The present disclosure relates to packaging. Example embodiments related to an insert for improved packaging of eggs in cartons.
An egg carton is a package designed for carrying and transporting whole eggs. Referring to
The egg carton may include a top 120. The top 120 may be flexibly connected along a top back edge 128 to a bottom back edge 118 in a manner allowing the top 120 to be closed over the bottom 110. When the carton is closed, a top rim 124 may be substantially in contact with one or more portions of the bottom rim 114. Each cone 116 may extend no higher than an inside upper surface of the top 122.
The egg carton may include a flap 130 flexibly connected to a bottom front edge 119 for releasably securing the top 120 in place when the carton 100 is closed. The flap outer surface 136 may abut a top inside front surface 126 when the carton 100 is closed. The flap 130 may include detents 132 sized and shaped to mate with holes 129 formed in the top 120 to releasably secure the top 120 in place when the carton 100 is closed.
This egg carton 100 structure may protect eggs against stresses exerted during some forms of transportation and storage by absorbing shock. An egg carton 100 may be manufactured from various materials, including foamed plastics such as polystyrene foam, clear plastic, recycled paper, and molded pulp.
While a typical egg carton 100 is illustrated in
Online grocers may allow consumers to order groceries and other products typically found in grocery stores, online. Either the grocer, or a third party, then may deliver the ordered goods to consumers. Often, a variety of mixed good, for example, eggs, bread, milk, and potato chips, are packaged in the same bag or box.
In certain example embodiments described herein, an egg carton insert includes an N row by M column array of interconnected domes. Each dome is sized to enclose a top portion of an egg. Each dome is connected to each neighboring dome in the array. The array of domes forms an opening between each group of four adjacent domes. The array is arranged such that each dome corresponds to a dimple of an egg carton into which the insert can be placed. The overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton.
In some embodiments, at least one dome defines therein a cutout along a portion of the at least one dome at a long side of the array. In some embodiments, the insert material is molded pulp.
In some embodiments, N is at least two and M is at least two. In such embodiments, in each even-numbered column, each odd-numbered dome position is vacant; and in each odd-numbered column, each even-numbered dome position is vacant.
In certain example embodiments described herein, a method for packing eggs includes providing an N row by M column egg carton containing a plurality of eggs. An egg carton insert is provided in the form of an N row by M column array of interconnected domes as described above. The array is placed over the eggs such that each dome aligns with a dimple. The egg carton is closed over the eggs and the egg carton insert.
In certain example embodiments described herein, an egg carton insert includes a substantially flat elongated rectangle of material. The material is characterized by a length less than the interior length of an egg carton, a width less than the interior width of the egg carton; and a thickness less than one half the height of an egg to be carried in the egg carton. The material defines therein an N row by M column array of through-holes of common diameter, the hole diameter less than the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton.
These and other aspects, objects, features, and advantages of the example embodiments will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of illustrated example embodiments.
Turning now to the remaining drawings, in which like numerals indicate like (but not necessarily identical) elements throughout the figures, example embodiments are described in detail.
Delivering eggs purchased from an online retailer in cartons can result very high egg breakage rates, especially if the online retailer uses a common carrier for delivery. Egg breakage rates can increase if the egg carton is delivered in the same overall package, for example a cardboard box, along with heavy products or products packaged in hard-sided containers. A typical egg carton is not designed to withstand the forces likely to be encountered by the eggs being handled like books, clothing, and other goods delivered by common carriers. Even specialty carriers, accustomed to transporting fragile items, can see unacceptable breakage rates. Private testing has shown breakage rates as high as 44% for 6-count and 12-count egg cartons shipped for overnight delivery in outer boxes with other grocery products.
Embodiments of the technology disclosed herein include devices, systems, and methods for supplementing a typical egg carton with an insert that can reduce the rate of egg breakage during transport. Some embodiments disclosed herein have demonstrated breakage rates of less than 3%.
Referring to
Each dome 210 in
Each dome 210 can be connected to each neighboring dome in the array. In the example embodiment of
The array of domes 210 forms an opening 230 between each group of four adjacent domes 210. Each opening 230 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 230 can provide lateral stability to the combined egg carton 100 and egg carton insert 200. The loose, but laterally restrained, coupling between the egg carton insert 200 and the egg carton 100 can contribute to the protection of the eggs contained in the egg carton 100. The egg carton insert 200 is arranged such that each dome 210 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 200 can be placed.
The overall dimensions of the egg carton insert 200 are such that the egg carton 100 can be closed when the egg carton insert 200 is placed over each egg occupying a dimple 116 of the egg carton 100.
In some embodiments, at least one dome 210 defines therein a cutout 212 along a portion of the at least one dome at a long side of the array. The cutout 212 is oriented substantially parallel to the long side of the array. The cutout 212 can be in the shape of an arch, a rectangle, or other shape for providing clearance for egg carton 100 features that would otherwise impede closing the egg carton 100 over the egg carton insert 200 when the egg carton 100 dimples 112 are holding eggs.
Referring to
Each ring 310 in
Each ring 310 is connected to each neighboring ring 310 in the array. In the example embodiment of
The array of rings 310 forms an opening 330 between each group of four adjacent rings 310. Each opening 330 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 330 can provide lateral stability to the combined egg carton 100 and egg carton insert 200. The loose, but laterally restrained, coupling between the egg carton insert 300 and the egg carton 100 can contribute to the protection of the eggs from damage. The egg carton insert 300 is arranged such that each ring 310 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 300 can be placed.
Referring to
Referring to
An N row by M column egg carton insert in the form of an array of interconnected domes is provided—Block 520. For example, the egg carton insert 200 in the form of a 6×2 array of domes 210 of
The array is placed over the eggs such that each dome 210 aligns with a dimple 116—Block 530. For example, the edges of the array can be aligned with the bottom rim 112 of the open egg carton 100. Even an imperfect alignment, up to one half an egg diameter off, between the egg carton insert 200 and the carton 100 containing eggs will create a self alignment. The egg carton, containing the eggs and the egg carton insert 200, is closed—Block 540. For example, closing the top 120 and locking the top by aligning detents 132 with holes 139 will further facilitate the self-alignment.
Referring to
An egg carton insert in the form of a substantially flat elongated rectangle of material is provided—Block 620. For example, the egg carton insert 300 having a length less than the interior length of the egg carton 100, a width less than the interior width of the egg carton 100, and a thickness less than one half the height of an egg in the egg carton 100 is provided. The material defines therein an N row by M column array of through-holes of common diameter. The hole diameter less then the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton.
The material is placed over the eggs such that each hole aligns with a dimple 116—Block 630. The egg carton, containing the eggs and the egg carton insert 300, is closed—Block 640.
The example systems, methods, and acts described in the embodiments presented previously are illustrative, and, in alternative embodiments, certain acts can be performed in a different order, in parallel with one another, omitted entirely, and/or combined between different example embodiments, and/or certain additional acts can be performed, without departing from the scope and spirit of various embodiments. Accordingly, such alternative embodiments are included in the technology described herein.
Although specific embodiments have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects described above are not intended as required or essential elements unless explicitly stated otherwise. Modifications of, and equivalent components or acts corresponding to, the disclosed aspects of the example embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of the present disclosure, without departing from the spirit and scope of embodiments defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures.