Patent Application
20180029743
The present disclosure relates to packaging. Example embodiments related to a cover for improved packaging of cartoned eggs, and to a kit including the cover and an egg carton insert.
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 made of various materials, including foamed plastics such as polystyrene foam, clear plastic, or may be manufactured from recycled paper or 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, a cover for cartoned eggs is disclosed. In such embodiments, the cover is a cruciform sheet of material having stiffness of at least corrugated cardboard. The cover includes a rectangular central section. The central section is dimensioned along each of the central section right edge and the central section left edge to the length of an egg carton, and along each of the central section top edge and the central section bottom edge to the width of the egg carton.
The cover includes a rectangular first right section abutting, and coextensive with, the central section right edge along the first right section left edge. The first right section is dimensioned along each of a first right section top edge and first right section bottom edge to the overall height of the egg carton plus the thickness of the sheet.
A rectangular second right section abuts, and is coextensive with, the first right section right edge along the second right section left edge. The second right section is dimensioned along each of a second right section top edge and second right section bottom edge to the overall width of the egg carton plus the thickness of the sheet.
The cover includes a rectangular first left section that is abutting, and coextensive with, the central section left edge along the first left section right edge. The first left section is dimensioned along each of a first left section top edge and first left section bottom edge to the overall height of the egg carton plus the thickness of the sheet.
A rectangular second left section abuts, and is coextensive with, the first left section left edge along the second left section right edge. The second left section is dimensioned along each of a second left section top edge and second left section bottom edge to the overall width of the egg carton.
The cover includes a rectangular top flap abutting, and coextensive with, the central section top edge along the top flap bottom edge. The top flap is dimensioned along each of the top flap left edge and the top flap right edge to the overall height of the egg carton.
A top tab abuts the top flap along the top edge of the top flap. The top tab is dimensioned along a top tab bottom edge and a top tab top edge less than the width of the egg carton by at least the thickness of the sheet.
The cover includes a rectangular bottom flap abutting, and coextensive with, the central section bottom edge along the bottom flap top edge. The bottom flap is dimensioned along each of the bottom flap left edge and the bottom flap right edge to the overall height of the egg carton.
A bottom tab abuts the bottom flap along the bottom edge of the bottom flap. The bottom tab is dimensioned along a bottom tab bottom edge and a bottom tab top edge less than the width of the egg carton by at least the thickness of the sheet.
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 container, 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 a cover that can reduce the rate of egg breakage during transport. Some embodiments combine a cover and an insert in a kit to package cartoned eggs. Some embodiments disclosed herein have demonstrated breakage rates of less than 3%.
Referring to
The cover 200 includes a rectangular central section 210 dimensioned along each of the central section right edge 212 and the central section left edge 214 to the length of an egg carton. The central section 210 is dimensioned along each of the central section top edge 216 and the central section bottom edge 218 to the width of the egg carton. In the continuing example, the central section 210 of the cover 200 is 11¾ inches along each of the central section right edge 212 and the central section left edge 214, and is 4½ inches along the central section top edge 218 and the central section bottom edge 218.
The cover includes a rectangular first right section 222 that abuts, and is coextensive with, the central section right edge 212 along the first right section left edge 223. The first right section 222 is dimensioned along each of a first right section top edge 224 and first right section bottom edge 225 to the overall height of the egg carton plus the thickness of the sheet. In the continuing example, the first right section top edge 224 and first right section bottom edge 225 are 3 inches across.
A rectangular second right section 226 abuts, and is coextensive with, the first right section right edge along the second right section left edge 227. The second right section 226 is dimensioned along each of a second right section top edge 228 and second right section bottom edge 229 to the overall width of the egg carton plus the thickness of the sheet. In the continuing example the second right section top edge 228 and second right section bottom edge 229 are 4½ inches across.
The cover includes a rectangular first left section 232 that abuts, and is coextensive with, the central section left edge 214 along the first left section right edge 233. The first left section 232 is dimensioned along each of a first left section top edge 234 and first left section bottom edge 235 to the overall height of the egg carton. In the continuing example, the first left section top edge 234 and the first left section bottom edge 235 are 2⅞ inches across.
A rectangular second left section 236 abuts, and is coextensive with, the first left section left edge along the second left section right edge 237. The second left section 236 is dimensioned along each of a second left section top edge 238 and second left section bottom edge 239 to the overall width of the egg carton. In the continuing example, the second left section top edge 238 and second left section bottom edge 239 are 4⅜ inches across.
The cover includes a rectangular top flap 242 abutting, and coextensive with, the central section top edge 216 along the top flap bottom edge 243. The top flap 242 is dimensioned along each of the top flap left edge 244 and the top flap right edge 245 to the overall height of the egg carton. In the continuing example, the top flap left edge 244 and the top flap right edge 245 are 2⅞ inches, while the distance between the edges is 4⅝ inches ( 2/8 inches more—twice the thickness of the sheet—than the second left section top edge and second left second bottom edge).
The cover includes a top tab 246 abutting the top flap 242 along the top edge of the top flap 247. The top tab 246 is dimensioned along a top tab bottom edge 248 and a top tab top edge 249 less than the width of the egg carton by at least the thickness of the sheet. In the continuing example, top tab bottom edge 248 and a top tab top edge 249 are 4⅜ inches across (twice the thickness of the sheet less than the width of the top flap 242).
A rectangular bottom flap 252 abuts, and is coextensive with, the central section bottom edge 218 along the bottom flap top edge 253. The bottom flap 252 is dimensioned along each of the bottom flap left edge 254 and the bottom flap right edge 255 to the overall height of the egg carton 100. In the continuing example, the bottom flap left edge 254 and the bottom flap right edge 255 are 2⅞ inches, while the distance between the edges is 4⅝ inches ( 2/8 inches more that the second left section top edge and second left second bottom edge).
The cover includes a bottom tab 256 abutting the bottom flap 252 along the bottom edge of the bottom flap 257; the bottom tab is 256 is dimensioned along a bottom tab bottom edge 258 and a bottom tab top edge 259 less than the width of the egg carton by at least the thickness of the sheet. In the continuing example, bottom tab bottom edge 248 and a bottom tab top edge 249 are 4⅜ inches across (twice the thickness of the sheet less than the width of the bottom flap 252).
In some embodiments, each central section edge (212, 214, 216, and 218), the second right section left edge 227, the second left section right edge 237, the top flap top edge 247, and bottom flap bottom edge 257 are creased toward the front face of the sheet. In some of those embodiments, the top flap bottom edge 243 and bottom flap top edge 253 are perforated.
In some embodiments of the cover 200, the second left section top edge 238 defines therein an upper tab 272 slotted inward from the second left section top edge 238, and the second right section top edge 228 forms therein an upper cutout 274 corresponding to the upper tab 272. Also, the second left section bottom edge 239 defines therein a lower tab 282 slotted inward from the second left section bottom edge 239, and the second right section bottom edge 229 forms therein a lower cutout 284 corresponding to the lower tab 282. In the continuing example, each of the upper tab 272 and lower tab 282 is trapezoidal with the trapezoid base at the respective edge. Tab shapes other then trapezoidal can be used, for example, portions of square, rectangular, and other regular and irregular polygons (such as an arrowhead), along with portions of curved shapes can be used. The upper tab 272 is adapted to be bent through the upper cutout 274 to secure the second right section 226 over the second left section 236 when the cover 200 is assembled around an egg carton 100.
In various embodiments, each of the top tab 282 and the bottom tab 272 are one of rounded and chamfered. In some embodiments, the cover material is one of corrugated fiberboard, corrugated cardboard, and plastic.
Referring to
An egg carton is placed on the cover with the egg carton bottom aligned with the central panel—Block 310.
The first left section of the cover is folded to contact the side of the egg carton nearest the central panel left edge, and the second left section is folded to be substantially parallel to the top of the egg carton—Block 320.
The first right section of the cover is folded to contact the side of the egg carton nearest the central panel right edge, and the second left section is folded to contact the top of the second left section, aligning the lower tab with the lower cutout, and aligning the upper tab with the upper cutout—Block 325.
The bottom flap of the cover is folded to be substantially parallel to the side of the egg carton nearest the central panel bottom edge, while the bottom tab is inserted between the folded second left section and the egg carton—Block 330.
The top flap of the cover is folded to be substantially parallel to the side of the egg carton nearest the central panel top edge, while the top tab is inserted between the folded second left section and the egg carton—Block 335.
The lower tab of the cover is bent through the lower cutout aligned therewith, and the upper tab is bent through the upper cutout—Block 340.
The various steps in the method, along with other methods disclosed herein, can be performed in an automated fashion. Variations in order and minor variations in the steps of the methods described herein are contemplated to be included in the methods. For example, while Block 320 and Block 325 should be performed in that order, the egg carton 100 can be inserted into an open end of the rectangular space formed after Block 320 and 325 have been completed. As another example, Block 330 and Block 335 can be performed immediately after Block 305.
In some variations, the cover 200 can include an adhesive applied to one or more surfaces, such as a release tape seal, a gum seal activated by moistening, a self-adhering latex adhesive applied to the back surface of the second right section and the second left section. In some variations, tape can be applied to secure one surface to another, for example, taping across the back side of the second right section to the back side of the first left section when the process described with reference to
The cover 200 can be used in combination with an egg carton insert to form a kit for packaging cartoned eggs. The process described above with reference to
Referring to
Each dome 510 in
Each dome 510 can be connected to each neighboring dome in the array. In the example embodiment of
The array of domes 510 forms an opening 530 between each group of four adjacent domes 510. Each opening 530 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 530 can provide lateral stability to the combined egg carton 100 and egg carton insert 500. The loose, but laterally restrained, coupling between the egg carton insert 500 and the egg carton 100 can contribute to the protection of the eggs contained in the egg carton 100. The egg carton insert 500 is arranged such that each dome 510 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 500 can be placed.
The overall dimensions of the egg carton insert 500 are such that the egg carton 100 can be closed when the egg carton insert 500 is placed over one egg occupying each dimple 116 of the egg carton 100.
In some embodiments, at least one dome 510 defines therein a cutout 512 along a portion of the at least one dome at a long side of the array. The cutout 512 is oriented substantially parallel to the long side of the array. The cutout 512 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 500 when the egg carton 100 dimples 112 are holding eggs.
Referring to
Each ring 610 in
Each ring 610 is connected to each neighboring ring 610 in the array. In the example embodiment of
The array of rings 610 forms an opening 630 between each group of four adjacent rings 610. Each opening 630 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 630 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 600 and the egg carton 100 can contribute to the protection of the eggs from damage. The egg carton insert 600 is arranged such that each ring 610 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 600 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 820. 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 830. The egg carton, containing the eggs and the egg carton insert 200, is closed—Block 840.
Referring to
An egg carton insert in the form of a substantially flat elongated rectangle of material is provided—Block 920. 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 930. The egg carton, containing the eggs and the egg carton insert 300, is closed—Block 940.
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.
