Patent Application
20130126384
The present invention relates to an improved egg carton for packaging eggs and a system for packaging eggs.
The natural egg structure is quite strong and indeed nearly impossible for a person to break by applying pressure to the ends of the egg with the human fingers. Despite its relative strength, the egg is an extremely fragile product and requires specialized packaging and processing methods.
Therefore, packaging is an important component in delivering quality eggs to consumers. Proper packaging and handling help to maintain or control moisture, temperature, and breathability, and to prevent egg damage, contamination or tainting. The packaging must be able to withstand diverse handling, egg size, storage and transport methods.
In addition, the packaging typically allows for consumers to open or inspect the eggs. Consumers generally prefer sealed containers or packaging to ensure product safety, although conventional egg packaging does not provide for such sealed containers. Moreover, packaging must provide for labels or identifiers for providing information about the product to wholesalers, retailers and consumers. Important facts on the label contain information for buyers concerning the eggs, their size and weight and quality/grade description. Labels may also indicate the producer, when the eggs were laid, how to store them and their expiration date.
The present invention is directed to an improved egg carton for packaging eggs and a system for packaging eggs. The disclosed egg packaging carton includes a plurality of egg holding compartments that may accommodate eggs of variable size and weight.
The present invention is directed to an egg packaging carton comprising a bottom portion and a top portion. The bottom portion includes a first plurality of egg receiving areas, each one of the egg receiving areas defined by a bottom surface, sidewalls extending upwardly from and surrounding the bottom surface, and flexible projections extending from the sidewalls and biased outwardly and into a corresponding egg receiving area. The top portion is coupleable to the bottom portion, and includes a second plurality of egg receiving areas, each of which is defined by a top surface, sidewalls extending upwardly from and surrounding the top surface, and flexible projections extending from the sidewalls and biased outwardly and into a corresponding egg receiving area. The first plurality of egg receiving areas is alignable with the second plurality of egg receiving areas to define a plurality of egg holding compartments when the top portion is coupled to the bottom portion.
In one embodiment, the bottom portion includes at least four projections disposed within each one of the first plurality of egg receiving areas. The projections are spaced around a central axis of the corresponding egg receiving area, so that an egg received therein is centered within the corresponding egg receiving area. The top portion may also include at least four projections disposed within each egg receiving area, which are likewise spaced around a central axis of the corresponding egg receiving areas so that an egg received therein is centered within the egg holding compartment.
In one embodiment, the bottom surface of each one of the first plurality of egg receiving areas includes a raised central segment extending inwardly toward the corresponding one of the first plurality of egg receiving areas. The raised central segment includes a dimpled area configured to receive a first end of an egg and generates a recoiling force against depression thereof by the egg.
In one embodiment, the bottom surface of each of the first plurality of egg receiving areas includes a plurality of lugs extending outwardly and away from the corresponding one of the first plurality of egg receiving areas. The first plurality of connecting segments is disposed between and interconnects the raised central segment and the lugs. In one implementation, the bottom surface includes a second plurality of connecting segments disposed between and interconnecting the raised central segment and the sidewalls, wherein the first and second pluralities of connecting segments alternate around the raised central segment.
In one embodiment, the top surface of each of the second plurality of egg receiving areas includes a raised central segment extending inwardly toward the corresponding one of the second plurality of egg receiving areas. The raised central segment includes a dimpled area configured to receive an opposite second end of the egg and generate a recoiling force against depression thereof by the egg. In one implementation, the dimpled areas of the first and second pluralities of egg receiving areas are axially aligned when the top portion is coupled to the bottom portion so that the recoiling forces oppose each other and bias the egg away from the bottom surface and the top surface toward a centered position within a corresponding one of the plurality of egg holding compartments.
In one embodiment, the top surface of each one of the second plurality of egg receiving areas includes a plurality of outwardly extending lugs, and a plurality of connecting segments disposed between and interconnecting the central segment and the lugs. In one implementation, the bottom portion includes lugs extending outwardly from the bottom surface thereof, and the top portion includes lugs extending outwardly from the top surface thereof. The lugs of the bottom portion are nestable and interlockable with the lugs of the top portion.
According to one embodiment, the bottom portion includes a first flanged edge extending outwardly from a perimeter thereof and having one or more engagement members thereon. The top portion includes a second flanged edge extending outwardly from a perimeter thereof and having one or more engagement members thereon. The engagement members of the first and second flanged edges cooperating to releasably secure the bottom portion to the top portion.
In one embodiment, the top portion is hingedly attachable to the bottom portion via a flexible label member.
The present invention also relates to a system of packaging eggs including at least a first egg carton and a second egg carton. Each of the egg cartons comprises a bottom portion including a first plurality of egg receiving areas. Each of the first plurality of egg receiving areas is defined by a bottom surface and sidewalls extending upwardly from and surrounding the bottom surface, and a plurality of lugs extending outwardly from the bottom surface of each one of the first plurality of egg receiving areas. A top portion is coupleable to the bottom portion, and includes a second plurality of egg receiving areas. Each of the second plurality of egg receiving areas is defined by a top surface and sidewalls extending upwardly from and surrounding the top surface, and a second plurality of lugs extending outwardly from the top surface thereof. The first plurality of egg receiving areas are alignable with the second plurality of egg receiving areas to define a plurality of egg holding compartments when the top portion is coupled to the bottom portion. The lugs of the bottom portion of the first egg packaging carton are nestable and interlockable with the lugs of the top portion of the second egg packaging carton.
In one embodiment, each of the first and second egg cartons further comprises flexible projections extending from the sidewalls of the bottom portion and biased outwardly and into a corresponding one of the first plurality of egg receiving areas, and flexible projections extending from the sidewalls of the top portion and biased outwardly and into a corresponding one of the second plurality of egg receiving areas.
In one embodiment, each of the first and second egg cartons further comprises a dimpled lower platform coupled to the bottom surface of each one of the first plurality of egg receiving areas. The dimpled lower platform extends away from the plurality of lugs of the bottom portion and is configured to receive a first end of an egg and generate a first recoiling force against depression thereof. The egg cartons further comprise a dimpled upper platform coupled to the top surface of each one of the second plurality of egg receiving areas. The dimpled upper platform extends away from the plurality of lugs of the top portion and is configured to receive an opposite second end of the egg and generate a second recoiling force against depression thereof. The second recoiling force opposes the first recoiling force.
In one embodiment, each of the first and second egg packaging cartons includes a front edge. When the lugs of the bottom portion of the first egg packaging carton are nested with the lugs of the top portion of the second egg packaging carton, the front edge of the first egg packaging carton is substantially parallel to the front edge of the second egg packaging carton, or alternatively the front edge of the first egg packaging carton is substantially perpendicular to the front edge of the second egg packaging carton. An egg carton is provided which includes a bottom portion including a plurality of egg receiving areas, and a top portion including a plurality of egg receiving areas. The plurality of egg receiving areas of the bottom portion are alignable with the plurality of egg receiving areas of the top portion to define a plurality of egg holding compartments. A plurality of eggs are disposed in the plurality of egg receiving areas of the bottom portion. The top portion is then moved toward the bottom portion until the top portion is coupled to the bottom portion to define the plurality of egg holding compartments with the eggs retained therein. The egg receiving areas of the top portion are axially aligned with the egg receiving areas of the bottom portion as the top portion is moved toward the bottom portion. Thus, the top portion is disconnected and discrete from the bottom portion.
In one embodiment, the disclosed method provides for the further step of biasing each of the plurality of eggs toward centered positions within corresponding egg holding compartments.
In another embodiment, the packaging method provides for the further step of affixing a flexible member to the egg carton after moving the top portion toward the bottom portion and thereby coupling the top and bottom portions together. The flexible member has a first portion coupled to the bottom portion and a second portion coupled to the top portion, thereby hingedly connecting the bottom portion to the top portion.
The terms “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points or portions of reference and do not limit the present invention to any particular orientation or configuration. Further, terms such as “first,” “second,” “third,” etc., merely identify one of a number of portions, components and/or points of reference as disclosed herein, and do not limit the present invention to any particular configuration or orientation.
Referring to
The egg carton 10 includes a top portion 12 and a bottom portion 14. The top portion 12 is separable from and releasable coupleable to the bottom portion 14. Referring to
With continued reference to
Within each compartment 20, the egg E is supported by the top and bottom portions 12, 14 of the carton 10, as shown in
The bottom portion 14 of the egg carton 10 includes feet or lugs 22. The lugs 22 include exteriorly disposed distal portions 24 that are engageable with a support surface, thereby stabilizing the egg carton 10 such as when resting on a generally planar support surface. In addition, the lugs 22 allow for the carton 10 to engage and nest into the top portion of another egg carton, as shown in
Referring to
The geometric configuration and location of the lugs 22 allow for the connection of multiple size cartons (e.g., egg cartons for holding 4, 12 or 18 eggs). In addition, the lugs 22 provide a method to interlock the egg cartons 10 together, such as for stacking during storage or transport. This interlock feature prevents slippage between stacked cartons, and also provides a mechanism for releasably attaching multiple cartons together while stacking. The interlock feature is achieved by the configuration of the lugs 22 on the top portion 12, which interlock with correspondingly configured lugs 22 on the bottom portion 14 (or vice versa).
Referring again to
In the bottom of the egg receiving area 16, a dimple shaped surface 30 surrounded by connecting regions or segments 32 are provided. In one implementation, eight segments 32 are provided. Four of the segments 32 are disposed between and interconnect the dimple surface 30 and the outside extended lug 22 that is proximate to the contact surface (e.g., the shelf or table). The remaining four segments 32 are disposed between and interconnect the raised portion which is above the support surface. In this way, the geometry of the egg carton 10 generates a spring.
In the egg receiving area 18 of the top portion 12, another dimple shaped surface 30 is provided, which is also surrounded by a surface consisting of eight segments 32. Four of the segments 32 connect between the dimpled surface 30 and the outside extended foot/lug that are near the contact surface to the shelf or table. The remaining four segments 32 connect to the raised portion which is above the shelf/table. This geometry likewise generates a spring. When the top portion 12 of the carton 10 is applied or releasably coupled to the bottom portion 14 of the carton 10, the springs within the egg receiving areas 16, 18 are aligned with and oppose each other in a vertical orientation. The position of the egg E within the carton 10 suspends the egg E within the compartment 20, and prevents the egg E from moving beyond the perimeter plane of the top and bottom feet/lugs.
The combination of the springs on the top and bottom portions 16, 18 places the eggs in compression between the bottom spring and the top spring. This feature creates a spring rate which allows for the secure positioning and holding of each egg while providing a cushion for movement during top load, stacking and shipping. In addition, this feature holds each egg in the carton in an optimal position, utilizing the most compression resistant portion and orientation of the egg's natural geometry (i.e., point to point).
Thus, the positioning of the eggs within the carton 10 advantageously utilizes the natural strength of the eggs. The carton 10 is designed to align the egg into each compartment 20 or cell. The compartments 20 within the bottom portion 14 of the carton 10 maintain each egg E in an upright position, while also being adjustable to and accommodating eggs of variable size in diameter and height. Each egg may be dropped into the egg receiving areas 16 in the bottom portion 14 of the carton 10 with the smaller point of the egg positioned downwardly, as determined by standard egg loading machinery. This alignment thereby harnesses the normal strength of the natural egg.
The cylindrical area or dimpled surface 30 in the egg receiving area 18 of the top portion 12 allow for the forces which hold the egg E within the carton 10 to be applied in a similar fashion as described above, to the ends of the egg. When the top portion 12 is applied to the bottom portion 14, the springs which support the cylindrical area or dimpled surfaces 30 on both the top and bottom portions 12, 14 or halves of the carton 10 apply pressure to the egg. The egg is thereby maintained in an upright position within the egg holding compartment 20 while in the carton 10.
It has been established by top load testing that the egg strength when used in this manner provides an increase in the top load capabilities of the overall carton. A stack of 2 cartons (which cartons are each configured to hold one dozen eggs) without eggs in the cells provided 87 lbs. of top load resistance at 0.250″ of deflection. The same 2 one dozen cartons with eggs in the cells provided 108 lbs. of top load resistance at 0.500″ of deflection. During less than 0.500″ of compression/deflection, the eggs are not in contact with each other and are suspended between the feet found on the bottom and top of the carton system. This test illustrates that the natural strength of the egg is being harnessed by the egg carton of the present invention to improve the overall top load characteristic of the single egg carton, particularly when interlocked with multiple cartons as the system provides, thereby adding strength to a cube of multiple egg cartons. Thus, the disclosed egg carton utilizes the natural geometry and strength of the egg for securely positioning and maintaining the eggs in the egg carton.
The spring configurations of the disclosed egg carton 10 also allow for the variation of size found in the natural geometry of the egg. While eggs are sold by weight, the variation of egg dimensions must be considered and accommodated in the egg carton. While each egg within the given egg carton size (e.g., 4, 6, 8, etc.) is important, the egg carton also accounts for overall spacing between the eggs within the carton. The eggs regardless of size or adjustment of the carton must fall into a grid of location while accounting for all carton geometry. For example, if a grid of 51.5 mm is the location of each egg center line vertical, all geometry, which includes all side wall and all other design features must be adjusted to keep the distances within each individual carton and all other nesting cartons on the same grid. This allows for the universal stack nest feature to work across the board in this carton system.
The connecting geometry between each egg location consists of a planer surface with arched bridge geometry to connect each egg compartment to the other egg compartments. This bridge offers structural enhancements and anti-racking geometry. At the base of each bridge found at the planer surface, there is a locking lug including a male on the top portion and a female on the bottom portion. At the exterior edge perimeter of the carton halves, this feature is a single lug. At the center locations, found at the middle of four egg locations, there is a multiple of four location lugs with a single round button snap connector. The center multiple lugs are similar to the outside lug, but are joined with additional geometry to provide more surface area from which to generate a positive connection. The area between the deepest portion of the carton, the feet/lugs and the planer surface are connected with sidewalls that have vertical surface pillars built into the surface. This surface is to provide improved top load capabilities.
Each corner is squared to meet the square perimeter of the overall carton shape. This provides a triangulated structure which leads into the more round surface of the egg compartment toward the round point end of each egg. This feature offers additional top load and structural characteristics to the overall carton. In the top half of the carton this feature is uninterrupted while in the bottom this feature is slightly modified to accommodate the egg positioning geometry.
Found at the perimeter of both the top and bottom portions 12, 14 of each carton 10, regardless of the number of eggs to be packaged, is a stepped (e.g. 90°)flanged edge that contains numerous elongated dimple snaps. On the top, the snaps are proud to the interior of the carton. On the bottom, the elongated dimple snaps are recessed to accept the positive features of the top. When these snaps occur at a 90 degree corner of the carton, approximately 30% of the snap is tapered away and functions as a mechanism to start the opening process by the consumer. The top flange extends half the distance of the matching flange of the bottom flange. This geometry is modified to accommodate the overlap of the formed material thickness of the top. This allows for the overall geometry of the combined carton halves (i.e. top and bottom portions 12, 14) not to exceed the given volume of the grid.
Referring to
The label feature eliminates the requirement or need for another hinge element or integrally connected halves, such as provided in conventional egg cartons. The egg carton of the present invention provides for a simple top portion 12 and bottom portion 14, which may be attached with the label. This provides the egg packager with the option to post label skews and/or to order generic cartons which are differentiated later in the egg packaging process with selected labels. The hinge is then applied with the selected label. The opposite side of the label may be a tamper evident feature to be opened by the purchasing consumer (such as with a tear string to release or break the label along one side of the carton 10. Because the cartons 10 are preferably clear, egg inspection by the consumer is provided at the point of sale but without the need to open the carton 10 or have direct access to the eggs therein.
The carton 10, including the two piece top and bottom portions 12, 14 or halves, may also or alternatively be connected together by geometry details to create an interlocking snapping connection. In addition, the carton may be labeled for identification by the consumer and to provide information about the package content.
Because the egg carton system of the present invention includes two separate parts, closure of the package is relatively simple compared to hinged conventional egg cartons. Dropping the top portion 12 into position over and against the bottom portion 14, and then applying pressure to the top portion 12 while supporting the bottom portion 14 secures the connection (e.g., such as by engaging cooperating snap fit elements on the top and bottom portions 12, 14), thereby reducing the prospect of egg damage such as by actuating a hinged conventional egg carton.
The label L may be dropped into position on the top portion 12 of the carton 10. The label provides surfaces for printed information and images. The label is shaped to provide openings that interact with the carton's geometry by providing windows so that the eggs are visible in the carton when the carton is closed. In addition, the label adds structure to the carton system. The label is shaped to provide added material on opposing sides of the carton 10. If the egg carton configuration is not square in overall shape, the added material occurs on the longest two length of the label. This added portion of the label becomes the hinge feature on one side and a tamper evident feature on the opposing side.
On the hinge side, the label may be glued or affixed to the carton bottom, thereby allowing for the rotation of the top when opened in the common egg carton method. On the tamper evident side, the label is glued or affixed to the bottom with a perforation or tear string method to open the egg carton after purchase and during consumption.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth.
This application is based on U.S. provisional application Ser. No. 61/562,550, filed Nov. 22, 2011, entitled “Egg Packaging Carton and System,” which application is incorporated herein by reference in its entirety and to which priority is claimed.
| Number | Date | Country | |
|---|---|---|---|
| 61562550 | Nov 2011 | US |
