PACKAGING UNIT FROM A MOULDED PULP MATERIAL WITH A SELF-ALIGNING ELEMENT AND METHOD FOR MANUFACTURING SUCH PACKAGING UNIT

Abstract

The present invention relates to a packaging unit (2) from a moulded pulp material, a method for packing products, and a method for manufacturing such packaging units. The packaging unit comprises: a bottom part (4) with product receiving compartments for holding respective products, with the bottom part at least having a bottom front (8), a bottom rear (14), and two bottom sides (10, 12); a cover part (6) at least having a cover front (20), a cover top (18), and two cover sides (22, 24); a hinge-element (28) for hingedly connecting the cover and bottom parts; anda lock (30) for locking the bottom and cover parts in a closed position of the packaging unit, and wherein the bottom side and cover side comprise a side edge having a self-aligning element (56).

Claims

1. Packaging unit from a moulded pulp material, the packaging unit comprising: a bottom part with product receiving compartments for holding respective products, with the bottom part at least having a bottom front, a bottom surface, and two bottom sides; a cover part at least having a cover front, a cover top, and two cover sides; a hinge-element for hingedly connecting the cover part and the bottom part; and a lock for locking the bottom part and the cover part in a closed position of the packaging unit, and wherein the bottom side and the cover side comprise a side edge having a self-aligning element.

2. Packaging unit according to claim 1, wherein the self-aligning element is substantially positioned in a front half of the side edge in the closed position of the packaging unit.

3. Packaging unit according to claim 1, wherein the self-aligning element comprises a smooth curvature.

4. Packaging unit according to claim 3, wherein the self-aligning element comprises a wave-shape.

5. Packaging unit according to claim 1, wherein the self-aligning element is configured for preventing or reducing relative movement between the cover part and the bottom part thereby stabilising the lock and/or fixating the relative position of the cover part and the bottom part thereby strengthening the packaging unit.

6. Packaging unit according to claim 1, further comprising an elevated hinge.

7. Packaging unit according to claim 1, wherein the side edges of the cover part and/or the bottom parts comprise at least one denesting support part, and wherein the at least one denesting support part is located within a distance of 20% of the total length of the side edge from the cover front.

8. Packaging unit according to claim 7, wherein the denesting support part at least partially overlaps with the self-aligning element.

9. Packaging unit according to claim 1, wherein the cover side and the bottom side comprise one or more ribs that substantially extend from the cover top surface in the direction of the bottom surface, and wherein the ribs protrude from the side surface and provide the cover part and the bottom part with additional support when stacking a number of packaging units.

10. Packaging unit according to claim 9, wherein the ribs extend to the bottom surface and provide the bottom surface with an additional bottom support surface that substantially corresponds to an additional cover support surface.

11. Packaging unit according to claim 10, wherein the additional cover support surface of a rim of the cover part has a support surface area of at least 0.35 cm.sup.2.

12. Packaging unit according to claim 11, wherein the rim has an average width of at least 10 mm.

13. Packaging unit according to claim 9, wherein the ribs protrude from the side surface over an average distance of at least 3 mm.

14. Packaging unit according to claim 1, wherein the lock comprises a lock opening and a cam element configured for protruding the lock opening, and wherein the cam element comprises a rib element that substantially protrudes from the cam element in a back to front direction of the packaging unit.

15. Packaging unit according to claim 1, wherein the lock comprises a lock opening and a cam element configured for protruding the lock opening, and wherein the cam element comprises a front edge and cam side edges, the front edge extending to sides of the cam into the cam side edges.

16. Packaging unit according to claim 14, wherein the cam element is provided on a flapless front surface of the bottom part.

17. Packaging unit according to claim 1, wherein the bottom front of the bottom part further comprises a front rib extending over a substantial part of a front edge of the bottom part.

18. Packaging unit according to claim 1, further comprising a full front label.

19. Packaging unit according to claim 17, wherein the full front label comprises a cut for a cam element of the lock.

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

21. Packaging unit according to claim 1, wherein the moulded pulp material comprises an amount of micro fibrillated fibers.

22. Packaging unit according to claim 21, wherein the amount of microfibrillated fibers is in the range of 1 to 3 wt % of the moulded pulp material.

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

24. 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.

25. Method for manufacturing a packaging unit from a moulded pulp material, the method comprising the steps of: preparing a moulded pulp material; and providing a packaging unit according to claim 1.

Description

[0065] 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:

[0066] FIG. 1 shows a packaging unit according to the invention for 10 eggs in a closed position;

[0067] FIG. 2 shows the packaging unit of FIG. 1 in a fully opened position;

[0068] FIG. 3A shows a front view of the packaging unit of FIGS. 1-2;

[0069] FIG. 3B shows a top view of the packaging unit of FIGS. 1-2;

[0070] FIG. 3C shows a side view of the packaging unit of FIGS. 1-2 in a closed position;

[0071] FIG. 3D shows a bottom view of the packaging unit of FIGS. 1-2;

[0072] FIG. 4 shows a stack of packaging units according to the invention;

[0073] FIG. 5 shows a bundle of packaging units according to the present invention;

[0074] FIG. 6 shows an alternative embodiment of a packaging unit according to the present invention for 12 eggs;

[0075] FIG. 7A-B shows views of an alternative embodiment of a packaging unit according to the present invention for a twinpack;

[0076] FIG. 8 shows an alternative embodiment according to the present invention for 12 eggs;

[0077] FIG. 9A-D shows an alternative embodiment according to the invention for 10 eggs;

[0078] FIGS. 10A-D and 11A-D show alternative embodiments to according to the invention for respectively 12 eggs and for 12 eggs in a twinpack;

[0079] FIG. 12A-F shows a further alternative embodiment according to the invention for 12 eggs;

[0080] FIGS. 13A-B and 14A-B show further alternative embodiments according to the invention for respectively 10 eggs and 12 eggs in a twinpack;

[0081] FIGS. 15A-B shows the lock in the embodiments of FIGS. 9-12; and

[0082] FIGS. 16 and 17 show views of alternative embodiments of a packaging unit according to the present invention.

[0083] Packaging unit 2 (FIGS. 1-5) comprises flapless bottom part 4 and cover part 6. Bottom part 4 comprises front surface 8, first side surface 10, second side surface 12, back surface 14, and bottom surface 16. Cover part 6 comprises top surface 18, front surface 20, first side surface 22, second side surface 24, and back surface 26. Hinge 28 connects back surfaces 14, 24 of bottom part 4 and cover part 6, respectively. Hinge 28 is located at the rear end of side edge 50 that defines the contact surface of bottom side surfaces 10, 12 with cover side surfaces 22, 24 in a closed position of packaging unit 2. (Elevated) hinge 28 is elevated as compared to the front end of side edge 50 over height E. In the illustrated embodiment transition region 19 between front surface 20 and top surface 18. This transition region 19 is optional for packaging unit 2.

[0084] In a closed position of packaging unit 2 (FIGS. 1 and 3A-D) front surfaces 8, 20 of bottom part 4 and cover part 6 are closed using lock 30. In the illustrated embodiment lock 30 comprises cam element 32 in bottom part 4 and lock opening 34 in cover part 6. In the illustrated embodiment opening 34 extends from front surface 20 into transition region 19, and optionally inwardly extending edge 35 is provided at the lower edge of opening 34. Edge 35 extends between 1 to 3 mm from opening 34, preferably about 2 mm.

[0085] Compartments 36 (FIG. 2) are provided in bottom part 4 and are capable of holding product P, such as an egg. Between compartments 36 there are provided a number of cones 38 that extend upwardly. Optionally, cones 38 are provided with openings or holes (not shown).

[0086] Hinge 28 comprises hinge support part 40 that in a closed position of packaging unit 2 engages cover 6 (FIGS. 2 and 3D).

[0087] Furthermore, in the illustrated embodiment cam 32 is provided with a top surface 42 (FIGS. 3C and 3D) that engages upper edge or support surface 44 of lock opening 34 in a closed position of packaging unit 2 (FIG. 1). Above lock opening 34 there is provided indent 46 (FIG. 2).

[0088] As illustrated, cam element 32 (partly) protrudes through opening 34 (FIG. 3C). Optionally, cam element 32 does not extend beyond cover front surface 20. Preferably, label 48 is provided on cover part 6. Optionally, opening 34 is somewhat wider as compared to cam element 32 to be more forgiving when closing packaging unit 2.

[0089] Side edge 50 comprises cover side edge 52 and bottom side edge 54 (FIGS. 2 and 3C). Hinge 28 is provided at a first height which is higher as compared to a second height of the front of bottom part 4 with height difference E (FIG. 3C). Therefore, on average edge 50 inclines downwards in a back to front direction (FIG. 3C). Edge 50 is provided with self-aligning element 56 (FIG. 3C) that is provided in the front half of side edge 50 as seen in the back to front direction D. In the illustrated embodiment element 56 is provided as a continuous semi-circle or smoothed bump, and is preferably provided with a wave-shape. In this illustrated embodiment the circle or bump 56 is positioned upwards. It will be understood that, alternatively, an upside-down configuration of element 56 can also be envisaged in accordance with the present invention. Denesting support element 58 (FIG. 3C) comprises cover support part 60 and bottom support part 62 that engage each other in a closed position of packaging unit 2. It will be understood that denesting support element 58 is optional in all embodiments of the present invention and that it can also be envisaged to only provide cover support part 60 or bottom support part 62. Denesting support part 58 is provided close to the front of edge 50, and in the illustrated embodiment a second denesting support part 64 with cover part 66 and bottom part 68 is provided on edge 50 close to the back of edge 50 as seen in the back to front direction D. in this illustrated embodiment cam 32 is positioned above hinge 28 to further improve the stability of the lock when handling packaging unit 2.

[0090] Side rib 70 (FIG. 3C) comprises cover rib 72 and bottom side rib 74 that are aligned in a closed position of packaging unit 2. Side rib 70 extends from top surface 18 to bottom surface 16 and provides an additional cover support surface 76 (FIGS. 1 and 3B) and bottom support surface 78 (FIG. 3D). In the illustrated embodiments ribs 70 comprise straight edges 80 that are provided at an angle ? relative to vertical part (FIG. 3C). Sides 22, 24 of cover part 6 are provided at angle ? relative to the vertical (FIG. 3A). In the illustrated embodiment ribs 70 are sharply separated from middle side surface 82. At corners 84 (FIG. 1) there is provided a transition part between side and front surfaces of packaging unit 2 with a circular shape. Front rib 86 extends between two adjacent cam supports 88 in a substantially horizontal direction (FIG. 2). Cam element 32 comprises cam ribs 90 that extend in a substantially vertical direction and protrude in back to front direction D (FIG. 3D).

[0091] The moulded pulp material is optionally provided with natural fibres 92 (FIG. 2) and/or a biodegradable material. Optionally, natural fibres 92 can be allowed to remain visible on packaging unit 2.

[0092] Stack 94 (FIG. 4) of packaging units 2 in a closed position shows in the illustrated embodiment a crosswise stacking with layers 96a,b,c, . . . . Bundle 98 (FIG. 5) comprises a number of packaging units 2 in a closed position.

[0093] Packaging unit 102 (FIG. 6) comprises flapless bottom part 104 and cover part 106. Bottom part 104 comprises front surface 108, first side surface 110, second side surface 112, back surface 114, and bottom surface 116. Cover part 106 comprises top surface 118, front surface 120, first side surface 122, second side surface 124, and back surface 126. Hinge 128 connects back surfaces 114, 124 of bottom part 104 and cover part 106, respectively. In the illustrated embodiment transition region 119 extends between front surface 120 and top surface 118. This transition region 119 is optional for packaging unit 102. Self-aligning element 56 is provided to packaging unit 102 as described in relation to other embodiments of the invention.

[0094] In the illustrated embodiment lock 130 comprises cam element 132 in bottom part 104 and lock opening 134 in cover part 106. In the illustrated embodiment opening 134 is provided in front surface 120 of cover part 106 and extends towards and/or into transition region 119. In the illustrated embodiment opening 134 is provided with support 135. Support 135 rests on cam element 132 in a closed position of packaging unit 102 to provide additional strength and stability. Optionally, recess or notch 137 is provided above support 135 to further improve the locking function of lock 130. It will be understood that dimensions and positions of lock 130 can be designed in accordance to the particular needs of packaging unit 102. For example, locks 130 can be positioned more towards side surfaces 122, 124. Support 135 extends in a front to back direction over a distance preferably between 1 to 8 mm, more preferably between 2 and 6 mm, or another suitable distance.

[0095] As indicated in relation to other embodiments of the invention, cam element 132 (partly) protrudes through opening 134. Optionally, cam element 132 does not extend beyond cover front surface 120. Preferably, a label is provided on cover part 106. Optionally, opening 134 is somewhat wider as compared to cam element 132 to be more forgiving when closing packaging unit 2.

[0096] Alternative packaging unit 202 (FIG. 7A-B) comprises flapless bottom part 204 and cover part 206. Bottom part 204 comprises front surface 208, first side surface 210, second side surface 212, back surface 214, and bottom surface 216. Cover part 206 comprises top surface 218, front surface 220, first side surface 222, second side surface 224, and back surface 226. Elevated hinge 228 connects back surfaces 214, 224 of bottom part 204 and cover part 206, respectively. In the illustrated embodiment transition region 219 extends between front surface 220 and top surface 218. This transition region 219 is optional for packaging unit 202. Self-aligning element 56 is provided to packaging unit 202 as described in relation to other embodiments of the invention. Elevated hinge 228 connects bottom part 204 and cover part 206. In this illustrated embodiment indent 230 is larger as compared to indent 46 (FIG. 1) to further enhance the locking effect in a closed position of packaging unit 202. In addition, indent 230 extends over substantially the entire height of transition region 219 on front surface 220 of cover part 206 (FIG. 7A). In this illustrated embodiment edge 244 is larger as compared to edge 44 (FIG. 1).

[0097] Alternative packaging unit 302 (FIG. 8) is provided with 12 compartments and is provided with a design that is closely related to that of packaging unit 202 (twinpack) with 2?6 compartments.

[0098] Alternative packaging unit 312 (FIG. 9A-D) is provided with 10 compartments and is closely related to the embodiments shown earlier. Next, only some differences will be discussed.

[0099] Indent 314 is extending slightly further to top surface 316. Denesting support part 318 are only provided in cover part 320 of packaging unit 312. Side edge 322 of front surface 324 of cover part 320 of packaging unit 312 is inclined and put at a somewhat larger angle relative to the vertical as compared to the earlier embodiments shows in FIGS. 1-8.

[0100] Alternative packaging unit 332 (FIG. 10A-D) is provided with 12 compartments. Alternative packaging unit 342 (FIG. 11A-D) is also provided with 12 compartments, however in a twinpack configuration. Further details of packaging units 332, 342 are similar to those of packaging unit 312 (FIG. 9A-D).

[0101] Alternative packaging unit 352 (FIG. 12A-F) is provided with 12 compartments and comprises flapless bottom part 354 and cover part 356. Bottom part 354 comprises front surface 358, first side surface 360, second side surface 362, back surface 364, and bottom surface 366. Cover part 356 comprises top surface 368, front surface 370, first side surface 372, second side surface 374, and back surface 376. Elevated hinge 378 connects back surfaces 364, 376 of bottom part 354 and cover part 356, respectively. Self-aligning element 56 is preferably wave-shaped and is provided to packaging unit 352 as described in relation to other embodiments of the invention. Front surface 370 is provided with a so-called deep front extending over distance D.sub.f. In this illustrated embodiment distance D.sub.f extends about 1 cm deeper towards the bottom in a closed position of the packaging unit. It will be understood that this significantly increases the front surface of the packaging unit and provides a larger display surface. In a presently preferred embodiment label 380 is provided having so-called smiley cuts 382 for the cam element of the lock.

[0102] Alternative packaging unit 384 (FIG. 13A-B) is provided with 10 compartments, and alternative packaging unit 386 (FIG. 14A-B) is provided with 12 compartments, however, in a twinpack configuration. In the illustrated embodiment packaging units 384, 386 are (optionally) provided with label 380 having smiley cuts 382. Further details of packaging units 384, 386 are similar to those of packaging unit 352 (FIG. 12A-F).

[0103] Lock 390 (FIG. 15A-B) is provided in the illustrated embodiments of FIGS. 9-14 and can also be applied to the other embodiments shown in FIGS. 1-8, if desired. Optionally, also lock 30 can alternatively be applied to the embodiments shown in FIGS. 9-14.

[0104] Lock 390 is provided with cam 392 having a top surface 394 that engages upper edge or support surface 396 of lock opening 398 in a closed position of packaging unit 2. In this embodiment front edge 397 of cam 392 extends somewhat further forward (and through opening 398) in a closed position of the packaging unit as compared to lock 30. Furthermore, front edge 397 extends to the sides of cam 392 into cam side edges 399.

[0105] As illustrated, cam element 392 (partly) protrudes through opening 398 in a closed position of the packaging unit. Optionally, cam element 392 does not extend beyond cover front surface 20. Preferably, a label is provided on the cover part of the packaging unit. Optionally, opening 398 is somewhat wider as compared to cam element 392 to be more forgiving when closing the packaging unit.

[0106] Alternative packaging units 402, 502 (FIGS. 16-17) comprise flapless bottom part 404 and cover part 406. Bottom part 404 comprises front surface 408, first side surface 410, second side surface 412, back surface 414, and bottom surface 416. Cover part 406 comprises top surface 418, front surface 420, first side surface 422, second side surface 424, and back surface 426. Elevated hinge 428 connects back surfaces 414, 424 of bottom part 404 and cover part 406, respectively. In the illustrated embodiment transition region 419 extends between front surface 420 and top surface 418. This transition region 419 is optional for packaging unit 402, 502. Self-aligning element 56 is preferably wave-shaped and is provided to packaging unit 402, 502 as described in relation to other embodiments of the invention. Also in this embodiment, indent 230 extends over substantially the entire height of transition region 219 on front surface 420 of cover part 406. Packaging unit 502 (FIG. 10) is provided with an additional shape 504 on at least one, or both, side surfaces 422, 424. In these illustrated embodiments edge 444 is larger as compared to edge 44 (FIG. 1). Front surfaces 420 of packaging units 402, 502 are larger as compared to front surface 20 of packaging unit 2 (FIG. 1). In addition, larger front surface 420 of packaging unit 502 is provided with additional wave-shape corner edges 506. Edges 506 provide additional stability when handling packaging units 502, for example in the filling process. In addition, edges 506 enhance the visual effect of wave-shaped self-aligning element 56.

[0107] In the illustrated embodiment packaging unit 2 comprises a number of product receiving compartments 36 that are provided in two rows of five or six compartments 36. It will be understood that other configurations with a different number of compartments and/or rows can also be envisaged in accordance to the invention.

[0108] When manufacturing packaging unit 2 the moulded pulp material is provided to a mould, preferably with the moulded pulp material comprising a number of additives, such as an amount of MFC, NFC and/or AKD, ASA and/or other sizing components. In the illustrated embodiment, packaging unit 2 is moulded in a moulding operation and then dried. The dried packaging units 2 are then used to pack products P by placing one product P in respective compartment 36 to provide a packaging unit that is filled with products P and ready for storage, transport and/or display. Such packaging unit enables a potential buyer to inspect products P while packaging unit 2 remains on the shelf, for example.

[0109] Tests with packaging unit 2 on an automated packing line show a significant reduction in problems associated with undesired opening of the packaging unit due to the self-aligning effect. It was shown that line capacity was significantly improved. In addition, due to the stabilising effect of self-aligning element 56, packaging units 2 were less damaged during handling, transport, storage and display.

[0110] 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. For example, lock 30 can be provided with differently shaped locking elements. Furthermore, a label can be attached to packaging unit 2, for example a full front label, optionally provided with a smiley cut. The illustrated packaging unit 2 comprises ten product receiving compartments 36. It will be understood that another number of product receiving compartments 36 can also be envisaged in accordance with the invention. Although packaging unit 2 is shown for eggs, it may also be used for other products such as kiwis and tomatoes, for example.