PACKAGING UNIT MOULDED FROM PULP MATERIALS WITH IMPROVED VENTILATION AND METHOD FOR MANUFACTURING THE SAME

Abstract

A packaging unit from a moulded pulp material and a manufacturing method therefor. The packaging unit comprises a bottom part with product receiving compartments and a number of cones that are provided between the compartments, a cover part, a hinge configured for hingedly connecting the bottom part with the cover part, and ventilation bridges formed into the bottom part between adjacent product receiving compartments. The ventilation bridges provide void spaces in a bottom surface of the bottom part and allow for the continuous flow of air through the bottom part of the packaging unit.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a packaging unit made of moulded pulp or molded fiber for products like eggs.

Egg cases, containers or cartons are known in practice and are generally fabricated from carton made from moulded pulp originating from paper material. Such packaging units comprise a bottom part that is provided with compartments for individual products, and a cover part that is often hingedly connected to the bottom part. Products such as eggs are transported and displayed in these packaging units.

WO 2015/160248 A1 discloses a packaging unit comprising such bottom and cover part and is provided with a hinge connecting both parts. The packaging unit further comprises a lock that is configured for locking the cover part and the bottom part in a closed position of the packaging unit.

Packing of the packaging units in a box or crate is often automated/robotized. A gripper clamps one or more of the packaging units and places the packaging units in such box or crate. Alternatively, a vacuum head engages the lid of the packaging unit, or lids of several packaging units, to lift the packaging unit and places it in a box or crate.

This packing with grippers and/or vacuum heads applies considerable force(s) onto the packaging unit. In practice, this may cause problems in the packing operation due to the packaging unit opening during the packing operation. This may cause a standstill in the process. Also, it may cause product loss.

The present invention has for its object to obviate or at least reduce the above stated problems in conventional packaging units, such as egg cases or egg cartons, and to provide a packaging unit that is better suitable for automated/robotized packing.

Another problem with moulded pulp egg cartons is the tendency to absorb moisture, and as a result, lose structural strength and integrity, which can cause the carton to break, deform, sag, and/or provide inadequate protection of the eggs contained therein. In the United States, eggs are typically refrigerated, and grocery stores and the like typically keep eggs in open-air refrigerator units for ease and convenience of the customers. Because these open-air refrigerator units encounter significant temperature and humidity level changes, condensation can often develop on the contents within the refrigerator units. As a result, the moisture absorbing problem known to molded pulp is most prominent for molded pulp egg cartons within these open-air refrigerator units. Condensate develops on the egg cartons, especially on the underside of the cartons either by the condensation forming directly on the carton itself or by the bottom of the carton absorbing moisture that has formed on or dripped down onto the supporting surface of the refrigerator unit where the carton is positioned. This can lead to egg cartons being unable to adequately support the eggs inside, breaking apart and/or becoming damaged when a user picks up said carton.

Accordingly, a need exists for an improved packaging unit made of pulp that is less susceptible to absorbing moisture. A need also exists for an improved packaging unit that is less susceptible condensate formation in open-air refrigerator units and less susceptible to structural degradation in the presence of moisture.

SUMMARY OF THE INVENTION

The present invention provides for its purpose a packaging unit comprising:

• • a bottom part with product receiving compartments and a number of cones that are provided between the compartments, and the bottom part comprising a bottom surface, two side surfaces, a back surface, and a front surface;
  • a cover part comprising a top surface, two side surfaces, a back surface, and a front surface;
  • a hinge configured for hingedly connecting the bottom part with the cover part; and
  • a bottom end construction including at least one ventilation bridge on the bottom surface of the bottom part, the at least one ventilation bridge provided between two adjacent compartments and forming a void space in the bottom surface between the two adjacent compartments.

A packaging unit with a bottom part and cover part that are hingedly connected provides a safe transport, storage and display of products without damaging these products. This is especially relevant in case of packing vulnerable products like eggs. These products are received by the product receiving compartments that are (partly) separated by a number of cones. The front, back and side surfaces of the bottom part and cover part preferably enable display of information. This information may relate to the products inside the packaging unit.

The packaging unit according to the present invention may comprise bottom end construction configured to allow for airflow and ventilation along the bottom surface of the bottom part of the packaging unit. The packaging unit may include one or more ventilation bridges located on the bottom part of the packaging unit. The ventilation bridges may be formed into the bottom part between adjacent product receiving compartments. The compartments in the bottom part may be arranged in two or more rows and ventilation bridges may be formed between adjacent compartments within each row and between adjacent compartments in adjacent rows. The ventilation bridges may be recessed structures formed into the bottom part and extend upward and away from the bottom surface.

The ventilation bridges may have any suitable shape within the bottom part of the packaging unit. According to certain embodiments, the ventilation bridges may have a U-shape structure. According to certain embodiments, the ventilation bridges may include upwardly extending sidewalls and an upper bridge portion or top wall spanning between the sidewalls. The sidewalls and upper bridge portion define a raised structure with a void space below. The sidewalls may extend upward at a slightly increasing inward angle and be connected at their upper end by the upper bridge portion or top wall.

The ventilation bridges may have a bridge width and a bridge height that define a total bridge area of the void space of the ventilation bridge. The bridge height of the ventilation bridges may be configured in proportion to the overall height of the bottom part of the packaging unit. According to one embodiment, the ratio between the bridge height of the ventilation bridges and the height of the bottom part may be approximately between 0.11 and 0.4, approximately between 0.18 and 0.25, or approximately 0.21. The total bridge width of the ventilation bridges on the front or side of the packaging unit may be configured in proportion to the overall length or width of the bottom part of the packaging unit. According to one embodiment, the ratio between the total bridge width along the front of the packaging unit and the length of the bottom part may be approximately between 0.3 and 0.5, approximately between 0.35 and 0.45, or approximately 0.4. The ratio between the total bridge width of the ventilation bridge or bridges on the side of the packaging unit and the width of the bottom part may be approximately between 0.15 and 0.35, approximately between 0.2 and 0.3, or approximately 0.25. The ratio between the total area of the ventilation bridges along the front of the packaging unit and the front surface of the bottom part may be approximately between 0.03 and 0.10, approximately between 0.05 and 0.08, or approximately 0.06. The ratio between the area of the ventilation bridge or bridges along the side of the packaging unit and the side surface of the bottom part may be approximately between 0.02 and 0.08, approximately between 0.03 and 0.05, or approximately 0.04.

The ventilation bridges may be appropriately sized relative to the bottom part of the packaging unit to facilitate the free movement of air under and/or through the bottom of the packaging unit. This configuration can reduce moisture accumulation and retention of the bottom part of the packaging unit. Particularly, the permitted airflow at the bottom part of the packaging unit can enable moisture to be flashed off by defrost cycles during refrigeration of the packaging unit. The specific dimensions and sizing ratios of the ventilation bridges disclosed herein can also optimize airflow and moisture transfer on the bottom surface of the packaging unit relative to conventional packaging unit designs.

The packaging unit according to the invention may further comprise a lock configured for locking the cover part to the bottom pan. The lock may comprise a number of (one or more) locking openings and a number of (one or more) corresponding locking cams. In a presently preferred embodiment the number of locking openings and cams is two. It will be understood that another number of openings and cams can also be envisaged in accordance with the invention. For example, for small size packaging units one opening and cam may be sufficient, while for larger packaging units a higher number of openings and cams can be provided.

The locking openings and locking cams are provided in the front surface of the bottom and cover parts. Preferably, the locking cam is connected to the bottom part and the locking opening is provided in the cover part. According to the present invention the locking opening and locking cams are provided adjacent or at a transition region between the front surface and the top surface of the cover part when the packaging unit is in a closed position.

This provides an elevated position of the locking elements, i.e., locking openings and locking cams, as compared to conventional packaging units, such as egg packaging units. Providing locking elements at such elevated position improves the locking security such that a more secure locking is achieved. This is especially relevant when lifting and/or gripping the packaging unit with a vacuum head and/or gripper during the packing operation. This significantly reduces the problems in these packing operations that result from undesired opening of the packaging units during the packing operation. Therefore, the packaging unit according to the invention reduces standstill of the operation and also reduces loss of products during the packing operation.

In addition, providing the locking elements at an elevated position adjacent or at the transition region, and preferably at least partly in the transition region between the front surface and the top surface of the cover part in the closed position of the packaging unit, increases the display surface of the front, surface of the cover part. This enables providing more and better information to a consumer, for example.

Furthermore, as a result of the improved locking the locking cams need not to protrude over a significant extent through the opening. In fact, in a presently preferred embodiment the locking cams do not protrude from the front surface of the packaging unit. This provides more space for maneuvering the grippers and/or vacuum heads in the automated/robotized packing operation. This further improves the packing operation and reduces standstill and/or product loss.

According to one embodiment of the invention, the bottom part may comprise a support member that is configured for engaging the cover part. This support member may engage the support part in the closed position of packaging unit. This provides additional strength and stability to the packaging unit. More specifically, the support member provides additional support that is especially beneficial or especially advantageous when stacking packaging units.

As a further effect of the elevated position of the locking elements, the outwards bending of the front surface of the cover part is significantly reduced. This improves the visual display of the front surface when displaying the packaging unit. In addition, this further improves locking security and also increases the maneuvering space or the grippers and/or vacuum heads in the packing operation. This may improve the packing operation and may increase the capacity of such packing operation.

As a further effect of the elevated position of the locking elements, the outwards bending of the front surface of the cover part is significantly reduced. This improves the visual display of the front, surface when displaying the packaging unit. In addition, this further improves locking security and also increases the maneuvering space or the grippers and/or vacuum heads in the packing operation. This may improve the packing operation and may increase the capacity of such packing operation.

As a further effect of the elevated position of the locking element a label can be provided easier over the locking cam. This renders the labelling operation more effective. This is even further improved in case the locking cam does not protrude significantly through the locking opening.

Furthermore, the locking opening may comprise and/or may be circumvented by a backwards curved upper end that is at least partially positioned in the transition region. This further enhances the labelling process. Furthermore, this improves the closing of the cover part over the bottom part as it provides a self-aligning effect of the locking cam into the locking opening.

Furthermore, the locking opening may comprise and/or may be circumvented by an inwards inclined lower edge having a length of at least 2.5 mm and extending over an inwards (horizontal) distance of at least 1.8 mm. This improves the locking security. Especially the combination of the backwards curved upper end and the inwards inclined lower edge improves the locking security and renders closing and opening of the packaging unit easier. This provides a user-friendly packaging unit. Also, experiments showed that the locking security can be further improved by the lower and upper edges, thereby further improving the packing operation. In one of the preferred embodiments of the invention the inwards inclined lower edge has a length of at least 5.5 mm and extending over an inwards (horizontal) distance of at least 4.5 mm. This further improves the locking security.

In a presently preferred embodiment, the locking cams are solid locking cams. This improves the strength of the lock and more specifically improves the locking security of the lock.

The locking cams and the support member are preferably provided on the closing flap of the bottom part of the packaging unit. This provides an effective packaging unit providing sufficient protection for especially vulnerable products like eggs.

In a presently preferred embodiment of the invention the locking cams remain behind a display surface of the packaging unit in a closed position of the packaging unit. By providing the locking cams behind a display surface this display surface is both enlarged and improves. The locking security can be guaranteed by the preferred combination of the elevated position of the locking elements and the ovoid shape of the locking elements and the shape and size of the upper and lower opening edges.

In a preferred embodiment of the invention the support members comprise a hook element. By providing the support member with a hook element an improved contact surface between the support, member and the cover part, more specifically the top surface thereof, is provided. This improves the strength and stability of the packaging unit. This is especially advantageous when stacking a number of packaging units.

In a further preferred embodiment of the invention two locking cams of the packaging unit are provided adjacent or close to a transition from front to side surfaces. By providing the locking elements relatively close to the side surfaces of the packaging unit the maneuvering space for the grippers and/or vacuum heads is further improved as they are not hindered by the locking elements. This improves the packing operation.

In a further preferred embodiment of the invention, the locking openings and locking cams have an ovoid shape. Providing the locking openings and locking cams with an ovoid shape has the advantage that a larger contact surface is provided between the upper edge of the opening and the upper edge of the cam when lifting a packaging unit and the locking cam is in contact with the upper edge of the locking opening. In addition, the ovoid shape guarantees an effective locking, also in the presence of manufacturing tolerances such that under practical circumstances a sufficient contact area is provided between the locking cam and the locking opening. This guarantees a secure locking for a relatively broad range of manufacturing tolerances. In practice, this reduces standstill of the packing operation and reduces product loss. Also, the ovoid shape provides an improved alignment of the cam when being moved into the opening.

In a further preferred embodiment of the invention the packaging unit further comprises a label without openings for the lock. Omitting locking openings in the label provides more strength to the label and reduces the risk of damaging, disrupting, etc., of the label. In addition, omitting locking openings increases the display surface and, therefore, the possibility to communicate with consumers.

Preferably, the front surface of the cover part is provided at an angle to the vertical in the range of 5° to 13°, preferably more preferably in the range of 8 to 12°, and wherein the angle is most preferably about 10°. This angle between the front surface of the cover part and the vertical provides a further improved display surface with a better view for a consumer. In addition, the maneuvering space for grippers and/or vacuum heads is further increased.

In one embodiment of the invention, the hinge may comprise an elevated hinge. Providing the hinge as an elevated hinge the hinge positions the hinge higher from the ground surface. This enables providing the front surface of the cover part extending below the elevated hinge of an adjacent packaging unit. This reduces the required space for two or more packaging units placed adjacent to each other. This is also beneficial in a packing operation in case grippers and vacuum heads grip and pickup several packaging units at once. This improves the efficiency of the patent operation. Preferably, the hinge width is reduced as compared to a conventional hinge width. This contributes to an overall reduction in size and improved packing operation.

In one embodiment of the invention, the side surfaces of the cover part may comprise one or more denesting elements, wherein the denesting elements comprise two elements provided at a distance of at least 70% of a width of the side surface, preferably at a distance of at least 77.5% and most preferably at a distance of at least 85%. This improves the denesting of packaging units when packing the units with products, for example. In one embodiment of the invention, the denesting elements may be positioned in or at one or more ovoid or egg shaped elements in or on the side surfaces.

The invention further relates to a method for manufacturing a packaging unit according to an embodiment of the present invention. Such method provides similar effects and advantages as described in relation to the packaging unit.

Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

FIG. 1 is a perspective view of a packaging unit according to one embodiment of the present invention;

FIG. 2 is a perspective view of the packaging unit of FIG. 1 in an open position;

FIGS. 3A-B are front elevation views of the packaging unit of FIG. 1 illustrating the packaging unit provided with a label with and without locking openings, respectively;

FIG. 4 is a cross-sectional side elevation view of the lock of the packaging unit of FIG. 1;

FIGS. 5A-B are perspective views of a packaging unit according to another embodiment of the present invention;

FIG. 6 is a perspective view of a packaging unit in an open position and containing ventilation bridge structures according to another embodiment of the present invention;

FIG. 7 is a top plan view of the packaging unit of FIG. 6;

FIG. 8 is a side elevation view of the packaging unit of FIG. 6;

FIG. 9 is an enlarged partial cross-sectional side elevation view of the packaging unit of FIG. 6 illustrating a ventilation bridge structure;

FIG. 10 is a side elevation view of the packaging unit of FIG. 6 in a closed position;

FIG. 11 is a front elevation view of the packaging unit of FIG. 6 in a closed position; and

FIG. 12 is a perspective view of the packaging unit of FIG. 6 illustrating an arrangement of ventilation bridges on the bottom surface of the packaging unit.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.

The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention.

Packaging unit 2 (FIG. 1) comprises cover part 4 and bottom part 6. Cover part 4 comprises top surface 8, cover hack surface 10, cover front surface 12 and two cover side surfaces 14. In the illustrated embodiment cover side surfaces 14 comprises two ovoid shaped elements 16 and two denest elements 18. Denest elements 18 are placed at the distance AW. In the illustrated embodiment ΔW is about 80 to 85% of the width W of packaging unit 2. Packaging unit 2 has further height H and length L. Bottom part 6 is provided with bottom front surface 20, bottom surface 22, bottom back surface 24, and two bottom side surfaces 26. Hinge 28 connects cover back surface 10 with bottom back surface 24. Hinge 28 is provided at an elevated height ΔH which relates to the height difference over the length of the contact line in a direction W between cover side surface 14 and bottom side surface 26 in the closed position of packaging unit 2.

In the illustrated embodiment L is about 291 mm, W is about 104 mm. It will be understood that other dimensions of packaging unit 2 can also be envisaged in accordance to the invention.

Lock 30 comprises locking opening 32 and locking cam 34 as locking elements. In the closed position of packaging unit 2 locking cams 34 engage locking openings 32. In the illustrated embodiment locking opening 32 and locking cam 34 are provided with a (partial) ovoid shape. Opening 32 comprises and/or is circumvented by lower edge 36 and upper edge 38. In the illustrated embodiment at least upper edge 38 is positioned in transition region 40 between top surface 8 and cover front surface 12. In the illustrated embodiment transition region 40 extends between lower limit 40a and upper limit 40b.

In the open position of packaging unit 2 (FIG. 2) there is shown closing flap 42 with support element or support edge 44 that is preferably shaped as a hook element. Cones 46 are provided between adjacent compartments 48 that are configured for receiving the products. Bottom front surface 20 is provided with additional supports 50.

Packaging unit 2 can be provided with label 52 (FIG. 3A) having openings that enable a view on lock 30. In an alternative embodiment packaging unit 2 is provided with label 54 (FIG. 3B) without openings such that lock 30 remains invisible in a front view of packaging unit 2. Optionally, a label cut is provided to enable lock 30 to push forward label 52 and/or partly protrude through label 52.

Lower edge 36 (FIG. 4) is provided at an angle of a relative to the horizontal. In the illustrated embodiment a is in the range of 25 to 45°. In the illustrated embodiment length D_e of lower edge 36 is 5.4 to 6.0 mm. The inward distance D_i in which lower edge 36 extends in a horizontal direction is about 5.0 to 5.3 mm. In a closed position of packaging unit 2, without external forces acting on packaging unit 2 distance D between tip 56 of lower edge 36 and lower surface 58 of locking cam 34, is about 2 mm.

In the illustrated embodiment locking cam 34 relates to a solid locking cam wherein bottom surface 58 of cam 34 is closed. This provides additional stability to locking cam 34 and lock 30.

In the illustrated embodiment flap 42 is provided with flap extension 60. Front surface 12 is provided at an angle β relative to the vertical. In the illustrated embodiment β is about 10°. Upper edge 38 of locking opening 32 is provided with curvature 62 in an upward direction in transition region 40 towards top surface 8. When packing the packaging units 2 use can be made of vacuum head 64 and/or grippers 66.

Packaging unit 102 (FIGS. 5A-B) comprises cover part 104 and bottom part 106. Packaging unit 102 has the same or similar features as described in relation to packaging unit 2 (FIGS. 1-4). A difference relates to lock 130 (FIGS. 5A-B) with locking openings 132 and locking cams 134. Lower edge 136 associated with opening 132 is smaller. Also, locking cam 134 (FIGS. 5A-B) is smaller as compared to locking cam 34 (FIGS. 1-4). In the illustrated in the presently preferred embodiment α is in the range of 25 to 45°. In the illustrated embodiment 102 length D_e of lower edge 36 is about 2.8 to 3.0 mm. The inward distance D_i in which lower edge 36 extends in a horizontal direction is about 1.9 to 2.1 mm. Experiments showed that lock 130 provides a robust lock that is optionally used in combination with a label having no openings for the lock. When packing products like eggs, the eggs are placed in compartments 48. Then the cover part 4 is closed with hinge 28 and lock 30 secures the connection between cover part 4 and bottom part 6. In a packing operation vacuum head 64 engages top surface 8 and/or gripper element 66 engage one or more of cover front surface 12 and cover back surface 10. Then packaging units 2 are positioned in a crate, box or other suitable location.

In the manufacturing process for packaging unit 2 a molding operation is performed. During the manufacturing process hinge 28 is positioned at an elevated position AH. Also locking elements 32, 34 are positioned at an elevated position preferably extending into the transition region 40.

FIGS. 6-12 illustrate packaging unit 2 in accordance with another embodiment of the present invention. Similar to the embodiment described above with reference to FIGS. 1-4, packaging unit 2 as shown in FIGS. 6-12 can include a cover part 4 and a bottom part 6. Cover part 4 may include a top surface 8, cover back surface 10, cover front surface 12 and two cover side surfaces 14. Bottom part 6 may be provided with a bottom front surface 20, bottom surface 22, bottom back surface 24, and two bottom side surfaces 26. As shown in FIGS. 7 and 11, packaging unit 2 includes a height H, length L and width W. Height H may be defined as the total height of packaging unit 2 in a closed configuration and can be measured from the lower end of bottom part 6 to upper end of cover part 4. Length L may be defined as the entire length of bottom part 6 and can be measured as the distance between side surfaces 26 of bottom part 6. Width W may be defined as the width of bottom part 6 along side surface 26 and can be measured as the distance between the front surface 20 and back surface 24. A hinge 28 may extend between cover part 4 and bottom part 6 and may connect cover back surface 10 with bottom back surface 24 in order to allow cover part 4 to rotate along hinge 28 and about a hinge axis extending along hinge 28. Hinge 28 allows for the packaging unit 2 to be moved into an open configuration and a closed configuration. The top surface 8 may contain locking openings 32. The bottom part 6 may include one or more locking cams 34 as locking elements paired with the one or more locking openings 32. The locking cams 34 may be coupled with the locking openings 32 to hold the packaging unit 2 in a closed position.

As best shown in FIGS. 6 and 7, bottom part 6 may include one or more cones 46 provided between adjacent compartments 48 configured for holding the products. According to one particular embodiment, packaging unit 2 may contain twelve compartments 48 arranged in two rows of six compartments 48 extending from one side surface 26 to the other. Other arrangements and quantities of compartments 48 may suitably be used in alternative embodiments. As non-limiting examples, in one embodiment (not shown), packaging unit 2 may include ten compartments 48 arranged in two rows of five compartments 48, and in another embodiment (not shown), packaging unit 2 may include eighteen compartments 48 arranged in three rows of six compartments 48.

As described above, the packaging unit 2 may have a unit length L, a unit width W, and a unit height H. As best shown in FIGS. 10 and 11, in addition to the overall unit dimensions of packaging unit 2, bottom part 6 may have a unit length L_b, a unit width W_b and a unit height H_b. Unit length L_b can be defined as distance between the side ends of bottom part 6 measured at bottom surface 22. Unit width W_b can be defined as the distance between the front and back ends of bottom part 6 measured at bottom surface 22. Unit height H_b can be defined as the distance between the bottom end of bottom part 6 and the upper end of bottom part 6.

As shown in FIGS. 6-12, packaging unit 2 may include an improved bottom end construction that can allow for airflow and ventilation along bottom surface 22 of bottom part 6 and packaging unit 2 and operate to reduce moisture absorption and damage to packaging unit 2 due to condensation formation in variable temperature and humidity conditions. As best shown in FIGS. 7, 10 and 11, packaging unit 2 may include one or more ventilation bridges 62 provided in bottom part 6. As illustrated in FIG. 7, ventilation bridges 62 may be located on the bottom surface 22 of bottom part 6 and packaging unit 2 between each set of adjacent compartments 48. As further illustrated in FIG. 7, ventilation bridges 62 may extend in either or both the width direction and length direction of packaging unit 2. In the width direction, ventilation bridges 62 extend between adjacent compartments 48 of different rows of compartments 48. In the length direction, ventilation bridges 62 extend between adjacent compartments 48 in the same row of compartments 48. Ventilation bridges 62 may be configured as recessed structures defined into bottom surface 22 and project upward within the interior of bottom part 6 between adjacent compartments 48 in both the length and width directions. The upper ends of ventilation bridges 62 may be defined raised ridges within the interior of bottom part 6 and provide a partial barrier between adjacent compartments 62. Each ventilation bridge 62 may extend from one compartment 48 to an adjacent compartment 48 to define a void space in bottom surface 22 so that the lowermost plane of bottom surface 22 and bottom part 6 includes the bottom ends of each compartment 48.

Ventilation bridges 62 may have a variety of shapes, including being U-shaped, V-shaped, quadrate, orthogonal or arcuate. In some embodiments the ventilation bridges 62 may include individual segments, including sidewalls 64 and an upper bridge portion 66 as illustrated in FIG. 9. Each segment of the ventilation bridges 62 may be rounded or straight or a combination of both. Additionally, the sidewalls 64 may extend vertically or at an angle. According to one embodiment as shown in FIG. 9, each ventilation bridge includes two angled arcuate sidewalls 64 that extend upward from a lower end of bottom surface 22 and transition to an upper bridge portion 66. Each sidewall 64 extends upwardly from bottom surface 22 of compartment 62 with an inward-oriented angle and includes a lower angled portion and an upper arcuate portion that curves toward upper bridge portion 66. The arcuate portion of each sidewall 64 (opposite of bottom surface 22) curves further inward at an increasing angle and transitions to the upper bridge portion 66. As also shown in FIG. 9, in this embodiment, the upper arcuate portion of each sidewall has increasing curvature as sidewall 64 approaches upper bridge portion 66. This configuration of ventilation bridge 64 may operate to increase airflow through the void spaces of bridges 64 and/or increase the structural strength of bottom part 6; however, it is recognized that a variety of shapes, configurations and arrangements of ventilation bridge 62 may be used, provided they provide adequate ventilation to the underside of the packaging unit 2. For example, in another embodiment (not shown), each ventilation bridge 62 may include sidewalls 64 with only angled portions that extend at a substantially constant angle to upper bridge portion 66. In another embodiment (not shown), each ventilation bridge 62 may include sidewalls 64 with only arcuate portions that with continuous curvature up to upper bridge portion 66. In another embodiment (not shown), each ventilation bridge 62 may include only sidewalls 64 (with one or both of angled and arcuate portions) that converge together and omit upper bridge portion 66.

As best shown in FIGS. 9-11, ventilation bridges 62 each have a bridge height Z and a bridge width X. Bridge height Z can be defined as the distance between the lowermost end of bottom surface 22 and upper bridge portion 66. Bridge width X can be defined as the distance between the two bridge sidewalls 64 (and the end edges of adjacent compartments 48). In the embodiment shown in FIG. 9, the bridge width X is the widest point of the ventilation bridge 62 and is longer that the length of the upper bridge portion 66. In the embodiment shown in the FIGS. 6-12, ventilation bridges 62 may all be configured with the same bridge height Z and bridge width X, including ventilation bridges 62 extending in the length direction and ventilation bridges 62 extending in the width direction (see FIGS. 10-12); however, it is recognized that in other embodiments, the bridge height Z and bridge width X of ventilation bridges 62 in the length direction may be different than the bridge height Z and bridge width X of ventilation bridges 62 in the width direction.

The ventilation bridges 62 span between each adjacent compartment 48 and include a void space defined by the sidewalls 64 and upper bridge portion 66. As best shown in FIG. 7, packaging unit 2 may include at least two row of compartments 48 extending in the length direction of packaging unit 2. Ventilation bridges 62 may be provided between each set of adjacent compartments 48 in each row. Ventilation bridges 62 may also be provided between adjacent compartments 48 in adjacent rows to extend in the width direction of packaging unit 2. In the embodiment illustrated in FIGS. 6-12, there are five ventilation bridges 62 formed along each row and visible from the front and back surfaces 20, 24 (see FIG. 11) and a single ventilation bridge 62 visible from each side surface 26 (see FIG. 10). However, it is recognized that a variety of different arrangements of the ventilation bridges 62 can be used depending on the compartment 48 configuration of packaging unit 2. The ventilation bridges 62 are appropriately sized to allow the free movement of air under and/or through the bottom of the packaging unit 2, which can reduce moisture accumulation and retention of bottom part 6. Particularly, the permitted airflow at bottom part 6 of packaging unit 2 can enable moisture to be flashed off by defrost cycles during refrigeration of the packaging unit 2.

As best shown in FIGS. 7 and 12, ventilation bridges 62 are arranged between adjacent compartments 48 in both the length and width directions packaging unit 2. Ventilation bridges 62 extending in the length direction (from one side 26 to the opposing side surface 26) form a continuous row of bridges 62 along the entire length of bottom surface 22 of bottom part 6. As further shown in FIGS. 7 and 12, the arrangement of ventilation bridges 62 provide a plurality of rows of bridges 62 extending in the width direction (from front surface 20 to back surface 22). The illustrated embodiment has five rows of bridges 62 extending in the width direction and one row of bridges extending in the length direction (for a total of sixteen bridges 62); however, in alternative embodiments with an alternative number of compartments 48 (such as an 18-count packaging unit) can have different numbers of rows of bridges 62 in both the length and width directions.

As best shown in FIG. 12, each continuous row of ventilation bridges 62 defines a continuous flow path for the flow of air below and/or through the bottom surface 22 of bottom part 6 and packaging unit 2. In the embodiment illustrated in FIG. 12, five total flow paths are provided from front surface 20 to back surface 24 of packaging unit 2 and one flow path is provided from one side surface 26 to the opposing side surface 26.

Ventilation bridges 62 may be configured with specific dimensions for the bridge height Z and bridge width X and the area of void space defined by each ventilation bridge 62. The specific dimensions and area may be determined relative to the unit length L, width W and height H of packaging unit 2 and/or relative to the unit length L_b, width W_b and height H_b of bottom part 6. The specific dimensions and area of ventilation bridges 62, in particular as a ratio to the unit dimensions of packaging unit 2 and/or bottom part 6, may provide improve moisture control and structural strength of packaging unit 2. The following provides one or more particular embodiments of packaging unit 2 with specific dimensions, areas and ratios (relative to unit dimensions of packaging unit 2 and/or bottom part 6) that have demonstrated improved moisture and structural properties when the packaging unit 2 is exposed to conditions typically present in open-air refrigerator units. However, it is recognized that the following are only exemplary embodiments and packaging unit 2 and ventilation bridges 62 may have any suitable dimensions and areas in alternative embodiments.

According to one non-limiting and exemplary embodiment of packaging unit 2, the unit length L may be between 280 and 300 mm, the unit width W may be between 90 and 110 mm, and the unit height H may be between 60 and 70 mm. The unit length L_b may be between 240 and 260 mm, the unit width W_b may be between 70 and 90 mm, and the unit height H_b may be between 25 and 45 mm. The bridge height Z may be between 5 and 10 mm and the bridge width X may be between 15 and 25 mm. The effective area of each ventilation bridge 62 may be between 90 and 140 mm². Packaging unit 2 may be configured as a twelve-count unit with twelve individual compartments 48 arranged in two rows of six compartments, which results in five ventilation bridges 62 along the front of the packaging unit 2. In this embodiment, the effective bridge width of the ventilation bridges 62 (i.e., the total combined width of ventilation bridges 62 in the length direction) may be between 80 and 110 mm.

For the specific embodiment and dimensions described above, the unit length L of packaging unit 2 may be between 2.5 and 3.75 times the effective bridge width. The unit length L_b of bottom part 6 may be between 2 and 3.25 times the effective bridge width. In one embodiment, the effective bridge width may be between 30% and 35% of unit length L, or approximately 32%, and the effective bridge width may be between 35% and 40% of unit length L_b, or approximately 37%.

For the specific embodiment and dimensions described above, the unit width W of packaging unit 2 may be between 3.5 and 6.75 times the bridge width X, and the unit width W_b of bottom part 6 may be between 2.75 and 6 times the bridge width X. In one embodiment, the bridge width X may be between 14% and 28% of unit width W, or approximately 19%, and the bridge width X may be between 17% and 36% of unit width W_b, or approximately 25%.

As described above, according to one exemplary embodiment, the area of each ventilation bridge may be between 90 and 140 mm², or approximately 110 mm². In an arrangement with five ventilation bridges 62 formed along the length of packaging unit 2, the effective area of the ventilation bridges 62 along the front surface 20 of bottom part 6 may be between 450 and 700 mm², or approximately 550 mm². According to this embodiment, the effective area of ventilation bridges 62 may be between 5% and 10% of the total area of front surface 20 of bottom part 6, or approximately 6%. On each side of packaging unit 2, the area of ventilation bridge 62 may be between 2% and 7% of the total area of side surface 26 of bottom part 6, or approximately 4%.

According to certain embodiments, that size and dimensions of the ventilation bridges 62 may be configured based on the size and dimensions of bottom part 6 of packaging unit 2. In particular, the overall size of ventilation bridges 62 may be configured as a ratio to the overall size of bottom part 6 in order to optimize airflow along the bottom surface of bottom part 6. According to one non-limiting embodiment, the ratio between the effective bridge width and the unit length L_b may be approximately between 0.3 and 0.5, approximately between 0.35 and 0.45, or approximately 0.4. The ratio between the effective bridge width and the unit width W_b may be approximately between 0.15 and 0.35, approximately between 0.25 and 0.35, or approximately 0.25. The ratio between the total area of the ventilation bridges 62 along the front surface of bottom part 6 and the front surface of bottom part 6 may be approximately 0.03 and 0.10, approximately between 0.5 and 0.8, or approximately 0.06. The ratio between the area of the ventilation bridge or bridges 62 along the side surface of bottom part 6 and the side surface of bottom part 6 may be approximately 0.02 and 0.08, approximately between 0.3 and 0.5, or approximately 0.04. The foregoing may also correspond to a ratio between the effective bridge width and the unit length L of packaging unit 2 may be approximately between 0.25 and 0.4, or approximately 0.3, and a ratio between the effective bridge width and the unit width W of packaging unit 2 may be approximately between 0.15 and 0.3, or approximately 0.2.

The height of ventilation bridges 62 may be configured based on the overall height of packaging unit 2 or bottom part 6. According to the embodiment described above, the height Z of ventilation bridges 62 may be approximately between 0.07 and 0.17 the overall height H of packaging unit 2 and/or the height Z of ventilation bridges 62 may be approximately between 0.11 and 0.4 the height H_b of bottom part 6. According to certain embodiments, the height Z of ventilation bridges 62 relative to the height H of packaging unit 2 may be approximately between 7-17%, approximately between 9-13%, or approximately 11%. According to certain embodiments, the height Z of ventilation bridges 62 relative to the height H_b of bottom part 6 may be approximately between 11-40%, approximately between 18-25%, or approximately 21%.

The foregoing dimensions of ventilation bridges 62 relative to packaging unit 2 and bottom part 6 and corresponding ratios are configured to improve the moisture control and structural strength of packaging unit 2 when in use, particularly in refrigerator conditions. The specific embodiments and sizing ratios thereof have demonstrated improved moisture control in open-air refrigerator conditions, and thus improved structural characteristics, as compared to conventional packaging units. The dimensions and area of ventilation bridges 62 relative to the remainder of bottom part 6 enable optimal airflow through the bottom part 6 of packaging unit 2 in order to reduce or minimize moisture formation on the outer surface of packaging unit 2 and improve moisture wicking and transfer to the air flowing through ventilation bridges 62. However, the foregoing dimensional arrangements are only intended to provide exemplary embodiments and it is recognized that alternative dimensions and ratios may be suitably used in alternative embodiments.

According to one specific embodiment of packaging unit 2, the unit length L may be approximately 292 mm, the unit width W may be approximately 102 mm, and the unit height H may be approximately 67 mm. The unit length L_b may be approximately 255 mm, the unit width W_b may be approximately 76 mm, and the unit height H_b may be approximately 35 mm. The bridge height Z may be approximately 7.5 mm and the bridge width X, may be approximately 19 mm. The area of each ventilation bridge 62 may be approximately 110 mm². Along the front of the packaging unit 2, the effective bridge width of the ventilation bridges 62 is approximately 95 mm, or approximately 0.33 the unit length L or approximately 0.37 the unit length L_b. The bridge width X, which is also the effective bridge width across a side surface 26 of bottom part 6, is approximately 0.19 the unit width W or approximately 0.25 the unit width W_b. the bridge height Z is approximately 0.11 the unit height H or approximately 0.21 the unit height H_b. The area of the ventilation bridges 62 along the front surface of a closed packaging unit 2 is approximately 0.028 of the area of the front surface when the packaging unit 2 is in a closed configuration or approximately 0.062 the area of bottom part 6 long the length of bottom part 6. The area of ventilation bridge 62 along the side of packaging unit 2 (i.e., in the width direction) is approximately 0.016 the area of the side surface of packaging unit 2 or approximately 0.041 the area of the side surface 26 of bottom part 6.

Further embodiments of packaging units that have different compartment configurations and may have different dimensions and ratios than those specified above. The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims within the scope of which many modifications can be envisaged.

Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any of the individual embodiments described above. The embodiments described herein are not meant to be an exhaustive presentation of how the various features of the subject matter herein may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

The numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure.

As used herein, “a,” “an,” or “the” can mean one or more than one. For example, “an” image can mean a single image or a plurality of images.

The term “and/or” as used in a phrase such as “A and/or B” herein can include both A and B; A or B; A (alone); and B (alone). Likewise, the term “and/or” as used in a phrase such as “A, B, and/or C” can include at least the following embodiments: A, B, and C; A, B, or C; A or C; A or B; B or C; A and C; A and B; B and C; A (alone); B (alone); and C (alone).

As used herein, the terms “about” and “approximately” when referring to a measurable value such as an amount, a temporal duration, and the like, can include variations of +/−20%, more preferably +/−10%, even more preferably +/−5% from the specified value, as such variations are appropriate to reproduce the disclosed methods and systems.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention.

Claims

1. A packaging unit comprising: a bottom part with product receiving compartments and a number of cones that are provided between the compartments, and the bottom part comprising a bottom surface, two side surfaces, a back surface, and a front surface;a cover part comprising a top surface, two side surfaces, a back surface, and a front surface;a hinge configured for hingedly connecting the bottom part with the cover part; andat least one ventilation bridge on the bottom surface of the bottom part, the at least one ventilation bridge provided between two adjacent compartments and forming a void space in the bottom surface between the two adjacent compartments, the at least one ventilation bridge comprising two sidewalls and a top wall, wherein the two sidewalls extend upward from the bottom surface and include an upper arcuate portion adjacent the top wall.

2. The packaging unit of claim 1, wherein the two sidewalls of the at least one ventilation bridge comprises a lower angled portion and an upper arcuate portion, wherein the lower angled portion extends upward from the bottom surface at a substantially constant inward angle and the upper arcuate portion extends from the lower angled portion with an increasing angle of curvature to the top wall.

3. The packaging unit of claim 1, wherein the at least one ventilation bridge comprises a plurality of ventilation bridges in a spaced arrangement along both a length of the bottom part and a width of the bottom part, wherein the plurality of ventilation bridges define a plurality of continuous flow paths for the flow of air through the bottom part.

4. The packaging unit of claim 1, wherein the at least one ventilation bridge has a height between 5 and 10 mm.

5. The packaging unit of claim 1, wherein the at least one ventilation bridge has a width between 15 and 25 mm.

6. The packaging unit of claim 1, wherein the void space defined by the at least one ventilation bridge has an area between 90 and 140 mm2.

7. The packaging unit of claim 1, wherein the bottom part comprises at least two rows of product receiving compartments, wherein the at least one ventilation bridge comprises a ventilation bridge positioned between each set of adjacent product receiving compartments in each row of product receiving compartments and a ventilation bridge between product receiving compartments in adjacent rows of the at least two rows of product receiving compartments.

8. The packaging unit of claim 7, wherein a total combined width of the ventilation bridges in each row of product receiving compartments is between 0.3 and 0.5 times a length of the bottom part.

9. The packaging unit of claim 7, wherein a width of each ventilation bridge is between 0.15 and 0.35 times a width of the bottom part.

10. The packaging unit of claim 7, wherein a height of each ventilation bridge is between 0.11 and 0.40 times a height of the bottom part.

11. The packaging unit of claim 1, wherein the packaging unit is made from a molded fiber material.

12. A packaging unit comprising: a bottom part with product receiving compartments and a number of cones that are provided between the compartments, and the bottom part comprising a bottom surface, two side surfaces, a back surface, and a front surface;a cover part comprising a top surface, two side surfaces, a back surface, and a front surface;a hinge configured for hingedly connecting the bottom part with the cover part; andat least one ventilation bridge on the bottom surface of the bottom part, the at least one ventilation bridge provided between two adjacent compartments and forming a void space in the bottom surface between the two adjacent compartments, wherein a height of the at least one ventilation bridge is between 0.11 and 0.4 times a height of the bottom part.

13. The packaging unit of claim 12, wherein the height of the at least one ventilation bridge is approximately 0.21 times the height of the bottom part.

14. The packaging unit of claim 12, wherein the at least one ventilation bridge includes two outer sidewalls and a top wall extending between the two outer sidewalls, wherein the two outer sidewalls are angled inward and form an arcuate shape with the top wall.

15. The packaging unit of claim 12, wherein each ventilation bridge has a U-shape and comprises a sidewall extending upward from the bottom surface, a top wall spanning across the sidewall, a void space below the top wall.

16. A packaging unit comprising: a bottom part with a first row of product receiving compartments, a second row of product receiving compartments, and a number of cones that are provided between the compartments of the first and second rows, and the bottom part comprising a bottom surface, two side surfaces, a back surface, and a front surface;a cover part comprising a top surface, two side surfaces, a back surface, and a front surface;a hinge configured for hingedly connecting the bottom part with the cover part; anda plurality of ventilation bridges formed into the bottom part, wherein the plurality of ventilation bridges comprises a ventilation bridge positioned between each two adjacent compartments in each of the first row and each two adjacent compartments in the second row and a ventilation bridge positioned between each two adjacent compartments of the first and second rows;wherein a total combined width of the ventilation bridges in the first row of product receiving compartments is between 0.3 and 0.5 times a length of the bottom part.

17. The packaging unit of claim 16, wherein the total combined width of the ventilation bridges in the first row of product receiving compartments is approximately 0.4 times the length of the bottom part.

18. The packaging unit of 16, wherein each ventilation bridge includes a height approximately between 5 and 10 mm and a width approximately between 15 and 25 mm, and a total void space area approximately between 90 and 140 mm2.

19. The packaging unit of claim 16, wherein the plurality of ventilation bridges forms a continuous flow path opening extending along an entire length of the bottom surface.

20. The packaging unit of claim 16, wherein the plurality of ventilation bridges forms at least one continuous flow path opening extending along an entire width of the bottom surface.