PACKAGING UNIT WITH RIBS AND METHOD FOR PACKING PRODUCTS

Abstract

The present invention relates to a packaging unit (2) with a label for products like eggs, and a method there for. The packaging unit according to the present invention comprises: a cover part (14) comprising top, front, side and rear surfaces; and a bottom part (4) comprising a number of compartments (26) for individual products, and a number of cones (28) that are positioned between adjacent compartments; wherein the bottom part comprising a number of ribs (34) extending between at least some of the compartments, wherein the bottom part further comprises a groove (48) between adjacent compartments, and wherein the grooves fire configured to receive part of the ribs of another packaging unit

Description

The present invention relates to a packaging unit made of moulded pulp for products like eggs and similar products like kiwis and tomatoes, for example. Such packaging unit may also relate to cases, boxes, cups, plates, carriers, sip lids etc.

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. Eggs, or other products, 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 and a lock that is configured for locking the cover part and the bottom part in a closed position of the packaging unit.

During transport, storage and display the packaging units are confronted with loads that may damage the packaging units and/or the products inside these packaging units. To withstand these loads, conventional packaging units have to be provided with sufficient strength, thereby requiring a certain amount of packaging material. This results in high packaging costs.

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 with improved strength and stability.

The present invention provides for this purpose a packaging unit according to the invention from a moulded pulp material for products like eggs, the packaging unit comprising:

• • a cover part comprising top, front, side and rear surfaces; and
  • a bottom part comprising a number of compartments for individual products, and a number of cones that are positioned between adjacent compartments;

wherein the bottom part comprising a number of ribs extending between at least some of the compartments, wherein the bottom part further comprises a groove between adjacent compartments, and wherein the grooves are configured to receive part of the ribs of another packaging unit.

Having a packaging unit with a bottom part and a cover part made of moulded pulp enables transport and display of products without damaging the products. This is especially relevant in case of vulnerable products like eggs. This is also relevant in the transport of empty packaging units that often takes place in stacks of packaging units in an open position.

In a preferred embodiment, the cover part is hingedly connected to the bottom part on the rear side thereof. On at least the front side of the packaging unit a lock is provided comprising a first locking element on the bottom part, such as a cam or edge, and a second locking element in the cover part, such as an opening, that is configured for receiving the first locking element.

The cone shaped element (partly) separates adjacent compartments and preferably supports the product(s). The cone shaped element may comprise a cone and/or equivalent separator between adjacent compartments.

According to the invention the bottom part further comprises a groove between adjacent compartments, wherein the grooves are configured to receive (at least a) part of the ribs of another packaging unit. Providing a groove enables improvement of the stacking stability of packaging units in an open position. Packaging units are often stored and/or stacked in open position before being filled with the product(s). Due to the groove being configured for receiving the rib, or at least a part of such rib, provides an aligning effect and an improved stability. Preferably, the groove is configured such that a clamping force acts on a rib that protrudes the groove. Experiments showed that even a small clamping force increases the stability of a stack without hindering the handling operation of the packaging units. This improves storage and transport of (empty) packaging units.

In a presently preferred embodiment of the invention at least the adjacent compartments at the sides of the packaging unit are provided with a groove.

Experiments have shown that especially the provision of grooves between adjacent compartments on the sides of the packaging unit provide an improved stability to the packaging unit, also in an open position of the packaging unit in a stack of packaging units.

Preferably, the grooves are configured to support the ribs of another packaging unit in a stack of packaging units. Especially in a stack of packaging units in an open position this improves the stability of the stack. More preferably, the shape of the grooves substantially corresponds to the shape of the (part of) the rib that is received and supported in the groove.

In a presently preferred embodiment of the invention the bottom part further comprises a number of ribs extending between at least some of the compartments, and wherein the ribs are provided with a V-shaped cross-section.

Providing ribs between adjacent compartments with a V-shaped cross-section increases the strength of the packaging unit. This is also an advantage for a stack of packaging units. For example, a stack may comprise more packaging units without damaging the (lower) packaging units in the stack. This reduces storage, transport and/or handling costs of the packaging units.

Furthermore, the V-shape provides a self-seeking or self-aligning effect when stacking packaging units according to the invention. This renders handling, specifically stacking, of the packaging units easier. As a further effect denesting of the packaging units is easier. This further improves handling op the packaging units, specifically the stacking and unstacking thereof. Preferably, the ribs have a height in the range of 5-12 mm, more preferably in the range of 6-10 mm, and most preferably in the range of 7-8 mm.

In a presently preferred embodiment of the invention the ribs are provided with a V-shape in length direction of the ribs.

Providing ribs with a V-shaped in length direction of the ribs further increases the strength of the packaging unit. The V-shaped rib as seen in length direction of the ribs are preferably applied in combination with the V-shaped cross-section of the ribs. Experiments showed relevant increase in strength and easier stacking involving nesting and denesting of the packaging units. It will be understood that the V-shaped ribs can also be applied independently from the other features in packaging units.

In a presently preferred embodiment the ribs connect to the compartments at a height of more than 4 mm above the ground surface as defined by the bottom side of the bottom part.

Providing elevated ribs surprisingly improves the strength and stability of the packaging units. This reduces the risk of undesired bending and torsion of the packaging unit. Preferably the connection height is above 4 mm, more preferably above 4.5 mm, and most preferably about 5 mm. Also preferably, the connection height is below 20 mm, more preferably below 15 mm, and most preferably below 10 mm.

A further effect of the application of the aforementioned height is the improved gripping of the packaging unit with grippers in the packing operation. This improves handling of the packaging unit when packing with products.

In a presently preferred embodiment of the invention at least a number of ribs extending in width direction of the packaging unit, such that the ribs extend substantially perpendicular to the front surface of the bottom, have a width of more than 0.9 mm, preferably more than 0.9 mm, and most preferably more than 1.0 mm.

By increasing the width of the ribs, seen in a substantially parallel direction with the front surface, the torsion resistance is significantly improved. This provides additional stability to the packaging unit. This width is preferably applied in combination with the V-shape of the ribs in width and/or length direction of the rib(s), and/or with the aforementioned elevated connection of the rib(s).

In a presently preferred embodiment of the invention the compartments comprise a bottom with an elevated portion, wherein the bottom of the elevated portion is provided with a convex shape.

Providing elevated portions provides the compartments with an additional “bumper” effect that improves the protection of the products. Providing the bottom of the elevated portion with a convex shape prevents undesired moving of the packaging units when being transported over a conveyor belt, or other transporting means. This provides a more stable position of the packaging units during transport that is typically an advantage when putting the products in the packaging unit. Preferably, the convex bottom shape of the elevated portions resembles a spherical or dome shape.

Preferably, the convex shaped bottom of elevated portions in the compartment is applied in combination with the V-shaped ribs are applied and/or the cones having one or more openings that are also presented in this description. This combination of openings and cones having one or more openings improves the strength of the packaging unit, while reducing material and drying costs. It will be understood that the convex shaped bottom of elevated portions can also be applied independently from the other features in packaging units.

In a presently preferred embodiment of the invention the bottom part comprises a number of denest-elements having a height in the range of 2-7 mm, preferably 3-6 mm.

Providing denest-elements improves denesting the packaging units from a stack. In a preferred embodiment the denest-elements have a height in the aforementioned range. This reduced height reduces the so-called stacking pitch of the packaging units. This has as an advantageous effect a shorter bundle length thereby preventing, or at least reducing, the overhang so that the packaging units better fit on a pallet, for example.

In one of the presently preferred embodiments of the invention at least some of the cones are provided with openings that are configured to enable a gas stream to pass through the opening.

Providing an opening in the cone enables a gas flow, preferably an air flow, through the cone. In the manufacturing process this significantly contributes to the drying process of the packaging unit. Therefore, the drying of the packaging unit is significantly improved. In addition, the drying operation of the packaging unit is more controlled and/or gradually. The improved drying increases the strength of the packaging unit without increasing the required amount of material and/or reduces the amount of material, while maintaining the strength of the packaging unit.

A further effect of providing the cones of the packaging units with one or more openings is the reduced overall weight of the packaging unit. This reduces the material costs, and may reduce drying costs and/or may improve handling of the packaging unit. For example, for a standard egg package the weight reduction may amount to about 1 gram.

As a further effect of providing the cones of the packaging unit with one or more openings is the reduction in product damage during storage, transport and/or display. This is specifically relevant for vulnerable products like eggs. The increased strength of the packaging unit therefore reduces product loss.

In a presently preferred embodiment of the invention the openings have an effective diameter in the range of 0.5-15 mm, preferably in the range of 1.0-10 mm, more preferably in the range of 2.0-8 mm, and most preferably in the range of 3-6 mm.

Experiments showed that providing openings with the effective range in the mentioned range achieves an increased strength due to the improved drying operation. The openings are preferably shaped as a circle having a diameter. This diameter corresponds to the effective diameter. It will be understood that other shapes for an opening are also possible. For example, the opening may be an ellipse. In such case the effective diameter corresponds to the diameter of a circular opening having an equal opening surface.

In a presently preferred embodiment of the invention at least some of the openings are provided at or close to the top of the cone.

Providing at least some of the openings at or close to the top of the cone achieves an effective drying operation. This further enhances the strength of the packaging unit.

Preferably, V-shaped ribs are applied in combination with the cones having one or more openings. This combination of openings and cones having one or more openings improves the strength of the packaging unit, while reducing material and drying costs.

In a presently preferred embodiment of the invention the moulded pulp material comprises an amount of natural fibers. Additionally, or alternatively, the moulded pulp material comprises an amount of a biodegradable material.

The application of natural fibers and/or biodegradable material, such as an aliphatic polyester, is described in WO 2018/067006 A1 of the same applicant. The use of natural fibers and/or biodegradable material results in packaging units that are substantially NIOSH and/or MOAH free, and/or are (home) compostable. These materials are preferably applied in combination with one or more of the aforementioned features, especially the cone having one or more openings, and the V-shaped ribs and/or bottom shape of the elevated portions of the compartments. Such combination provides additional strength to the packaging units providing more possibilities to use alternative materials without reducing the behavior of the packaging units.

The present invention further relates to a method for packing products like eggs, comprising the steps of providing a packaging unit as described above, and placing therein one or more of the products.

Such method provides the same effects and advantages as described with respect of the packaging unit.

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

FIG. 1 shows a 3-dimensional view of a packaging unit according to the invention;

FIG. 2A shows a top view of the packaging unit of FIG. 1 in an open position;

FIGS. 2B-D show a side view and two cross-sections of the packaging unit of FIG. 2A, respectively;

FIGS. 2E-F show views of the bottom and top parts of the packaging unit of FIG. 2A in the open position, respectively;

FIGS. 3A-D show top, front, side and bottom view of the packaging unit of FIG. 1 in a closed position, respectively; and

FIGS. 4A-B a 3-dimensional view of an alternative packaging unit with 10 compartments;

FIGS. 4C-D a 3-dimensional view of a further alternative packaging unit with 12 compartments; and

FIGS. 4E-F a 3-dimensional view of an even further alternative packaging as a twin-pack.

A packaging unit 2 (FIG. 1) comprises bottom part 4 with front surface 6, two side surfaces 8, rear side 10, and bottom side 12. In the illustrated embodiment, cover part 14 is hingedly connected with hinge 16 to bottom part 4 to allow cover part 14 to move relatively to bottom part 4 between an open (FIG. 2A-F) and a closed (FIG. 3A-D) position. Cover part 14 further comprises front surface 18, two side surfaces 20, rear side 22 and top surface 24.

On the inside of bottom part 4 (FIGS. 1 and 2A-F) product receiving compartments 26 are provided having contours matching at least partially the outer contours of the products, like eggs, kiwis and tomatoes, for example. Support cones 28 are provided to add stability and strength to packaging unit 2.

Cones 28 are provided with opening 30. In the illustrated embodiment opening 30 is provided at the top of cone 28. It will be understood that additional openings and/or alternative positions can also be envisaged in accordance to the present invention. In the illustrated embodiment opening 30 has an (effective) diameter of about 5.6 mm it will be understood that other sizes and shapes of opening 30 can also be envisaged in alternative embodiments of the invention. Opening 30 provides channel 32 in or through cone 28 to enable a gas flow through cone 28, especially during drying.

Ribs 34 (FIGS. 1-3) are provided between adjacent compartments 26. Ribs 34 have a V-shaped cross-section and a V-shape when seen in length direction of rib 34 between two adjacent compartments 26. Ribs 34 connect to compartments 26 at a height H above the ground surface as defined by bottom side 12 of bottom part 4. In the illustrated embodiment height H is about 5 mm. Providing height H enables grippers to grip packaging unit 2. This improves handling of packaging unit 2. In the illustrated embodiment ribs 34 have a height of about 7.5 mm. Tests showed an effective increase of the overall strength of packaging unit 2.

Compartments 26 of bottom part 4 have support surfaces 36 comprise elevated bottom 38 having a spherical shape. Denest elements 40a in cover part 14 are provided having a height of about 6-8 mm. Denest elements 40b in bottom part 4 are providing having a height of about 3-6 mm extending from edge 41. Optionally, a label (not shown) is provided to one or more of the surfaces of packaging unit 2.

Lock 42 comprises opening 44 in cover part 14 and nose shaped cam 46 of bottom part 4. Cam 46 is provided on flap 49 that is hingedly connected by connection 50 to bottom part 4 of packaging unit 2. Optionally, cam 46 defines a closed outer surface or outer contour defining a chamber. In the illustrated embodiment the substantially downward facing surface of cam 46 may contact opening 44 to achieve lock 42. In the closed position of packaging unit 2 (FIG. 3A-D), cam 46 partly extends through opening 44 that is provided in the front surface 18 of cover part 14. The upper edge of opening 44 is optionally provided at a small angle and is slightly pushed inwards. It will be understood that according to the invention other locks may also be applied.

When packing products like eggs, the products are placed in compartments 28. In the illustrated embodiment, when cover part 14 is closed lock 42 with locking elements 44, 46 locks packaging unit 2. In the illustrated embodiment, in such closed position cam 46 partly extends and protrudes through opening 44 of front surface 18 of cover part 14.

Grooves 48 are provided in bottom part 4. Grooves 48 are configured to receive part of ribs 34. Grooves 48 are optionally provided between all adjacent compartments 26. In the illustrated embodiment grooves 48 are specifically (and only) provided between the two outer compartments 26′ at the sides of bottom part 4.

In the illustrated embodiment packaging unit 2 has a length L in a closed position (FIG. 3A-D) of about 247 mm, a width W of about 107 mm, and a height H_p of about 68 mm. It will be understood that other dimensions are also possible and may depend on the number of compartments 26 in packaging unit 2. Packaging unit 2 is made of a moulded pulp material that optionally comprises a biodegradable material such an aliphatic polyester, for example PLA, PBS. Also optionally, the moulded pulp material may comprise an amount of natural fibers such as grass fibers. Further examples of biodegradable materials and/or natural fibers are described in WO 2018/067006 A1 of the same applicant.

In the manufacturing process packaging units 2 are formed from moulded pulp. After forming packaging units 2 are dried. Opening 30 in cones 28 enable a gas flow through channel 32, thereby improving the drying process.

It will be understood that packaging unit 2 having ten product compartments can also be provided as a related packaging unit with another number of product compartments. For example, similar packaging units having twelve product compartments or twin pack units having two packaging units with each 6 product compartments. Also, these related packaging units can be provided in a similar design having the same or at least similar features as shown for packaging unit 2.

Alternative packaging unit 102 (FIG. 4A-B) comprises bottom part 104 with front surface 106, two side surfaces 108, rear side 110, and bottom side 112. In the illustrated embodiment, cover part 114 is hingedly connected with hinge 116 to bottom part 104 to allow cover part 114 to move relatively to bottom part 104 between an open (FIG. 4B) and a closed (FIG. 4A) position. Cover part 114 further comprises front surface 118, two side surfaces 120, rear side 122 and top surface 124.

On the inside of bottom part 4 (FIG. 4B) product receiving compartments 126 are provided having contours matching at least partially the outer contours of the products, like eggs, kiwis and tomatoes, for example. Support cones 128 are provided to add stability and strength to packaging unit 2. In this embodiment support cones 128 are provided with closed top 130.

Ribs 134 are provided between adjacent compartments 126 and have a V-shaped cross-section and a V-shape when seen in length direction of rib 134 between two adjacent compartments 126. Ribs 134 connect to compartments 126 at a height H above the ground surface as defined by bottom side 112 of bottom part 104. In the illustrated embodiment height H is about 5 mm. Providing height H enables grippers to grip packaging unit 102. This improves handling of packaging unit 102. In the illustrated embodiment ribs 134 have a height of about 7.5 mm. Tests showed an effective increase of the overall strength of packaging unit 102.

Compartments 126 of bottom part 104 resemble compartments 26 as shown for packaging unit 2. Also lock 142 resembles lock 42 as shown for packaging unit 2. It will be understood that according to the invention other locks may also be applied. Grooves 148 are provided in bottom part 104. Grooves 148 are configured to receive part of ribs 134. Grooves 148 are optionally provided between all adjacent compartments 126. In the illustrated embodiment grooves 148 are specifically (and only) provided between the two outer compartments 126′ at the sides of bottom part 104. Dimensions and/or materials are similar to the dimensions and/or materials described in relation to packaging unit 2.

Packaging unit 202 (FIG. 4C-D) is provided with twelve compartments 126. Other features are the same or similar to that of packaging unit 102 having ten compartments 126.

Packaging unit 302 (FIG. 4E-F) is provided as a so-called twin-pack having two connected (sub)packaging units each having 6 product compartments.

Alternative packaging units according to the invention may hold other products, like kiwi's, eggs, tomatoes, apples etc. and/or also a hamburger, salad etc.

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 are possible.

Claims

1. Packaging unit from a moulded pulp material for products like eggs, comprising: a cover part comprising top, front, side and rear surfaces; anda bottom part comprising a number of compartments for individual products, and a number of cones that are positioned between adjacent compartments;wherein the bottom part comprises a number of ribs extending between at least some of the compartments, wherein the bottom part further comprises a groove between adjacent compartments, and wherein at least one of the grooves is configured to receive at least part of one of the ribs of another similar packaging unit.

2. Packaging unit according to claim 1, wherein at least the adjacent compartments at the sides of the packaging unit are provided with a groove.

3. Packaging unit according to claim 1, wherein the grooves are configured to support the ribs of another packaging unit in a stack of packaging units.

4. Packaging unit according to claim 1, the ribs are provided with a V-shaped cross-section.

5. Packaging unit according to claim 1, wherein the ribs are provided with a V-shape in a length direction of the ribs.

6. Packaging unit according to claim 1, wherein the ribs connect to the compartments at a height of more than 4 mm above the ground surface as defined by the bottom side of the bottom part.

7. Packaging unit according to claim 1, wherein at least a number of ribs extend in a width direction of the packaging unit, such that the ribs extend substantially perpendicular to a front surface of the bottom and have a width of more than 0.9 mm.

8. Packaging unit according to claim 1, wherein the compartments comprise a bottom with an elevated portion, wherein the bottom of the elevated portion is provided with a convex shape.

9. Packaging unit according to claim 1, wherein the bottom part comprises a number of denest-elements having a height in the range of 2-7 mm.

10. Packaging unit according to claim 1, wherein at least some of the cones are provided with openings that are configured to enable a gas stream to pass through the opening.

11. Packaging unit according to claim 10, wherein the openings having an effective diameter in the range of 0.5-15 mm.

12. Packaging unit according to claim 10, wherein at least some of the openings are provided at or close to the top of the cone.

13. Packaging unit according to claim 1, wherein the moulded pulp material comprises an amount of natural fibers.

14. Packaging unit according to claim 1, wherein the moulded pulp material comprises an amount of a biodegradable material.

15. Method for packing products like eggs, comprising the step of providing a packaging unit according to claim 1, and placing therein one or more of the products.