., bouncing) of the toilet tank lid in toilet tank lid cavity. Cushioning bumpsmay have a height that is less than the height of tank lid cavity, such that they do not extend above the top of tank lid cavity.

In some embodiments, toilet tank lid cavityincludes at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 cushioning bumps. A cushioning bump may protrude from the surface of toilet tank lid cavityby between 2 and 20 mm, between 3 and 18 mm, between 4 and 17 mm, between 5 and 16 mm, between 6 and 15 mm, between 7 and 14 mm, between 8 and 13 mm, between 9 and 12 mm, or between 10 and 11 mm. For example, a cushioning bump may protrude from the surface of toilet tank lid cavityby about 10 mm, about 10.5 mm, about 11 mm, about 11.5 mm, about 12 mm, or about 12.5 mm. In some embodiments, each cushioning bump has the same shape and/or the same orientation relative to the other cushioning bumps. For instance,illustrate rib-shaped cushioning bumps, cushioning ribsin the toilet tank lid cavity, that all have the same orientation. In other embodiments, one or more cushioning bumps may have different shapes or different relative orientations.

Bottom surfaceof first molded fiber traycan include one or more ribsconfigured to prevent trayfrom deforming and/or bending in the region proximal to rear edge, where additional rigidity for traymay be needed on portions of the tray that are not directly adjacent to toilet tankwhen packed. In some embodiments, bottom surfaceincludes at least 2, at least 3, at least 4, or at least 5 ribs. Each rib may have the same geometrical configuration. For instance, tray strengthening ribs, shown in, have the same geometrical configuration. Alternatively, one or more ribs may have different geometrical configurations.provide a perspective view of ribs,in a bottom surfaceof a first molded fiber tray, whileprovides a close-up view of ribs.

As previously described, front edgeof first molded fiber traymay be oriented proximal to the nose of the toilet bowl when first molded fiber trayis used to package a toilet. To protect the nose of the toilet bowl from damage (as the nose may be particularly susceptible to breakage from impact during shipping), front edgemay include an overhangthat is configured to extend over the nose of the toilet bowl toward the base of the toilet bowl along the outer surface of the toilet bowl. Nose overhangmay be, e.g., pyramidal or prism shaped, for example rectangular-prism-shaped or trapezoidal-prism-shaped. In some embodiments, nose overhangmay extend over the nose of the toilet bowl by at least 5 mm, at least 10 mm, at least 15 mm, at least 20 mm, at least 25 mm, or at least 30 mm. Nose overhangmay be at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at least 10 mm thick at its thickest point. In some embodiments, front edgeof first molded fiber trayincludes multiple nose overhangs, for example two, three, four, or five or more nose overhangs.provide perspective and close-up views, respectively of a nose overhangon a front edgeof an example molded fiber tray.

In some embodiments, top surfaceof first molded fiber trayincludes a hardware cavity. Hardware cavitymay be configured to receive one or more boxes containing hardware such as wax rings and fasteners for the toilet. Hardware cavitymay be a square cavity with edge lengths between 50 and 300 mm, between 75 and 275 mm, between 100 and 250 mm, between 125 and 225 mm, or between 150 and 200 mm. For example, hardware cavitymay be a square cavity with edge lengths of about 140 mm, 145 mm, 150 mm, 155 mm, or 160 mm. Hardware cavitymay have a maximum depth between 40 and 220 mm, between 50 and 210 mm, between 60 and 200 mm, between 70 and 180 mm, between 60 and 170 mm, between 70 and 160 mm, between 80 and 150 mm, between 90 and 140 mm, or between 100 and 140 mm. For instance, hardware cavitymay have a maximum depth of about 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or 80 mm.shows an exemplary hardware boxthat may be contained by hardware cavity;show hardware box(es)inserted into a hardware cavityin a first molded fiber tray.

Turning to the second molded fiber tray,provide diagrams of various surfaces and edges of an exemplary second molded fiber tray. As shown in, second molded fiber traymay be configured to protect a front surface of a toilet tank and a front edge of a toilet tank lid. Accordingly, a bottom surfaceof second molded fiber traymay include a toilet tank cavitythat is molded to the shape of a front surface of a toilet tank (e.g., front surfaceof toilet tankshown in) and a toilet tank lid cavitythat is molded to a front edge of a toilet tank lid (e.g., front edgeof toilet tank lidshown in).

When second molded fiber trayis used to package a toilet, traymay be oriented such that a front edgeof trayis proximal to a nose of the toilet bowl (e.g., noseof toilet bowlshown in) and a rear edgeof trayis distal from the nose of the toilet bowl. That is, front edgemay be aligned with front edgeof first molded fiber trayand rear edgemay be aligned with rear edgeof first molded fiber tray. Side edgesof second molded fiber traymay be oriented approximately parallel to the sides of the toilet bowl. In this orientation, second molded fiber traymay be placed over a toilet tank and a toilet tank lid that have been placed in a first molded fiber traysuch that a front surface of the toilet tank is inserted into toilet tank cavityand a front edge of the toilet tank lid is inserted into toilet tank lid cavity.

Bottom surfaceof second molded fiber traymay include one or more protrusionsbetween toilet tank cavityand toilet tank lid cavitythat are configured to prevent the collisions between the toilet tank lid and the toilet tank when in the packaged arrangement. In some embodiments, bottom surfaceincludes between 2 and 10 protrusions, between 3 and 9 protrusions, between 4 and 8 protrusions, or between 5 and 7 protrusions. In other embodiments, bottom surfaceincludes at least 11 protrusions. Protrusionscan be cylindrical, pyramidal, or prism-shaped (e.g., rectangular-prism-shaped, trapezoidal-prism-shaped, etc.). In some embodiments, each protrusionhas the same shape; in other embodiments, protrusionsinclude at least two protrusions having different shapes. Examples of protrusions(which may be the same as or include similar aspects as described with respect to protrusions) that are configured to prevent collisions between the toilet tank cavity and toilet tank lid cavity are shown in.

The front surface of a toilet tank may include a flush lever for flushing the toilet. Toilet tank cavitymay include at least one flush lever cavityconfigured to encase a flush lever. Flush lever cavitymay be configured to surround but not make contact with the flush lever. In some embodiments, toilet tank cavityincludes a pair of flush lever cavities, as shown in. This may allow second molded fiber trayto be used with toilets that include a flush lever on a left side of the front surface of the toilet tank, as shown with flush leverin, and with toilets that include a flush lever on a right side of the front surface of the toilet tank.

In some embodiments, bottom surfaceof second molded fiber trayincludes a hardware cavity. Hardware cavitymay be correspond to hardware cavityin top surfaceof first molded fiber trayand may be configured to contain one or more hardware boxescontaining hardware such as wax rings and fasteners for the toilet, as shown in. Hardware cavitymay be a square cavity with edge lengths between 50 and 300 mm, between 75 and 275 mm, between 100 and 250 mm, between 125 and 225 mm, or between 150 and 200 mm. For example, hardware cavitymay be a square cavity with edge lengths of about 140 mm, 145 mm, 150 mm, 155 mm, or 160 mm. Hardware cavitymay have a maximum depth between 40 and 220 mm, between 50 and 210 mm, between 60 and 200 mm, between 70 and 180 mm, between 60 and 170 mm, between 70 and 160 mm, between 80 and 150 mm, between 90 and 140 mm, or between 100 and 140 mm. For instance, hardware cavitymay have a maximum depth of about 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or 80 mm.

When used to package a toilet, first molded fiber trayand second molded fiber traymay be strapped together, for example using plastic or nylon straps. As shown in, bottom surfaceof first molded fiber traymay include one or more strap channelsthat are configured to receive straps. Strap channelsmay hold strapsin an optimal position and may prevent strapsfrom deforming first molded fiber tray(e.g., may prevent first molded fiber trayfrom folding or bending about straps). In some embodiments, the strap channelsmay have a width of 25-50 mm. In some embodiments, the strap channelsmay have a width of greater than or equal to 25 mm, 30 mm, 35 mm, 40 mm, or 45 mm. In some embodiments, the strap channelsmay have a width of less than or equal to 30 mm, 35 mm, 40 mm, 45 mm, or 50 mm. In some examples, strapsare at least 9.5 mm wide. In some examples, strapsare 9.5-45 mm wide, 9.5-40 mm wide, 9.5-35 mm wide, or 9.5-30 mm wide. The toilet packaging system with strapsaround first molded fiber trayand second molded fiber trayis shown in.

The foregoing description, for the purpose of explanation, has been described with reference to specific embodiments and/or examples. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated.

Although the disclosure and examples have been fully described with reference to the accompanying figures, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims. Finally, the entire disclosure of the patents and publications referred to in this application are hereby incorporated herein by reference.