U.S. patent application number 13/681857 was filed with the patent office on 2013-05-23 for egg packaging carton and system.
This patent application is currently assigned to OGG DESIGN, INC.. The applicant listed for this patent is Ogg Design, Inc.. Invention is credited to Richard K. Ogg.
Application Number | 20130126384 13/681857 |
Document ID | / |
Family ID | 48425763 |
Filed Date | 2013-05-23 |
United States Patent
Application |
20130126384 |
Kind Code |
A1 |
Ogg; Richard K. |
May 23, 2013 |
Egg Packaging Carton and System
Abstract
An improved egg carton for packaging one or more eggs includes
an egg holding compartment that maintains the egg in a desired
position, and accommodates eggs of variable sizes. A system of
packaging eggs utilizing the egg carton of the present invention is
also disclosed.
Inventors: |
Ogg; Richard K.;
(Littlestown, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ogg Design, Inc.; |
Littlestown |
PA |
US |
|
|
Assignee: |
OGG DESIGN, INC.
Littlestown
PA
|
Family ID: |
48425763 |
Appl. No.: |
13/681857 |
Filed: |
November 20, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61562550 |
Nov 22, 2011 |
|
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Current U.S.
Class: |
206/521.15 ;
53/473 |
Current CPC
Class: |
B65D 21/0235 20130101;
B65D 21/0217 20130101; B65D 81/05 20130101; B65D 81/133 20130101;
B65D 85/32 20130101 |
Class at
Publication: |
206/521.15 ;
53/473 |
International
Class: |
B65D 81/05 20060101
B65D081/05 |
Claims
1. An egg packaging carton, comprising: a bottom portion including
a first plurality of egg receiving areas, each one of said first
plurality of egg receiving areas defined by a bottom surface,
sidewalls extending upwardly from and surrounding said bottom
surface, and flexible projections extending from said sidewalls and
biased outwardly and into a corresponding one of said first
plurality of egg receiving areas; and a top portion coupleable to
said bottom portion, said top portion including a second plurality
of egg receiving areas, each one of said second plurality of egg
receiving areas defined by a top surface, sidewalls extending
upwardly from and surrounding said top surface, and flexible
projections extending from said sidewalls and biased outwardly and
into a corresponding one of said second plurality of egg receiving
areas, wherein said first plurality of egg receiving areas is
alignable with said second plurality of egg receiving areas to
define a plurality of egg holding compartments when said top
portion is coupled to said bottom portion.
2. The egg packaging carton of claim 1, wherein said bottom portion
includes at least four projections disposed within each one of said
first plurality of egg receiving areas, said projections spaced
around a central axis of the corresponding one of said first
plurality of egg receiving areas so that an egg received therein is
centered within the corresponding one of said first plurality of
egg receiving areas.
3. The egg packaging carton of claim 1, wherein said top portion
includes at least four projections disposed within each one of said
second plurality of egg receiving areas, said projections spaced
around a central axis of the corresponding one of said second
plurality of egg receiving areas so that an egg received therein is
centered within a corresponding one of said plurality of egg
holding compartments.
4. The egg packaging carton of claim 1, wherein said bottom surface
of each one of said first plurality of egg receiving areas includes
a raised central segment extending inwardly toward the
corresponding one of said first plurality of egg receiving areas,
said raised central segment including a dimpled area configured to
receive a first end of an egg and generating a recoiling force
against depression thereof by the egg.
5. The egg packaging carton of claim 4, wherein said bottom surface
of each one of said first plurality of egg receiving areas includes
a plurality of lugs extending outwardly and away from the
corresponding one of said first plurality of egg receiving areas,
and a first plurality of connecting segments disposed between and
interconnecting said raised central segment and said lugs.
6. The egg packaging carton of claim 5, wherein said bottom surface
includes a second plurality of connecting segments disposed between
and interconnecting said raised central segment and said sidewalls,
said first and second pluralities of connecting segments
alternating around said raised central segment.
7. The egg packaging carton of claim 4, wherein said top surface of
each one of said second plurality of egg receiving areas includes a
raised central segment extending inwardly toward the corresponding
one of said second plurality of egg receiving areas, said raised
central segment including a dimpled area configured to receive an
opposite second end of the egg and generating a recoiling force
against depression thereof by the egg.
8. The egg packaging carton of claim 7, wherein said dimpled areas
of said first and second pluralities of egg receiving areas are
axially aligned when said top portion is coupled to said bottom
portion so that the recoiling forces oppose each other and bias the
egg away from said bottom surface and said top surface toward a
centered position within a corresponding one of said plurality of
egg holding compartments.
9. The egg packaging carton of claim 7, wherein said top surface of
each one of said second plurality of egg receiving areas includes a
plurality of outwardly extending lugs, and a plurality of
connecting segments disposed between and interconnecting said
central segment and said lugs.
10. The egg packaging carton of claim 1, wherein said bottom
portion includes lugs extending outwardly from said bottom surface
thereof, and said top portion includes lugs extending outwardly
from said top surface thereof, said lugs of said bottom portion
being nestable and interlockable with said lugs of said top
portion.
11. The egg packaging carton of claim 1, wherein said plurality of
egg holding compartments accommodate eggs of variable size and
weight.
12. The egg packaging carton of claim 1, wherein said bottom
portion includes a first flanged edge extending outwardly from a
perimeter thereof and having one or more engagement members
thereon, and said top portion includes a second flanged edge
extending outwardly from a perimeter thereof and having one or more
engagement members thereon, said engagement members of said first
and second flanged edges cooperating to releasably secure said
bottom portion to said top portion.
13. The egg packaging carton of claim 1, wherein said top portion
is hingedly attachable to said bottom portion via a flexible label
member.
14. A system of packaging eggs including at least a first egg
carton and a second egg carton, each of said first and second egg
cartons comprising: a bottom portion including a first plurality of
egg receiving areas, each one of said first plurality of egg
receiving areas defined by a bottom surface and sidewalls extending
upwardly from and surrounding said bottom surface, and a plurality
of lugs extending outwardly from said bottom surface of each one of
said first plurality of egg receiving areas; and a top portion
coupleable to said bottom portion, said top portion including a
second plurality of egg receiving areas, each one of said second
plurality of egg receiving areas defined by a top surface and
sidewalls extending upwardly from and surrounding said top surface,
and a second plurality of lugs extending outwardly from said top
surface thereof, wherein said first plurality of egg receiving
areas are alignable with said second plurality of egg receiving
areas to define a plurality of egg holding compartments when said
top portion is coupled to said bottom portion, and wherein said
lugs of said bottom portion of the first egg packaging carton are
nestable and interlockable with said lugs of said top portion of
the second egg packaging carton.
15. The system of claim 14, wherein each of said first and second
egg cartons further comprises: flexible projections extending from
said sidewalls of said bottom portion and biased outwardly and into
a corresponding one of said first plurality of egg receiving areas;
and flexible projections extending from said sidewalls of said top
portion and biased outwardly and into a corresponding one of said
second plurality of egg receiving areas.
16. The system of claim 14, wherein each of said first and second
egg cartons further comprises: a dimpled lower platform coupled to
said bottom surface of each one of said first plurality of egg
receiving areas, said dimpled lower platform extending away from
said plurality of lugs of said bottom portion and configured to
receive a first end of an egg, and generating a first recoiling
force against depression thereof; and a dimpled upper platform
coupled to said top surface of each one of said second plurality of
egg receiving areas, said dimpled upper platform extending away
from said plurality of lugs of said top portion and configured to
receive an opposite second end of the egg, and generating a second
recoiling force against depression thereof, said second recoiling
force opposing said first recoiling force.
17. The system of claim 14, wherein each of the first and second
egg packaging cartons includes a front edge, and wherein when said
lugs of said bottom portion of the first egg packaging carton are
nested with said lugs of said top portion of the second egg
packaging carton: the front edge of the first egg packaging carton
is substantially parallel to the front edge of the second egg
packaging carton; or the front edge of the first egg packaging
carton is substantially perpendicular to the front edge of the
second egg packaging carton.
18. A method of packaging eggs, comprising the steps of: providing
an egg carton including a bottom portion including a plurality of
egg receiving areas, and a top portion including a plurality of egg
receiving areas, the plurality of egg receiving areas of the bottom
portion alignable with the plurality of egg receiving areas of the
top portion to define a plurality of egg holding compartments;
disposing a plurality of eggs in the plurality of egg receiving
areas of the bottom portion; and moving the top portion toward the
bottom portion until the top portion is coupled to the bottom
portion to define the plurality of egg holding compartments,
wherein the egg receiving areas of the top portion are axially
aligned with the egg receiving areas of the bottom portion during
said moving step.
19. The method of claim 18, comprising the further step of biasing
each of the plurality of eggs toward centered positions within
corresponding egg holding compartments.
20. The method of claim 18, comprising the further step of affixing
a flexible member to the egg carton after said moving step, the
flexible member having a first portion coupled to the bottom
portion and a second portion coupled to the top portion, thereby
hingedly connecting the bottom portion to the top portion.
Description
CROSS REFERENCE TO RELATED APPLICATION AND CLAIM TO PRIORITY
[0001] This application is based on U.S. provisional application
Ser. No. 61/562,550, filed Nov. 22, 2011, entitled "Egg Packaging
Carton and System," which application is incorporated herein by
reference in its entirety and to which priority is claimed.
FIELD OF THE INVENTION
[0002] The present invention relates to an improved egg carton for
packaging eggs and a system for packaging eggs.
BACKGROUND OF THE INVENTION
[0003] The natural egg structure is quite strong and indeed nearly
impossible for a person to break by applying pressure to the ends
of the egg with the human fingers. Despite its relative strength,
the egg is an extremely fragile product and requires specialized
packaging and processing methods.
[0004] Therefore, packaging is an important component in delivering
quality eggs to consumers. Proper packaging and handling help to
maintain or control moisture, temperature, and breathability, and
to prevent egg damage, contamination or tainting. The packaging
must be able to withstand diverse handling, egg size, storage and
transport methods.
[0005] In addition, the packaging typically allows for consumers to
open or inspect the eggs. Consumers generally prefer sealed
containers or packaging to ensure product safety, although
conventional egg packaging does not provide for such sealed
containers. Moreover, packaging must provide for labels or
identifiers for providing information about the product to
wholesalers, retailers and consumers. Important facts on the label
contain information for buyers concerning the eggs, their size and
weight and quality/grade description. Labels may also indicate the
producer, when the eggs were laid, how to store them and their
expiration date.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to an improved egg carton
for packaging eggs and a system for packaging eggs. The disclosed
egg packaging carton includes a plurality of egg holding
compartments that may accommodate eggs of variable size and
weight.
[0007] The present invention is directed to an egg packaging carton
comprising a bottom portion and a top portion. The bottom portion
includes a first plurality of egg receiving areas, each one of the
egg receiving areas defined by a bottom surface, sidewalls
extending upwardly from and surrounding the bottom surface, and
flexible projections extending from the sidewalls and biased
outwardly and into a corresponding egg receiving area. The top
portion is coupleable to the bottom portion, and includes a second
plurality of egg receiving areas, each of which is defined by a top
surface, sidewalls extending upwardly from and surrounding the top
surface, and flexible projections extending from the sidewalls and
biased outwardly and into a corresponding egg receiving area. The
first plurality of egg receiving areas is alignable with the second
plurality of egg receiving areas to define a plurality of egg
holding compartments when the top portion is coupled to the bottom
portion.
[0008] In one embodiment, the bottom portion includes at least four
projections disposed within each one of the first plurality of egg
receiving areas. The projections are spaced around a central axis
of the corresponding egg receiving area, so that an egg received
therein is centered within the corresponding egg receiving area.
The top portion may also include at least four projections disposed
within each egg receiving area, which are likewise spaced around a
central axis of the corresponding egg receiving areas so that an
egg received therein is centered within the egg holding
compartment.
[0009] In one embodiment, the bottom surface of each one of the
first plurality of egg receiving areas includes a raised central
segment extending inwardly toward the corresponding one of the
first plurality of egg receiving areas. The raised central segment
includes a dimpled area configured to receive a first end of an egg
and generates a recoiling force against depression thereof by the
egg.
[0010] In one embodiment, the bottom surface of each of the first
plurality of egg receiving areas includes a plurality of lugs
extending outwardly and away from the corresponding one of the
first plurality of egg receiving areas. The first plurality of
connecting segments is disposed between and interconnects the
raised central segment and the lugs. In one implementation, the
bottom surface includes a second plurality of connecting segments
disposed between and interconnecting the raised central segment and
the sidewalls, wherein the first and second pluralities of
connecting segments alternate around the raised central
segment.
[0011] In one embodiment, the top surface of each of the second
plurality of egg receiving areas includes a raised central segment
extending inwardly toward the corresponding one of the second
plurality of egg receiving areas. The raised central segment
includes a dimpled area configured to receive an opposite second
end of the egg and generate a recoiling force against depression
thereof by the egg. In one implementation, the dimpled areas of the
first and second pluralities of egg receiving areas are axially
aligned when the top portion is coupled to the bottom portion so
that the recoiling forces oppose each other and bias the egg away
from the bottom surface and the top surface toward a centered
position within a corresponding one of the plurality of egg holding
compartments.
[0012] In one embodiment, the top surface of each one of the second
plurality of egg receiving areas includes a plurality of outwardly
extending lugs, and a plurality of connecting segments disposed
between and interconnecting the central segment and the lugs. In
one implementation, the bottom portion includes lugs extending
outwardly from the bottom surface thereof, and the top portion
includes lugs extending outwardly from the top surface thereof. The
lugs of the bottom portion are nestable and interlockable with the
lugs of the top portion.
[0013] According to one embodiment, the bottom portion includes a
first flanged edge extending outwardly from a perimeter thereof and
having one or more engagement members thereon. The top portion
includes a second flanged edge extending outwardly from a perimeter
thereof and having one or more engagement members thereon. The
engagement members of the first and second flanged edges
cooperating to releasably secure the bottom portion to the top
portion.
[0014] In one embodiment, the top portion is hingedly attachable to
the bottom portion via a flexible label member.
[0015] The present invention also relates to a system of packaging
eggs including at least a first egg carton and a second egg carton.
Each of the egg cartons comprises a bottom portion including a
first plurality of egg receiving areas. Each of the first plurality
of egg receiving areas is defined by a bottom surface and sidewalls
extending upwardly from and surrounding the bottom surface, and a
plurality of lugs extending outwardly from the bottom surface of
each one of the first plurality of egg receiving areas. A top
portion is coupleable to the bottom portion, and includes a second
plurality of egg receiving areas. Each of the second plurality of
egg receiving areas is defined by a top surface and sidewalls
extending upwardly from and surrounding the top surface, and a
second plurality of lugs extending outwardly from the top surface
thereof. The first plurality of egg receiving areas are alignable
with the second plurality of egg receiving areas to define a
plurality of egg holding compartments when the top portion is
coupled to the bottom portion. The lugs of the bottom portion of
the first egg packaging carton are nestable and interlockable with
the lugs of the top portion of the second egg packaging carton.
[0016] In one embodiment, each of the first and second egg cartons
further comprises flexible projections extending from the sidewalls
of the bottom portion and biased outwardly and into a corresponding
one of the first plurality of egg receiving areas, and flexible
projections extending from the sidewalls of the top portion and
biased outwardly and into a corresponding one of the second
plurality of egg receiving areas.
[0017] In one embodiment, each of the first and second egg cartons
further comprises a dimpled lower platform coupled to the bottom
surface of each one of the first plurality of egg receiving areas.
The dimpled lower platform extends away from the plurality of lugs
of the bottom portion and is configured to receive a first end of
an egg and generate a first recoiling force against depression
thereof. The egg cartons further comprise a dimpled upper platform
coupled to the top surface of each one of the second plurality of
egg receiving areas. The dimpled upper platform extends away from
the plurality of lugs of the top portion and is configured to
receive an opposite second end of the egg and generate a second
recoiling force against depression thereof. The second recoiling
force opposes the first recoiling force.
[0018] In one embodiment, each of the first and second egg
packaging cartons includes a front edge. When the lugs of the
bottom portion of the first egg packaging carton are nested with
the lugs of the top portion of the second egg packaging carton, the
front edge of the first egg packaging carton is substantially
parallel to the front edge of the second egg packaging carton, or
alternatively the front edge of the first egg packaging carton is
substantially perpendicular to the front edge of the second egg
packaging carton. An egg carton is provided which includes a bottom
portion including a plurality of egg receiving areas, and a top
portion including a plurality of egg receiving areas. The plurality
of egg receiving areas of the bottom portion are alignable with the
plurality of egg receiving areas of the top portion to define a
plurality of egg holding compartments. A plurality of eggs are
disposed in the plurality of egg receiving areas of the bottom
portion. The top portion is then moved toward the bottom portion
until the top portion is coupled to the bottom portion to define
the plurality of egg holding compartments with the eggs retained
therein. The egg receiving areas of the top portion are axially
aligned with the egg receiving areas of the bottom portion as the
top portion is moved toward the bottom portion. Thus, the top
portion is disconnected and discrete from the bottom portion.
[0019] In one embodiment, the disclosed method provides for the
further step of biasing each of the plurality of eggs toward
centered positions within corresponding egg holding
compartments.
[0020] In another embodiment, the packaging method provides for the
further step of affixing a flexible member to the egg carton after
moving the top portion toward the bottom portion and thereby
coupling the top and bottom portions together. The flexible member
has a first portion coupled to the bottom portion and a second
portion coupled to the top portion, thereby hingedly connecting the
bottom portion to the top portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates a perspective view of an egg carton
according to an embodiment of the present invention, and showing a
top portion of the carton detached from a bottom portion
thereof.
[0022] FIG. 2 illustrates a side elevational view of the egg carton
of FIG. 1.
[0023] FIG. 3 illustrates a perspective view of an end of the egg
carton of FIG. 1 and showing a portion of the end in section.
[0024] FIG. 4 illustrates a sectional view of an end of the egg
carton of FIG. 1 and showing an egg disposed within an egg holding
compartment of the carton.
[0025] FIG. 5 illustrates a perspective view of three egg cartons
according to the present invention showing the cartons stacked and
interlocked together.
[0026] FIG. 6 illustrates a side elevational view of the stacked
cartons of FIG. 5.
[0027] FIG. 7 illustrates a perspective view of a first row of egg
cartons and a second row egg carton interlocked with the first row
and disposed perpendicular thereto.
[0028] FIG. 8 illustrates an elevational view of the interlocked
and stacked egg cartons of FIG. 7.
[0029] FIG. 9 illustrates an elevational view of the interlocked
and stacked egg cartons of FIG. 7 and additionally another egg
carton disposed within a first row of cartons.
[0030] FIG. 10 illustrates an egg carton and label affixed thereto
according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The terms "left," "right," "top," "bottom," "front," "rear,"
"side," "height," "length," "width," "upper," "lower," "interior,"
"exterior," "inner," "outer" and the like as may be used herein,
merely describe points or portions of reference and do not limit
the present invention to any particular orientation or
configuration. Further, terms such as "first," "second," "third,"
etc., merely identify one of a number of portions, components
and/or points of reference as disclosed herein, and do not limit
the present invention to any particular configuration or
orientation.
[0032] Referring to FIGS. 1 and 2, an egg carton 10 according to an
embodiment of the present invention is illustrated. The egg carton
10 may be manufactured from a polyethylene terephthalate (PET)
sheet material via a thermoforming process. In other embodiments,
the egg carton 10 is manufactured from other materials, such as
other suitable polymer materials and/or utilizing other
manufacturing processes. The specific spring rates and
configurations of the egg cartons disclosed herein indicate that
plastic recyclable materials may be utilized in a preferred
embodiment.
[0033] The egg carton 10 includes a top portion 12 and a bottom
portion 14. The top portion 12 is separable from and releasable
coupleable to the bottom portion 14. Referring to FIGS. 3 and 4,
the bottom portion 14 includes one or more egg receiving areas 16,
and preferably includes a plurality of egg receiving areas 16
(e.g., 4, 6, 8, 12, etc.). The top portion 12 also includes one
more egg receiving areas 18, which are aligned with the egg
receiving areas 16 in the bottom portion 14 when the top portion 12
and the bottom portion 14 are releasably coupled together.
[0034] With continued reference to FIGS. 3 and 4, the egg receiving
areas 16, 18 cooperate to define an egg holding compartment 20. An
egg E may be maintained within a compartment 20, as shown in FIG.
4. Thus, the egg carton 10 includes discrete egg holding
compartments 20 within the multi-egg carton 10. Each egg E is
supported within a compartment 20 found within the contiguous egg
carton 10, which may be configured to hold any number of eggs E
(e.g., 4, 6, 8, 10 12, 18, 24, 30, or 36).
[0035] Within each compartment 20, the egg E is supported by the
top and bottom portions 12, 14 of the carton 10, as shown in FIG.
4. In one implementation, the bottom portion 14 and the top portion
12 have different configurations but function collectively to
support and protect the eggs with coordinating features.
[0036] The bottom portion 14 of the egg carton 10 includes feet or
lugs 22. The lugs 22 include exteriorly disposed distal portions 24
that are engageable with a support surface, thereby stabilizing the
egg carton 10 such as when resting on a generally planar support
surface. In addition, the lugs 22 allow for the carton 10 to engage
and nest into the top portion of another egg carton, as shown in
FIGS. 5 and 6.
[0037] Referring to FIG. 7, a first row R1 of cartons 10 may be
aligned with each other, such as in a parallel configuration. A
second row R2 of cartons 10 may then be aligned with and engage the
first row of cartons, whereby the cartons 10 forming the second row
R2 may be either parallel to or perpendicular to (as shown in FIG.
7) the cartons forming the first row R1 in the stack of cartons 10.
This allows the cartons 10 in one row to be placed in the same
attitude of stack, or to be placed in a perpendicular attitude
relative to cartons 10 in another row, thereby allowing for
numerous cartons to be locked together, as shown in FIGS. 7, 8 and
9.
[0038] The geometric configuration and location of the lugs 22
allow for the connection of multiple size cartons (e.g., egg
cartons for holding 4, 12 or 18 eggs). In addition, the lugs 22
provide a method to interlock the egg cartons 10 together, such as
for stacking during storage or transport. This interlock feature
prevents slippage between stacked cartons, and also provides a
mechanism for releasably attaching multiple cartons together while
stacking. The interlock feature is achieved by the configuration of
the lugs 22 on the top portion 12, which interlock with
correspondingly configured lugs 22 on the bottom portion 14 (or
vice versa).
[0039] Referring again to FIGS. 3 and 4, the egg holding
compartment 20 is configured so that each egg therein is properly
aligned within the carton 10. There are four spring zones 26 at the
corner regions of each egg receiving area 16 of the bottom portion
14. Each spring zone 26 includes a projection 28 that extends
outwardly and into the egg receiving area 16. The projections 28
are flexible and biased outwardly, providing a spring rate that
allows for the variation of size eggs as the eggs E are placed into
the egg receiving areas 16 of the bottom portion 14 of the carton
10. The smaller diameter end of the egg is positioned downwardly
and within the bottom portion 14, according to customary egg
packaging methods in the egg packaging industry. The geometry of
the egg carton 10 and egg receiving area 16 with projections 28
centers the egg within the egg receiving area 16 of the bottom
portion 14 in an optimal position, and maintains the egg in an
upright position until the top portion 12 of the carton 10 is
secured to the bottom portion 14.
[0040] In the bottom of the egg receiving area 16, a dimple shaped
surface 30 surrounded by connecting regions or segments 32 are
provided. In one implementation, eight segments 32 are provided.
Four of the segments 32 are disposed between and interconnect the
dimple surface 30 and the outside extended lug 22 that is proximate
to the contact surface (e.g., the shelf or table). The remaining
four segments 32 are disposed between and interconnect the raised
portion which is above the support surface. In this way, the
geometry of the egg carton 10 generates a spring.
[0041] In the egg receiving area 18 of the top portion 12, another
dimple shaped surface 30 is provided, which is also surrounded by a
surface consisting of eight segments 32. Four of the segments 32
connect between the dimpled surface 30 and the outside extended
foot/lug that are near the contact surface to the shelf or table.
The remaining four segments 32 connect to the raised portion which
is above the shelf/table. This geometry likewise generates a
spring. When the top portion 12 of the carton 10 is applied or
releasably coupled to the bottom portion 14 of the carton 10, the
springs within the egg receiving areas 16, 18 are aligned with and
oppose each other in a vertical orientation. The position of the
egg E within the carton 10 suspends the egg E within the
compartment 20, and prevents the egg E from moving beyond the
perimeter plane of the top and bottom feet/lugs.
[0042] The combination of the springs on the top and bottom
portions 16, 18 places the eggs in compression between the bottom
spring and the top spring. This feature creates a spring rate which
allows for the secure positioning and holding of each egg while
providing a cushion for movement during top load, stacking and
shipping. In addition, this feature holds each egg in the carton in
an optimal position, utilizing the most compression resistant
portion and orientation of the egg's natural geometry (i.e., point
to point).
[0043] Thus, the positioning of the eggs within the carton 10
advantageously utilizes the natural strength of the eggs. The
carton 10 is designed to align the egg into each compartment 20 or
cell. The compartments 20 within the bottom portion 14 of the
carton 10 maintain each egg E in an upright position, while also
being adjustable to and accommodating eggs of variable size in
diameter and height. Each egg may be dropped into the egg receiving
areas 16 in the bottom portion 14 of the carton 10 with the smaller
point of the egg positioned downwardly, as determined by standard
egg loading machinery. This alignment thereby harnesses the normal
strength of the natural egg.
[0044] The cylindrical area or dimpled surface 30 in the egg
receiving area 18 of the top portion 12 allow for the forces which
hold the egg E within the carton 10 to be applied in a similar
fashion as described above, to the ends of the egg. When the top
portion 12 is applied to the bottom portion 14, the springs which
support the cylindrical area or dimpled surfaces 30 on both the top
and bottom portions 12, 14 or halves of the carton 10 apply
pressure to the egg. The egg is thereby maintained in an upright
position within the egg holding compartment 20 while in the carton
10.
[0045] It has been established by top load testing that the egg
strength when used in this manner provides an increase in the top
load capabilities of the overall carton. A stack of 2 cartons
(which cartons are each configured to hold one dozen eggs) without
eggs in the cells provided 87 lbs. of top load resistance at
0.250'' of deflection. The same 2 one dozen cartons with eggs in
the cells provided 108 lbs. of top load resistance at 0.500'' of
deflection. During less than 0.500'' of compression/deflection, the
eggs are not in contact with each other and are suspended between
the feet found on the bottom and top of the carton system. This
test illustrates that the natural strength of the egg is being
harnessed by the egg carton of the present invention to improve the
overall top load characteristic of the single egg carton,
particularly when interlocked with multiple cartons as the system
provides, thereby adding strength to a cube of multiple egg
cartons. Thus, the disclosed egg carton utilizes the natural
geometry and strength of the egg for securely positioning and
maintaining the eggs in the egg carton.
[0046] The spring configurations of the disclosed egg carton 10
also allow for the variation of size found in the natural geometry
of the egg. While eggs are sold by weight, the variation of egg
dimensions must be considered and accommodated in the egg carton.
While each egg within the given egg carton size (e.g., 4, 6, 8,
etc.) is important, the egg carton also accounts for overall
spacing between the eggs within the carton. The eggs regardless of
size or adjustment of the carton must fall into a grid of location
while accounting for all carton geometry. For example, if a grid of
51.5 mm is the location of each egg center line vertical, all
geometry, which includes all side wall and all other design
features must be adjusted to keep the distances within each
individual carton and all other nesting cartons on the same grid.
This allows for the universal stack nest feature to work across the
board in this carton system.
[0047] The connecting geometry between each egg location consists
of a planer surface with arched bridge geometry to connect each egg
compartment to the other egg compartments. This bridge offers
structural enhancements and anti-racking geometry. At the base of
each bridge found at the planer surface, there is a locking lug
including a male on the top portion and a female on the bottom
portion. At the exterior edge perimeter of the carton halves, this
feature is a single lug. At the center locations, found at the
middle of four egg locations, there is a multiple of four location
lugs with a single round button snap connector. The center multiple
lugs are similar to the outside lug, but are joined with additional
geometry to provide more surface area from which to generate a
positive connection. The area between the deepest portion of the
carton, the feet/lugs and the planer surface are connected with
sidewalls that have vertical surface pillars built into the
surface. This surface is to provide improved top load
capabilities.
[0048] Each corner is squared to meet the square perimeter of the
overall carton shape. This provides a triangulated structure which
leads into the more round surface of the egg compartment toward the
round point end of each egg. This feature offers additional top
load and structural characteristics to the overall carton. In the
top half of the carton this feature is uninterrupted while in the
bottom this feature is slightly modified to accommodate the egg
positioning geometry.
[0049] Found at the perimeter of both the top and bottom portions
12, 14 of each carton 10, regardless of the number of eggs to be
packaged, is a stepped (e.g. 90.degree.)flanged edge that contains
numerous elongated dimple snaps. On the top, the snaps are proud to
the interior of the carton. On the bottom, the elongated dimple
snaps are recessed to accept the positive features of the top. When
these snaps occur at a 90 degree corner of the carton,
approximately 30% of the snap is tapered away and functions as a
mechanism to start the opening process by the consumer. The top
flange extends half the distance of the matching flange of the
bottom flange. This geometry is modified to accommodate the overlap
of the formed material thickness of the top. This allows for the
overall geometry of the combined carton halves (i.e. top and bottom
portions 12, 14) not to exceed the given volume of the grid.
[0050] Referring to FIG. 10, in one embodiment, along one of the
longitudinal sides of the carton (or a selected side), a label L
may be glued or affixed thereto. The label L thereby functions as a
hinge, so that the top portion 12 is hingedly attachable to the
bottom portion 14 upon securing the label to the carton 10.
[0051] The label feature eliminates the requirement or need for
another hinge element or integrally connected halves, such as
provided in conventional egg cartons. The egg carton of the present
invention provides for a simple top portion 12 and bottom portion
14, which may be attached with the label. This provides the egg
packager with the option to post label skews and/or to order
generic cartons which are differentiated later in the egg packaging
process with selected labels. The hinge is then applied with the
selected label. The opposite side of the label may be a tamper
evident feature to be opened by the purchasing consumer (such as
with a tear string to release or break the label along one side of
the carton 10. Because the cartons 10 are preferably clear, egg
inspection by the consumer is provided at the point of sale but
without the need to open the carton 10 or have direct access to the
eggs therein.
[0052] The carton 10, including the two piece top and bottom
portions 12, 14 or halves, may also or alternatively be connected
together by geometry details to create an interlocking snapping
connection. In addition, the carton may be labeled for
identification by the consumer and to provide information about the
package content.
[0053] Because the egg carton system of the present invention
includes two separate parts, closure of the package is relatively
simple compared to hinged conventional egg cartons. Dropping the
top portion 12 into position over and against the bottom portion
14, and then applying pressure to the top portion 12 while
supporting the bottom portion 14 secures the connection (e.g., such
as by engaging cooperating snap fit elements on the top and bottom
portions 12, 14), thereby reducing the prospect of egg damage such
as by actuating a hinged conventional egg carton.
[0054] The label L may be dropped into position on the top portion
12 of the carton 10. The label provides surfaces for printed
information and images. The label is shaped to provide openings
that interact with the carton's geometry by providing windows so
that the eggs are visible in the carton when the carton is closed.
In addition, the label adds structure to the carton system. The
label is shaped to provide added material on opposing sides of the
carton 10. If the egg carton configuration is not square in overall
shape, the added material occurs on the longest two length of the
label. This added portion of the label becomes the hinge feature on
one side and a tamper evident feature on the opposing side.
[0055] On the hinge side, the label may be glued or affixed to the
carton bottom, thereby allowing for the rotation of the top when
opened in the common egg carton method. On the tamper evident side,
the label is glued or affixed to the bottom with a perforation or
tear string method to open the egg carton after purchase and during
consumption.
[0056] While the invention has been described in connection with
specific embodiments thereof, it will be understood that it is
capable of further modifications and this application is intended
to cover any variations, uses, or adaptations of the invention
following, in general, the principles of the invention and
including such departures from the present disclosure as come
within known or customary practice within the art to which the
invention pertains and as may be applied to the essential features
hereinbefore set forth.
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