Packaging Unit from a Moulded Pulp Material with Elevated Lock and Method for Manufacturing Such Packaging Unit

Abstract

The present invention relates to 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, and the bottom part comprising a bottom surface, two side surfaces, a back surface, a front surface, and a closing flap; 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; a lock configured for locking the cover part to the bottom part, with the lock comprising a one or more locking, openings and one or more corresponding locking cams, wherein the one or more locking openings and locking cams are provided adjacent or at a transition region between the front surface and the top surface of the cover part in a closed position of the packaging unit,
wherein the bottom part comprises a support member that is configured for engaging the cover part, and
wherein the one or more locking openings comprise and/or are circumvented by a backwards curved upper edge that is at least partially positioned in the transition region, and an inwards inclined lower edge having a length of at least 2.5 mm and extending over an inward distance of at least 1.8 mm.

Claims

1. A packaging unit from a moulded pulp material, the 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, a front surface, and a closing flap; 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 lock configured for locking the cover part to the bottom part, with the lock comprising one or more locking openings and one or more of corresponding locking cams, wherein the one or more locking openings and locking cams are provided adjacent or at a transition region between the front surface and the top surface of the cover part in a closed position of the packaging unit, wherein the bottom part comprises a support member that is configured for engaging the cover part, and wherein the one or more locking openings comprise and/or are circumvented by a backwards curved upper edge that is at least partially positioned in the transition region, and an inwards inclined lower edge having a length of at least 2.5 mm and extending over an inward distance of at least 1.8 mm.

2. The packaging unit according to claim 1, wherein the one or more locking cams are solid locking cams.

3. The packaging unit according to claim 1, wherein the one or more locking cams and the support member are provided on the closing flap.

4. The packaging unit according to claim 1, wherein the one or more locking cams remain behind a display surface of the packaging unit in a closed position of the packaging unit.

5. The packaging unit according to clam 1, wherein the support member comprises a hook element.

6. The packaging unit according to claim 1, wherein two locking cams are provided adjacent or close to a transition to the side surfaces.

7. The packaging unit according to claim 1, wherein the one or more locking openings and locking cams have an ovoid shape.

8. The packaging unit according to claim 1, further comprising a label without openings for the lock.

9. The packaging unit according to claim 1, wherein the front surface of the cover part is provided at an angle to the vertical in the range of 5° to 13°.

10. The packaging unit according to claim 1, wherein the hinge comprises an elevated hinge.

11. The packaging unit according to claim 1, wherein the side surfaces of the cover part comprise on 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.

12. A method for manufacturing a packaging unit from a moulded pulp material, the method comprising the steps of: preparing a moulded pulp material; and providing the packaging unit from a moulded pulp material, the 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, a front surface, and a closing flap; 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 lock configured for locking the cover part to the bottom part, with the lock comprising one or more locking openings and one or more of corresponding locking cams, wherein the one or more locking openings and locking cams are provided adjacent or at a transition region between the front surface and the top surface of the cover part in a closed position of the packaging unit, wherein the bottom part comprises a support member that is configured for engaging the cover part, and wherein the one or more locking openings comprise and/or are circumvented by a backwards curved upper edge that is at least partially positioned in the transition region, and an inwards inclined lower edge having a length of at least 2.5 mm and extending over an inward distance of at least 1.8 mm. according to one or more of the foregoing claims.

13. The packaging unit according to claim 2, wherein the one or more locking cams and the support member are provided on the closing flap and wherein the one or more locking cams remain behind a display surface of the packaging unit in a closed position of the packaging unit.

14. The packaging unit according to claim 13, wherein the support member comprises a hook element.

15. The packaging unit according to claim 13, further comprising a label without openings for the lock.

16. A packaging unit from a moulded pulp material, the 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, a front surface, and a closing flap; 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 lock configured for locking the cover part to the bottom part, with the lock comprising one or more locking openings and one or more of corresponding locking cams, wherein the one or more locking openings and locking cams are provided adjacent or at a transition region between the front surface and the top surface of the cover part in a closed position of the packaging unit, wherein the bottom part comprises a support member that is configured for engaging the cover part, and wherein the one or more locking openings comprise and/or are circumvented by a backwards curved upper edge that is at least partially positioned in the transition region, and an inwards inclined lower edge having a length of at least 2.5 mm and extending over an inward distance of at least 1.8 mm, further comprising a label without openings for the lock such that the lock remains invisible in a front view of the packaging unit.

17. The packaging unit according to claim 16, wherein the one or more locking openings and locking cams have an ovoid shape.

18. The packaging unit according to claim 17, wherein the front surface of the cover part is provided at an angle to the vertical in the range of 5° to 13°.

19. The packaging unit according to claim 18, wherein two locking cams are provided adjacent or close to a transition to the side surfaces.

20. The packaging unit according to claim 19, wherein the one or more locking cams remain behind a display surface of the packaging unit in a closed position of the packaging unit.

Description

[0044] 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, in which:

[0045] FIG. 1 shows a packaging unit according to the present invention:

[0046] FIG. 2 shows the packaging unit of FIG. 1 in an open position and;

[0047] FIGS. 3A-B show front views of the packaging unit of FIGS. 1 and 2 provided with a label with and without locking openings, respectively;

[0048] FIG. 4 shows a cross-sectional view of the lock of the packaging unit of FIGS. 1-3; and

[0049] FIGS. 5A-B shows an alternative embodiment of a packaging unit according to the invention.

[0050] 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 ΔW. 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] Lower edge 36 (FIG. 4) is provided at an angle of a relative to the horizontal. In the illustrated embodiment α is in the range of 25 to 45°. In the illustrated embodiment length De of lower edge 36 is 5.4 to 6.0 mm. The inward distance Di 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.

[0056] 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.

[0057] 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.

[0058] 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 De of lower edge 36 is about 2.8 to 3.0 mm. The inward distance Di 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.

[0059] 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 ΔH. Also locking elements 32, 34 are positioned at an elevated position preferably extending into the transition region 40.

[0060] 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.