U.S. patent application number 13/440669 was filed with the patent office on 2013-10-10 for transparent egg carton.
This patent application is currently assigned to CLEAR VIEW CARTONS, INC.. The applicant listed for this patent is Marvin Aardema, Michael Borse, Robert Borse, John Camphouse. Invention is credited to Marvin Aardema, Michael Borse, Robert Borse, John Camphouse.
Application Number | 20130264243 13/440669 |
Document ID | / |
Family ID | 49291457 |
Filed Date | 2013-10-10 |
United States Patent
Application |
20130264243 |
Kind Code |
A1 |
Aardema; Marvin ; et
al. |
October 10, 2013 |
TRANSPARENT EGG CARTON
Abstract
The present invention provides an egg carton having a tray
having a first row of a first plurality of spaced egg compartments
and a second row of a second plurality of spaced egg compartments,
the first row of egg compartments being disposed in parallel spaced
relationship to the second row of egg compartments; a plurality of
spaced tower elements extending along a centerline of the tray and
extending vertically from a plane of the tray, each tower element
having four egg contacting surfaces; a plurality of spaced post
elements extending along a front edge of the tray and extending
vertically from a plane of the tray, each post element having two
egg contacting surfaces; and a lid hingedly connected along a rear
edge of the tray and movable from an open condition to a closed
condition.
Inventors: |
Aardema; Marvin; (South
Holland, IL) ; Camphouse; John; (South Holland,
IL) ; Borse; Robert; (Burr Ridge, IL) ; Borse;
Michael; (Burr Ridge, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Aardema; Marvin
Camphouse; John
Borse; Robert
Borse; Michael |
South Holland
South Holland
Burr Ridge
Burr Ridge |
IL
IL
IL
IL |
US
US
US
US |
|
|
Assignee: |
CLEAR VIEW CARTONS, INC.
South Holland
IL
|
Family ID: |
49291457 |
Appl. No.: |
13/440669 |
Filed: |
April 5, 2012 |
Current U.S.
Class: |
206/521.1 |
Current CPC
Class: |
B65D 85/32 20130101 |
Class at
Publication: |
206/521.1 |
International
Class: |
B65D 81/02 20060101
B65D081/02 |
Claims
1. An egg carton comprising: a tray having a first row of a first
plurality of spaced egg compartments and a second row of a second
plurality of spaced egg compartments, the first row of egg
compartments being disposed in parallel spaced relationship to the
second row of egg compartments; a plurality of spaced tower
elements extending along a centerline of the tray and extending
vertically from a plane of the tray, each tower element having four
egg contacting surfaces; a plurality of spaced post elements
extending along a front edge of the tray and extending vertically
from a plane of the tray, each post element having two egg
contacting surfaces; and a lid hingedly connected along a rear edge
of the tray and movable from an open condition to a closed
condition.
2. The egg carton of claim 1 wherein each of the plurality of post
elements is aligned with each of the plurality of tower
elements.
3. The egg carton of claim 1 wherein the first plurality of egg
compartments and the second plurality of egg compartments comprises
at least two egg compartments.
4. The egg carton of claim 1 wherein the post elements are
positioned between adjacent egg compartments of the first plurality
of egg compartments.
5. The egg carton of claim 1 wherein one of each of the two egg
contacting surfaces of the post elements form a portion of each of
two adjacent egg compartments.
6. The egg carton of claim 1 further comprising a first button tab
on a first post element and a first mating button surface on the
lid, wherein when the egg carton is in the closed condition the
first button tab is positioned in the first mating button surface
to releasably interlock the lid to the tray.
7. The egg carton of claim 6 wherein the first mating button
surface is an indentation in the lid or a through hole in the
lid.
8. The egg carton of claim 6 further comprising a second button tab
on a second post element and a second mating button surface on the
lid spaced from the first mating button surface, wherein when the
egg carton is in the closed condition the second button tab is
positioned in the second button surface to releasably interlock the
lid to the tray.
9. The egg carton of claim 8 wherein the second mating button
surface is an indentation in the lid or a through hole in the
lid.
10. The egg carton of claim 8 further comprising a third button tab
on a third post element positioned between the first post element
and the second post element and a third mating button surface on
the lid positioned between the first mating button surface and the
second mating button surface and wherein when the egg carton is in
the closed condition the third button tab is positioned in the
third mating button surface.
11. The egg carton of claim 8 wherein the first button tab
comprises a flange extending outwardly from a portion of the first
post element and having a downwardly facing surface.
12. The egg carton of claim 11 wherein the downwardly facing
surface has a groove dimensioned to releasably retain the first
mating tab surface.
13. The egg carton of claim 1 further comprising a plurality of
spaced supports positioned along a rear edge of the tray that
extend vertically from a plane of the tray.
14. The egg carton of claim 13 wherein each support of the
plurality of supports have two egg contacting surfaces.
15. The egg carton of claim 13 wherein one of each of the plurality
of supports is in alignment with one of each of the plurality of
tower elements.
16. The egg carton of claim 13 wherein the supports are positioned
between two adjacent egg compartments of the second plurality of
egg compartments.
17. The egg carton of claim 13 wherein the tower elements extend a
first vertical distance from a plane of the tray, the post elements
extend a second vertical distance from the plane and the supports
extend a third vertical distance wherein the first vertical
distance is greater than the second vertical distance and the third
vertical distance.
18. The egg carton of claim 17 wherein the second vertical distance
is greater than the third vertical distance.
19. The egg carton of claim 1 further comprising a gutter extending
from the front edge of the tray and dimensioned to releasably
retain a portion of the lid when in the closed condition.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention provides an egg carton and more
particularly an egg carton of a transparent polymeric material.
[0003] 2. Background of the Invention
[0004] Conventional egg cartons in wide use today are typically
made either of a fibrous material, such as cardboard, or a foamed
polymeric material, such as foamed polystyrene. While these
materials are inexpensive to prepare they share the same
disadvantage of being opaque, requiring a consumer to open the lid
of the egg carton to inspect the eggs for damage.
[0005] Egg cartons made of a transparent polymeric materials, such
as polyethylene terephthalate (PET) polymers have also come into
use, although to a more limited extent than cardboard and foamed
polystyrene cartons. Such transparent egg cartons exhibit various
disadvantages that result from the properties of the materials
used. For example, while these materials are recyclable, they are
not biodegradable.
[0006] Transparent polymeric egg containers in the market today
commonly have two lids in a trifold design. The first lid is
conformed to fit over the top of the eggs, and the second lid is
conformed to fit over the first lid. In another design, instead of
using a flap, the lid and tray of the carton are configured with a
series of snap locks around the rim. Another egg carton disclosed
in U.S. Pat. No. 4,240,575 shows a locking flap and hinge at an
obtuse angle so that the flap is situated in a partially closed
position. However, this design does not eliminate the problem of
bending of the egg carton when grasped from the end.
[0007] One observation of some transparent egg cartons is it is
difficult for consumers to release the lid from the interlocking
tabs and holes. In the cardboard or foamed polystyrene designs, the
consumer typically pulls the front of the lid forward from the
center to clear the holes from the tabs and rotates the lid upward
to open the carton. However, if the flap and lid are made of
typical transparent polymeric materials, which are more pliable
than cardboard or foamed polystyrene, pulling the front surface of
the lid forward from the middle creates a bow action that results
in bowing of the middle of the flap outward and the lateral sides
of the flap inward, making it difficult to release the lid from the
button tabs on the flap. One method of overcoming this problem is
exemplified by U.S. Pat. No. 4,463,894 where it is disclosed to
make the lateral portions of the flap thicker than the central
portion to reduce the bowing effect. A problem with this design is
that more material is required to form the flap.
[0008] Commonly assigned U.S. Pat. No. 7,258,234 discloses a
transparent egg carton having a tray, a lid and a flap hingedly
connected to a front edge of the tray for securing the lid to the
tray when in a closed condition. The '234 patent discloses an egg
carton formed from transparent plastic material such as polylactic
acid or other biodegradable polymers. The flap is made with lattice
struts to increase the lateral strength of the flap and has three
button tabs for interlocking the flap to the lid.
[0009] Accordingly there is a need in the art to provide
transparent egg cartons that have the advantages of cardboard and
foamed polystyrene egg cartons while lacking the disadvantages
inherent to cartons made of transparent polymeric materials.
SUMMARY OF THE INVENTION
[0010] The present invention provides an egg carton having a tray
having a first row of a first plurality of spaced egg compartments
and a second row of a second plurality of spaced egg compartments,
the first row of egg compartments being disposed in parallel spaced
relationship to the second row of egg compartments; a plurality of
spaced tower elements extending along a centerline of the tray and
extending vertically from a plane of the tray, each tower element
having four egg contacting surfaces; a plurality of spaced post
elements extending along a front edge of the tray and extending
vertically from a plane of the tray, each post element having two
egg contacting surfaces; and a lid hingedly connected along a rear
edge of the tray and movable from an open condition to a closed
condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of an embodiment of an egg
carton in an open condition;
[0012] FIG. 2 is a perspective view of the egg carton of FIG. 1 in
a closed condition;
[0013] FIG. 3 is a top plan view of the egg carton of FIG. 1;
[0014] FIG. 4 is a side elevation view of the egg container of FIG.
1;
[0015] FIG. 5 is a bottom plan view of a tray of an egg carton;
[0016] FIG. 6 is a top plan view of a second embodiment of an egg
carton;
[0017] FIG. 7a is a side elevation view in cut away of the second
embodiment of the egg carton of FIG. 6 in a closed condition;
and
[0018] FIG. 7b is a side elevation view in cut away of the second
embodiment of the egg carton of FIG. 6 in an open condition.
DETAILED DESCRIPTION OF THE INVENTION
[0019] While this invention is susceptible of embodiment in many
different forms, there is shown in the drawings, and will be
described herein in detail, specific embodiments thereof with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the invention to the specific embodiments
illustrated.
[0020] Described herein are various features of a transparent egg
carton 10, which is suitable for embodiments using a variety of
transparent polymeric materials, including, but not limited to
relatively pliable recyclable polymeric materials such as
polyethylene terephthalate (PET), which is an amorphous polyester;
clarified polypropylene (CPP), which is polypropylene containing
nucleating agents to increase clarity; styrene butadiene copolymers
(SBC) without impact modifiers; copolymer blends of SBC with
crystalline polystyrene (cPS), which is commercially known as
"K-Resin/Crystal.TM.", oriented polystyrene (OPS); polyvinyl
chloride (PVC); styrene acrylonitrile polymer (SAN); polymethyl
methacrylate (PMM) and copolymers thereof, commercially known as
Plexiglas; and polycarbonate (PC). In advantageous embodiments, the
features of the egg carton 10 are also suitable for a newer class
of transparent polymeric materials that are recyclable and
biodegradable. Examples of such polymeric materials include
polylactic acid (PLA), polyglycolic acid (PGA) and polylactic
acid-glycolic acid copolymers (PLGA). In a preferred form of the
invention, the egg carton 10 is preferably made of PLA, PGA, or
PLGA in commonly known polymeric processing techniques such as
thermoforming, injection molding, vacuum forming or other
techniques well known to those skilled in the art.
[0021] FIG. 1 shows a transparent egg carton 10 having a tray 12
and a lid 14 hingedly connected thereto for movement between and
open condition (FIG. 1) to a closed condition (FIG. 2). The tray 10
has a generally rectangular peripheral wall 16 having a front edge
18 and a rear edge 20 defining an imaginary plane of the tray 22.
The tray has a first row 24 of a plurality of egg compartments 26
and a second row 28 of a plurality of egg compartments 26 in
parallel spaced relationship to the first row. While it is shown
that each of the first and second rows of egg compartments have six
compartments it is contemplated that each row could have from as
little as two up to twelve or more compartments provided the
container has sufficient physical properties to protect the eggs
during shipment and handling by a user of the eggs. Each egg
compartment 26 has a generally ovoid shaped wall 30 that extends
downward below the plane of the tray 22 and is closed by an end
wall 32. In one preferred form of the invention, the end wall has
an inner surface 34 that extends concave upwardly. A plurality of
circumferentially spaced and inwardly extending tabs 36 are
deformed from the wall for engaging an outer surface of an egg. The
tabs are generally rectangular shaped with rounded ends with the
length dimension oriented parallel to an axis of the compartment.
In a preferred form of the invention eight tabs are provided and
are equally spaced about the circumference of the wall 30 of the
compartment. The tabs contact the shell of an egg to reduce the
surface area that the shell is in contact with the wall 30. By
reducing the surface area contact between the wall and the egg
shell reduces the tendency for the egg to stick to the wall of the
compartment and to become damaged upon removal from the
compartment.
[0022] FIGS. 1-3 show a plurality of tower elements 40 spaced
horizontally along a centerline 42 of the tray and extending
vertically upwardly above the plane of the tray by a first
distance. Each tower element 40 has four egg contacting surfaces 44
one of each surface associated with a different egg compartment.
The egg contacting surfaces 44 are concave to conform to a portion
of an egg that extends above the plane of the tray. Each tower
element 40 has a top end 46 that is generally circular and has a
flat surface 48 for contacting a bottom surface of the lid 14 to
protect the egg contents from crushing even upon stacking of other
similar filled egg cartons on top of the lid. A notch 47 is
provided along a wall connecting each adjacent tower element 40 to
provide a vent for when eggs are inserted into each egg
compartment.
[0023] A plurality of horizontally-spaced supports 50 are provided
along the front edge 18 of the tray. The supports 50 extend above
the plane 22 a second distance which is less than the first
distance. Each of the supports 50 have two egg contacting surfaces
52 for contacting eggs in two adjacent egg compartments of the
first row 24. The egg contacting surfaces 52 are generally concave
to conform to the shape of an egg placed in the compartment. The
supports 50 have the shape of a truncated equilateral triangle in
horizontal cross-section dimension with a truncated apex 54
pointing inward of the container toward the tower elements 40. In a
preferred form of the invention, two of the outermost supports,
those closest to lateral edges 56 of the tray, have a tooth-shaped
protuberance 58 extending outwardly of the container from an outer
surface 60. The tooth-shaped protuberance 58 has an outwardly
tapering and downwardly extending surface 62 defining a downwardly
facing surface 64 with a laterally extending groove 66. The
protuberance 58 is commonly known as a button tab and is for
releasably engaging a button tab mating surface 68 on the lid 14,
as will be discussed in greater detail below.
[0024] As seen in FIG. 1, the center support 70 is segmented with a
lower section 72 and an upper section 74 connected by a tapering
middle transition section 76. During closing of the lid, the
transition section 76 engages a tab mating surface 68 of the lid
and guides the lid into proper alignment for engagement of the
lower section 72 with a button tab mating surface 68 on the
lid.
[0025] A plurality of horizontally-spaced post elements 80 are
positioned along the rear edge 20 of the tray each of which has two
egg contacting surfaces 82 for contacting two eggs one of each in
adjacent egg compartments of the second row of egg compartments 26.
Each of the post elements 80 have the shape of a truncated
equilateral triangle in horizontal cross-section dimension with a
truncated apex 84 pointing inward of the container toward the tower
elements 40. Each of the post elements 80 extend vertically upward
above the plane 22 of the tray a third distance and terminate in a
flat upper surface 86. The third distance is less than the second
distance.
[0026] FIGS. 1 and 3 also show an optional feature of four corner
tabs 90 that extend vertically above the plane 22 of the tray and
each has an egg contacting surface 92 that is generally concave, a
rear wall that is generally convex 94 and has a flat top surface
96. The corner tabs engage optional compartments in the lid to
ensure proper alignment of the lid with the tray when in the closed
condition and to resist inadvertent opening of the lid.
[0027] As best seen in FIGS. 5 and 6, a buttress 98 extends below
the plane 22 of the tray and between each adjacent egg compartment
to provide support along the longitudinal dimension of the tray. In
a preferred form of the invention, the buttress extends from about
40% to about 90%, more preferably from about 45% to about 85% and
most preferably from about 50% to about 80%, or any range or
combination of ranges therein, as far as the end wall 32 extends
from the plane 22. The buttress is generally U-shaped in vertical
cross-section dimension and in a preferred form of the invention
has an optional strut 100 that is generally arcuate shaped and
extends upward into the tray and between two legs of the U-shaped
buttress. The strut is to provide support along the latitudinal
dimension of the carton.
[0028] FIGS. 1-5 show the generally rectangular shaped lid 14
having two horizontally spaced end walls 102, a front wall 104 and
a rear wall 106 in parallel spaced relationship, all of which are
vertically upstanding and are connected by a horizontally extending
top wall 108. The front wall 104 has three button-tab mating
surfaces 68. In another preferred form of the invention only the
two outermost button tabs are provided; thus, the center button tab
shown is optional. In one preferred form of the invention, the two
outermost button-tab mating surfaces consist of a generally
rectangular opening 110 through the entire thickness of the front
wall. When the lid is in the closed condition, each of the
tooth-shaped protuberances 58 extend through the opening 110 and a
lateral edge of each tooth engages a vertically extending edge 112
of the opening and the groove 66 engages a bottom 114, horizontally
extending edge of the opening to releasably engage the lid. The
distance between the vertically extending edges 112 is about the
same as the distance between the lateral edges of each tooth they
engage to place the lid under lateral tension to resists
inadvertent opening of the lid. The optional middle button-mating
surface 68 is rectangular shaped indentation that is dimensioned to
interlock with the lower section 72 of the center support 70 when
the lid is in the closed condition (FIG. 2). It should be
understood that the button-mating surfaces described above are
interchangeable and any combination of the same could be used.
[0029] At each of the corners 116 of the lid are optional arcuate
shaped pockets 118 having a bottom wall 120 for engaging the corner
tabs 90 of the tray. FIG. 3 also shows several optional
strengthening indentations 120 deformed from the top wall 108 of
the lid--two optional longitudinally extending indents 122 in
registration with a centerline drawn through the centers of the
first and second rows of egg compartments 24,26 and four optional
lattitudinally extending indents 126 forming a line between
adjacent tower elements 40. Vertically extending indents 126 are
also provided on the lid front and rear walls 104,106 in alignment
respectively with the supports 50 and the post elements 80. The
lateral end walls of the lid each have two raised areas 129 that
are in registration with raised areas 130 on the tray lateral walls
to form vents that are in alignment with the center of the first
and second row of egg compartments.
[0030] The lid rear wall 106 is hingedly connected to the rear edge
of the tray 20 with a W-shaped hinge or a box hinge 131 as set
forth in U.S. Pat. No. 7,258,234 which is incorporated herein by
reference and made a part hereof.
[0031] FIGS. 6, 7a,b show another preferred form of the invention
that differs from the embodiment shown in FIGS. 1-5 by the
provision of a gutter 132 that extends from the front edge of the
tray 18 and is dimensioned to releasably interlock with a tab 134
extending from the lid front wall 104. The gutter and tab have
complementary shapes such as concave and convex for the parts to
fit together and form an interference fit. Also provided on the
front edge of the tray 18 is a finger recessed area 136 generally
centrally located thereon.
[0032] One advantage of the present invention is that the
transparent, polymeric egg carton has no flap extending from the
front edge of the tray. This provides significant savings in terms
of material used without diminishing the desirable physical
properties of the carton and its ease of use by consumers.
[0033] From the foregoing, it will be observed that numerous
variations and modifications may be effected without departing from
the spirit and scope of the invention. It is to be understood that
no limitation with respect to the specific apparatus illustrated
herein is intended or should be inferred. It is, of course,
intended to cover by the appended claims all such modifications as
fall within the scope of the claims
* * * * *