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.

Claims

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.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0016] The following figures show various views and components of a molded fiber packaging system for toilets. The system (and components thereof) shown in the figures may have any one or more of the characteristics described herein.

[0017] FIG. 1A shows an assembled toilet, according to some embodiments.

[0018] FIG. 1B shows an assembled toilet, according to some embodiments.

[0019] FIG. 1C shows a side perspective view of a toilet bowl that is packed into a molded fiber tray, according to some embodiments.

[0020] FIG. 1D shows a side perspective view of a toilet bowl, a toilet tank, and a toilet tank lid that are packed into a molded fiber tray, according to some embodiments.

[0021] FIG. 1E shows a side perspective view of a toilet bowl, a toilet tank, and a toilet tank lid that are packed into a pair of molded fiber trays, according to some embodiments.

[0022] FIG. 1F shows an exploded view of a molded fiber packaging system for a toilet, according to some embodiments.

[0023] FIG. 2A shows a diagram of a bottom surface of a first molded fiber tray, according to some embodiments.

[0024] FIG. 2B shows a diagram of a top surface of a first molded fiber tray, according to some embodiments.

[0025] FIG. 2C shows a diagram a front-edge-view of a first molded fiber tray, according to some embodiments.

[0026] FIG. 2D shows a diagram of a side-edge-view of a first molded fiber tray, according to some embodiments.

[0027] FIG. 3A shows a diagram of a bottom surface of a second molded fiber tray, according to some embodiments.

[0028] FIG. 3B shows a diagram of a side-edge-view of a second molded fiber tray, according to some embodiments.

[0029] FIG. 4A shows a perspective view of cushioning bumps in a toilet tank cavity in a first molded fiber tray, according to some embodiments.

[0030] FIG. 4B shows a close-up view of cushioning bumps in a toilet tank cavity in a first molded fiber tray, according to some embodiments.

[0031] FIG. 4C shows a perspective view of cushioning bumps in a toilet tank cavity in a first molded fiber tray, according to some embodiments.

[0032] FIG. 5 shows a perspective view of strengthening ribs in the bottom surface of a first molded fiber tray, according to some embodiments.

[0033] FIG. 6A shows a perspective view of a nose overhang on a first molded fiber tray, according to some embodiments.

[0034] FIG. 6B shows a close-up view of a nose overhang on a first molded fiber tray, according to some embodiments.

[0035] FIG. 7A shows a hardware box, according to some embodiments.

[0036] FIG. 7B shows hardware boxes being placed in a hardware cavity in a first molded fiber tray, according to some embodiments.

[0037] FIG. 7C shows hardware boxes contained in a hardware cavity in a first molded fiber tray, according to some embodiments.

[0038] FIG. 8A shows a perspective view of strap channels in a first molded fiber tray, according to some embodiments.

[0039] FIG. 8B shows a close-up view of strap channels in a first molded fiber tray, according to some embodiments.

[0040] FIG. 8C shows a bottom view of strap channels in a first molded fiber tray, according to some embodiments.

[0041] FIG. 9 shows a perspective view of a molded fiber tray, according to some embodiments.

[0042] FIG. 10 shows a toilet seat and a toilet bowl lid disassembled from a toilet bowl, according to some embodiments.

[0043] FIG. 11 shows a side perspective view of a packing arrangement of a toilet bowl, a toilet tank lid, and a toilet bowl lid, according to some embodiments.

[0044] FIG. 12A shows a side perspective view of a packing arrangement of a toilet bowl base, a toilet tank, and a toilet tank lid in a bottom molded fiber tray, according to some embodiments.

[0045] FIG. 12B shows a side perspective view of a packing arrangement of a toilet bowl base, a toilet tank, and a toilet tank lid in a top molded fiber tray, according to some embodiments.

[0046] FIGS. 13A-13B show perspective views of cushioning bumps in a molded fiber tray, according to some embodiments.

[0047] FIG. 13C shows a close-up view of cushioning bumps in a molded fiber tray, according to some embodiments.

[0048] FIG. 14A shows a top perspective view of cushioning ribs in a molded fiber tray, according to some embodiments.

[0049] FIG. 14B shows a perspective view of the underside of cushioning ribs in a molded fiber tray, according to some embodiments.

[0050] FIG. 14C shows a top perspective view of cushioning ribs in a molded fiber tray, according to some embodiments.

[0051] FIGS. 15A-15B show perspective views of tray strengthening ribs underneath a molded fiber tray, according to some embodiments.

[0052] FIGS. 16A-16B show protrusions between a toilet tank cavity and a toilet tank lid cavity in a molded fiber tray, according to some embodiments.

[0053] FIGS. 17A-17B show flush lever cavities of a molded fiber tray, according to some embodiments.

[0054] FIGS. 18A-18B show a hardware box in a hardware box cavity of a molded fiber tray, according to some embodiments.

[0055] FIGS. 19A-19C and FIG. 20 show straps within strap channels of a molded fiber tray, according to some embodiments.

DETAILED DESCRIPTION

[0056] 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.

[0057] 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.

[0058] As used herein, the singular forms a, an, and the include the plural reference unless the context clearly dictates otherwise.

[0059] 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.

[0060] 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.

[0061] Exemplary toilets that may be packaged using the provided molded fiber packaging systems are shown in FIGS. 1A-1B. A toilet may include a toilet bowl 106 and a toilet tank 108, which may be detachable from one another for shipping/storage and may be attached to one another (in the assembled position shown in FIGS. 1A-1B) when assembled. The nose 106a of toilet bowl 106 may be a portion of toilet bowl that is distal from toilet tank 108. 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 base 106b of toilet bowl 106 may be a surface of toilet bowl 106 that mounts to a floor (e.g., a bathroom floor) when the toilet is installed. The top surface 106c of toilet bowl 106 may be a surface of toilet bowl 106 that includes the opening to the bowl. A toilet bowl lid 112a may be configured to cover a toilet seat 112b, and the toilet seat 112b may be configured to cover top surface 106c of toilet bowl 106 as shown in FIG. 1A and FIG. 10. Toilet tank 108 may have a front surface 108a and a back surface 108b. The front surface 108a of toilet tank 108 may be approximately normal to a direction in which the nose 106a of toilet bowl 106 points when the toilet is fully assembled. The back surface 108b of toilet tank 108 may face in the opposite direction as the nose 106a of toilet bowl 106 when the toilet is fully assembled. Toilet tank 108 may be covered by a toilet tank lid 110, which may have a front edge 110a that faces the same direction as the front surface 108a of toilet tank 108 and a back edge 110b that faces the same direction as the back surface 108b of toilet tank 108 when the toilet is fully assembled.

[0062] FIGS. 1C-1F show perspective views of a toilet being packed using a molded fiber packaging system. A first molded fiber tray 102 may be placed on the top surface (e.g., top surface 106c shown in FIG. 1B) of toilet bowl 106. Toilet tank 108 and toilet tank lid 110 may then be placed within appropriate cavities in first molded fiber tray 102. To ensure the toilet is packed compactly and to minimize risk of breakage, tank 108 may be laid on its back surface (e.g., back surface 108b shown in FIGS. 1A-1B) and toilet tank lid 110 may be laid on its back edge (e.g., back edge 110b shown in FIGS. 1A-1B). A second molded fiber tray 104 may be fitted over the front surface (e.g., front surface 108a shown in FIGS. 1A-1B) of toilet tank 106 and the front edge (e.g., front edge 110a shown in FIGS. 1A-1B) of toilet tank lid 110. The toilet bowl lid 112a may be packaged alongside toilet bowl 106, and toilet tank lid 110 may be supported by the first molded fiber tray 102 and the second molded fiber tray 104 as shown in FIG. 11. 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.

[0063] In some embodiments, a third molded fiber tray may be provided beneath the toilet bowl base 106b. This third molded fiber tray may support the toilet bowl base 106b and/or the laterally positioned toilet bowl lid 112a. 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.

[0064] FIGS. 2A-2D provide diagrams of various surfaces and edges of an exemplary first molded fiber tray 102. As shown in FIGS. 1C-1F, first molded fiber tray 102 may 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 surface 214 of first molded fiber tray 102 may include a toilet bowl cavity 216 that is molded to the shape of a top surface of a toilet bowl (e.g., top surface 106c of toilet bowl 106 shown in FIG. 1B). Bottom surface 214 may also include a toilet bowl lid cavity 238 that is configured to receive an edge portion of a toilet bowl lid (e.g., toilet bowl lid 112a shown in FIGS. 1A-1B) when the toilet bowl lid is placed alongside the toilet bowl as shown in FIG. 1F. A top surface 226 of first molded fiber tray 102 may include a toilet tank cavity 228 that is molded to the shape of a back surface of a toilet tank (e.g., back surface 108b of toilet tank 108 shown in FIGS. 1A-1B) and a toilet tank lid cavity 242 that is molded to the shape of a back edge of a toilet tank lid (e.g., back edge 110b of toilet tank lid 110 shown in FIGS. 1A-1B). The packing arrangement of the toilet tank 108 in the toilet tank cavity 228 and the toilet tank lid 110 in the toilet tank lid cavity 242 is shown in FIGS. 12A and 12B.

[0065] When first molded fiber tray 102 is used to package a toilet, tray 102 may be oriented such that a front edge 218 of tray 102 is proximal to a nose of the toilet bowl (e.g., nose 106a of toilet bowl 106 shown in FIGS. 1A-1B) and a rear edge 222 of tray 102 is distal from the nose of the toilet bowl. Side edges 220 of first molded fiber tray 102 may 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 cavity 216 in bottom surface 214. Once toilet bowl cavity 216 is fitted over the top surface of the toilet bowl, the toilet tank may be placed on its back surface within toilet tank cavity 228 and the toilet tank lid may be placed on its back edge within toilet tank lid cavity 242.

[0066] Top surface 226 of first molded fiber tray 102 may include one or more protrusions 230 between toilet tank cavity 228 and toilet tank lid cavity 242 that 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 surface 226 includes between two and ten protrusions 230, between 3 and 9 protrusions 230, between four and eight protrusions 230, or between five and seven protrusions 230. In other embodiments, top surface 226 includes at least 11 protrusions 230. Protrusions 230 can be cylindrical, pyramidal, or prism-shaped (e.g., rectangular prism-shaped, trapezoidal prism-shaped, etc.). In some embodiments, each protrusion 230 has the same shape; in other embodiments, protrusions 230 include at least two protrusions having different shapes.

[0067] A plurality of cushioning bumps 232 may be provided within toilet tank cavity 228 of the first molded fiber tray 102, as shown in FIGS. 13A-13C. Cushioning bumps 232 may prevent first molded fiber tray 102 from bending or otherwise deforming when a toilet tank is placed within tank cavity 228. Additionally, cushioning bumps 232 may 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 228. Cushioning bumps 232 may have a height that is less than the height of tank cavity 228, such that they do not extend above the top of tank cavity 228.

[0068] In some embodiments, toilet tank cavity 228 includes 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 232. A cushioning bump may protrude from the surface of toilet tank cavity 228 by 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 cavity 228 by 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 bumps 232 in a toilet tank cavity 228 of a molded fiber tray 102 are shown in FIGS. 4A-4C and 13A-13C.

[0069] Tank lid cavity 242 may include a plurality of cushioning bumps 234. Just as cushioning bumps 232 may prevent first molded fiber tray 102 from bending or otherwise deforming when a toilet tank is placed within tank cavity 228, cushioning bumps 234 in tank lid cavity 242 may prevent first molded fiber tray 102 from bending or otherwise deforming when a toilet tank lid is placed within tank lid cavity 242. Cushioning bumps 234 may 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 242. Cushioning bumps 234 may have a height that is less than the height of tank lid cavity 242, such that they do not extend above the top of tank lid cavity 242.

[0070] In some embodiments, toilet tank lid cavity 242 includes 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 234. A cushioning bump may protrude from the surface of toilet tank lid cavity 242 by 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 cavity 242 by 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, FIGS. 14A-14C illustrate rib-shaped cushioning bumps, cushioning ribs 1402 in 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.

[0071] Bottom surface 214 of first molded fiber tray 102 can include one or more ribs 236 configured to prevent tray 102 from deforming and/or bending in the region proximal to rear edge 222, where additional rigidity for tray 102 may be needed on portions of the tray that are not directly adjacent to toilet tank 108 when packed. In some embodiments, bottom surface 214 includes at least 2, at least 3, at least 4, or at least 5 ribs 236. Each rib may have the same geometrical configuration. For instance, tray strengthening ribs 1502, shown in FIGS. 15A-15C, have the same geometrical configuration. Alternatively, one or more ribs may have different geometrical configurations. FIGS. 5 and 15A provide a perspective view of ribs 236, 1502 in a bottom surface 214 of a first molded fiber tray 102, while FIG. 15B provides a close-up view of ribs 1502.

[0072] As previously described, front edge 218 of first molded fiber tray 102 may be oriented proximal to the nose of the toilet bowl when first molded fiber tray 102 is 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 edge 218 may include an overhang 224 that 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 overhang 224 may be, e.g., pyramidal or prism shaped, for example rectangular-prism-shaped or trapezoidal-prism-shaped. In some embodiments, nose overhang 224 may 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 overhang 224 may 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 edge 218 of first molded fiber tray 102 includes multiple nose overhangs 224, for example two, three, four, or five or more nose overhangs 224. FIGS. 6A-6B provide perspective and close-up views, respectively of a nose overhang 224 on a front edge 218 of an example molded fiber tray 102.

[0073] In some embodiments, top surface 226 of first molded fiber tray 102 includes a hardware cavity 240. Hardware cavity 240 may be configured to receive one or more boxes containing hardware such as wax rings and fasteners for the toilet. Hardware cavity 240 may 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 cavity 240 may be a square cavity with edge lengths of about 140 mm, 145 mm, 150 mm, 155 mm, or 160 mm. Hardware cavity 240 may 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 cavity 240 may have a maximum depth of about 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or 80 mm. FIG. 7A shows an exemplary hardware box 962 that may be contained by hardware cavity 240; FIGS. 7B-7C show hardware box(es) 964 inserted into a hardware cavity 240 in a first molded fiber tray 102.

[0074] Turning to the second molded fiber tray 104, FIGS. 3A-3B provide diagrams of various surfaces and edges of an exemplary second molded fiber tray 104. As shown in FIGS. 1C-1F, second molded fiber tray 104 may be configured to protect a front surface of a toilet tank and a front edge of a toilet tank lid. Accordingly, a bottom surface 350 of second molded fiber tray 104 may include a toilet tank cavity 352 that is molded to the shape of a front surface of a toilet tank (e.g., front surface 108a of toilet tank 108 shown in FIGS. 1A-1B) and a toilet tank lid cavity 354 that is molded to a front edge of a toilet tank lid (e.g., front edge 110a of toilet tank lid 110 shown in FIGS. 1A-1B).

[0075] When second molded fiber tray 104 is used to package a toilet, tray 104 may be oriented such that a front edge 344 of tray 104 is proximal to a nose of the toilet bowl (e.g., nose 106a of toilet bowl 106 shown in FIGS. 1A-1B) and a rear edge 348 of tray 104 is distal from the nose of the toilet bowl. That is, front edge 344 may be aligned with front edge 218 of first molded fiber tray 102 and rear edge 348 may be aligned with rear edge 222 of first molded fiber tray 102. Side edges 346 of second molded fiber tray 104 may be oriented approximately parallel to the sides of the toilet bowl. In this orientation, second molded fiber tray 104 may be placed over a toilet tank and a toilet tank lid that have been placed in a first molded fiber tray 102 such that a front surface of the toilet tank is inserted into toilet tank cavity 352 and a front edge of the toilet tank lid is inserted into toilet tank lid cavity 354.

[0076] Bottom surface 350 of second molded fiber tray 104 may include one or more protrusions 356 between toilet tank cavity 352 and toilet tank lid cavity 354 that are configured to prevent the collisions between the toilet tank lid and the toilet tank when in the packaged arrangement. In some embodiments, bottom surface 350 includes between 2 and 10 protrusions 356, between 3 and 9 protrusions 356, between 4 and 8 protrusions 356, or between 5 and 7 protrusions 356. In other embodiments, bottom surface 350 includes at least 11 protrusions 356. Protrusions 356 can be cylindrical, pyramidal, or prism-shaped (e.g., rectangular-prism-shaped, trapezoidal-prism-shaped, etc.). In some embodiments, each protrusion 356 has the same shape; in other embodiments, protrusions 354 include at least two protrusions having different shapes. Examples of protrusions 1602 (which may be the same as or include similar aspects as described with respect to protrusions 356) that are configured to prevent collisions between the toilet tank cavity and toilet tank lid cavity are shown in FIGS. 16A and 16B.

[0077] The front surface of a toilet tank may include a flush lever for flushing the toilet. Toilet tank cavity 352 may include at least one flush lever cavity 358 configured to encase a flush lever. Flush lever cavity 358 may be configured to surround but not make contact with the flush lever. In some embodiments, toilet tank cavity 352 includes a pair of flush lever cavities 358, as shown in FIGS. 17A and 17B. This may allow second molded fiber tray 104 to 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 lever 1702 in FIGS. 17A and 17B, and with toilets that include a flush lever on a right side of the front surface of the toilet tank.

[0078] In some embodiments, bottom surface 350 of second molded fiber tray 104 includes a hardware cavity 362. Hardware cavity 362 may be correspond to hardware cavity 240 in top surface 226 of first molded fiber tray 102 and may be configured to contain one or more hardware boxes 962 containing hardware such as wax rings and fasteners for the toilet, as shown in FIGS. 18A and 18B. Hardware cavity 362 may 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 cavity 362 may be a square cavity with edge lengths of about 140 mm, 145 mm, 150 mm, 155 mm, or 160 mm. Hardware cavity 362 may 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 cavity 362 may have a maximum depth of about 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or 80 mm.

[0079] When used to package a toilet, first molded fiber tray 102 and second molded fiber tray 104 may be strapped together, for example using plastic or nylon straps. As shown in FIGS. 8A-8C and 19A-19C, bottom surface 214 of first molded fiber tray 102 may include one or more strap channels 1366 that are configured to receive straps 1368. Strap channels 1366 may hold straps 1368 in an optimal position and may prevent straps 1368 from deforming first molded fiber tray 102 (e.g., may prevent first molded fiber tray 102 from folding or bending about straps 1368). In some embodiments, the strap channels 1366 may have a width of 25-50 mm. In some embodiments, the strap channels 1366 may 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 channels 1366 may have a width of less than or equal to 30 mm, 35 mm, 40 mm, 45 mm, or 50 mm. In some examples, straps 1368 are at least 9.5 mm wide. In some examples, straps 1368 are 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 straps 1368 around first molded fiber tray 102 and second molded fiber tray 104 is shown in FIG. 20.

[0080] 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.

[0081] 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.