Egg carton with mating cell and lid post structure

Abstract

Plastic egg cartons having mating cell and lid posts for improved egg protection. The carton has a base tray and hinged lid, the tray including a plurality of cells for receiving individual eggs, and the tray having a plurality of cell posts each formed at an intersection of four adjacent cells as an extension of the sidewalls of the four adjacent cells. Preferable, each cell post has four generally planar ramp surfaces, one disposed respectively on each of the four sidewall extensions. The lid has a plurality of lid posts for mating with the cell posts when the lid is in a closed position.

Claims

1. A method of stacking a plurality of plastic egg cartons on top of one another, each egg carton having a tray and a lid hingedly connected to the tray for pivoting between open and closed positions, the tray and the lid having respective peripheral edges that mate with each other in the closed position, the egg carton having in the closed position a length, a width and a height; the tray having a plurality of cells for receiving individual eggs, the cells being arranged successively adjacent each other along the length and width of the carton; each cell having a bottom and a sidewall extending upwardly from the bottom to form a corresponding one of the cells; the tray having a plurality of cell posts, extending upwardly toward the lid above the peripheral edge of the tray, each cell post having a central axis aligned with the height of the carton and being formed at an intersection of four adjacent cells as an extension of the sidewalls of the four adjacent cells; each cell post having four generally planar ramp surfaces, one disposed respectively on each of the four sidewall extensions between the sidewalls of two adjacent cells, the planar ramp surfaces being aligned at an angle of from about 20 to about 45 degrees relative to the central axis of the cell post; and, the lid having a plurality of lid posts, wherein the cell posts and lid posts are configured to hold each egg axially aligned with the central axis, each lid post extending downwardly toward the tray and including complementary planar ramp surfaces for mating with the planar ramp surfaces of the cell post when the lid is in the closed position and wherein each lid post includes four downwardly extending figners, each finger having one of the complementary planar ramp surfaces, the method comprising steps of: filling the cells of each egg carton with eggs axially aligned with the central axis of its respective cell, closing the lids, and stacking the filled closed egg cartons on top of one another.

2. The egg carton of claim 1 wherein each lid post has four contoured surfaces, one between each pair of adjacent fingers, for mating with eggs received within the four adjacent cells when the lid is in the closed position.

3. The egg carton of claim 1 wherein the lid includes a connecting wall between each pair of adjacent lid posts, the connecting wall including a pair of partial ovoid shaped depressions for mating with eggs received in the adjacent cells.

4. The egg carton of claim 3 wherein the lid post has four contoured surfaces, one between each pair of adjacent fingers, for mating with eggs received within the four adjacent cells when the lid is in the closed position.

5. The egg carton of claim 1 wherein the ramp angle is from about 30 to about 45 degrees.

6. The egg carton of claim 1 wherein the ramp angle is from about 35 to about 45 degrees.

7. The egg carton of claim 1 wherein the egg carton comprises one of a 23, 2 4, 2 5, 26, 33, 34, 35, 36, 44, 455, 56 or 66 matrix of the cells.

8. A method of stacking a plurality of plastic egg cartons on top of one another, each egg carton having a tray and a lid hingedly connected to the tray for pivoting between open and closed positions, the tray and the lid having respective peripheral edges that mate with each other in the closed position, the egg carton having in the closed position a length, a width and a height; the tray having a plurality of cells for receiving individual eggs, the cells being arranged successively adjacent each other along the length and width of the carton; each cell having a bottom and a sidewall extending upwardly from the bottom to form a corresponding one of the cells; the tray having a plurality of cell posts extending above the peripheral edge of the tray, each cell post having a central axis aligned with the height of the carton and being formed at an intersection of four adjacent cells as a central dome and an extension of the sidewalls of the four adjacent cells, each cell post having four generally planar ramp surfaces, one disposed respectively on each of the four sidewall extensions between the sidewalls of two adjacent cells, the planar ramp surfaces being aligned at an angle of from about 20 to about 45 degrees relative to the central axis of the cell post; the lid having a plurality of lid posts, wherein the cell posts and lid posts are configured to hold each egg axially aligned with the central axis, and each lid post having a complementary crown adapted to receive the cell post dome and having four fingers extending downwardly from the crown for mating with the four sidewall extensions of the cell post respectively when the lid is in the closed position, and wherein each lid post includes four downwardly extending fingers, each finger having one of the complementary planar ramp surfaces; the method comprising steps of: filling the cells of each egg carton with eggs axially aligned with the central axis of its respective cell, closing the lids, and stacking the filled closed egg cartons on top of one another.

9. The egg carton of claim 8 wherein each lid post has four contoured surfaces, one between each pair of adjacent fingers, for mating with eggs received within the four adjacent cells when the lid is in the closed position.

10. The egg carton of claim 9 wherein the lid post has four contoured surfaces, one between each pair of adjacent fingers, for mating with eggs received within the four adjacent cells when the lid is in the closed position.

11. The egg carton of claim 8 wherein the lid includes a connecting wall between each pair of adjacent lid posts, the connecting wall including a pair of partial ovoid shaped depressions for mating with eggs received in the adjacent cells.

12. The egg carton of claim 8 wherein the ramp angle is from about 30 to about 45 degrees.

13. The egg carton of claim 8 wherein the ramp angle is from about 35 to about 45 degrees.

14. The egg carton of claim 8 wherein the egg carton comprises one of a 23, 24, 25, 26, 33, 34, 35, 36, 44, 45, 46, 55, 56 or 66 matrix of the cells.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The drawings depict various embodiments of the invention wherein:

(2) FIG. 1 is a top plan view of an egg carton according to one embodiment of the invention, showing the hinged lid and the bottom tray portions in an open position, and the bottom tray portion comprising a 26 matrix of egg receiving cells;

(3) FIG. 2 is a lateral sectional view taken along lines 2-2 of FIG. 1;

(4) FIG. 3 is a longitudinal sectional view of the FIG. 1 embodiment with the lid and the tray in a closed position;

(5) FIG. 4 is a top perspective view of the FIG. 1 egg carton with the lid and tray in a partially open position, showing the interior of the carton and the contours of the cell pockets, cell posts and lid posts;

(6) FIG. 5 is a top perspective, partial sectional view of the FIG. 1 egg carton with the lid partially cut-away and the lid and tray in a closed position, showing the contours of the lid post having downwardly projecting fingers engaging the sidewall extensions of the tray cell post;

(7) FIG. 6 is a top plan view of another embodiment of the invention, showing the hinged lid and tray in an open position, and the tray comprising a 36 matrix of egg receiving cells;

(8) FIG. 7 is a lateral sectional view taken along lines 7-7 of FIG. 6;

(9) FIG. 8 is a longitudinal sectional view of the FIG. 6 egg carton with the lid and tray in a closed position;

(10) FIG. 9 is a top perspective view of the FIG. 6 egg carton with the lid and tray in a partially open position, showing the interior of the carton and the contours of the cell pockets, cell posts and lid posts;

(11) FIG. 10 is a side view of a pallet of stacked egg cartons showing a crane depositing another group of stacked cartons on top of the stack already on the pallet; and

(12) FIGS. 11 A-D are perspective views of different stacking patterns of cartons packed in different types of containers.

DETAILED DESCRIPTION

(13) FIGS. 1-5 illustrate one embodiment of the invention, a 26 matrix plastic egg carton with mating cell and lid posts. The carton has cell pockets sized to hold up to a jumbo egg, between about 2.50 and about 2.75 ounces, while the carton occupies no more than a standard (non-jumbo) egg carton footprint. The invention is not limited to such standard footprint egg cartons, for jumbo eggs; rather the mating lid and cell post structure can be used with substantially any cell and carton size, for holding any size eggs, where the overall carton dimensions are not limited. The increased strength of the mating lid and cell post structure is useful for various purposes in addition to improved egg protection, including lightweighting of the carton (saving material costs), the use of alternative materials or manufacturing processes, increasing the stacking height, etc.

(14) FIGS. 6-9 illustrate a second embodiment of the invention, similar to the first, and designed to hold jumbo eggs in a 36 matrix. Again, this is a non-limiting example.

(15) FIG. 1 shows in top plan view the interior of an open 26 matrix egg carton 10 according to one embodiment of the invention. When closed (see FIG. 3) the carton 10 occupies a volume having a length L, width W, and height H. The carton is comprised of a lid 20 connected via a hinge 12 to a base tray 30, the tray comprising a plurality of egg receiving cells 40 arranged in the 26 matrix. The matrix includes four corner cells 42, one at each corner of the carton, and eight edge cells 41, with four edge cells extending along each of the two opposing longitudinal edges 11a, 11b of the carton, between the corner cells. At each cross-hair (+) intersection of four adjacent cells (22 matrix), a cell post 60 is provided. Each cell is configured to have a contour (shape and dimensions) complementary to the shape of an egg 4 (shown in dashed lines in FIG. 2). As used herein complementary means conforming at least in part to the contour (size and shape) of the egg being held or the surface being mated with. It is contemplated that various sized eggs can be inserted into a cell, in one or both of an oriented and non-oriented direction.

(16) In the present embodiment, the carton 10 is integrally molded from a sheet of thermoplastic material, here polystyrene foam, which sheet is formed into an end product (carton) having the structural components described herein via conventional molding processes, e.g., pressing the polystyrene foam sheet between male and female dies to form shaped lid and base portions and then removing (trimming) any remaining portions of the sheet to form an integral carton. The formation and structure of components such as the hinge 12, lid flap 15, and base-locking nubs 14 and associated locking apertures 16, are shown and described in the prior art such as in U.S. Pat. Nos. 6,012,583 and 5,494,164, the entire disclosures of which are incorporated herein by reference as if fully set forth herein.

(17) As shown in FIGS. 1-2, the lid 20 has a generally flat (planar) uppermost top wall 21 and a surrounding downwardly extending peripheral sidewall 23 which has a peripheral lower edge 27 that mates with a peripheral upper edge 31 of the tray. The lid has a plurality of lid posts 25 projecting axially A downwardly D toward the tray 30 and disposed along a centerline C1 of the longitudinal length L of the lid 20. The five (5) downwardly D projecting lid posts 25 are each arranged to mate with one each of the five (5) cell posts 60 of the tray 30.

(18) A trough 50 is also formed within the body of the lid 20, as a generally elongated rectangular depression within the body of the planar top wall 21 and peripheral sidewall 23, the trough having opposing longitudinal side walls 52 and opposing lateral end walls 51 that extend axially A downwardly D and below the planar top wall 21 of the lid 20. As shown, the lid posts 25 project further downwardly D from a bottom wall 53 of the trough 50. The bottom wall 53 includes a connecting wall portion 54 between each pair of adjacent lid posts 25, and between each of the two end lid posts and lateral edges 51 of the trough respectively.

(19) The lid further includes contoured (partial ovoid shaped) portions 28 forming an upper part of the cell pocket structure for securing/protecting the eggs in the cell pockets. The contoured portions 28 are disposed between each pair of adjacent lid posts, and between each lateral end lid post and lateral trough end wall 51. The ovoid-shaped contoured portion 28, disposed on opposing sides of a centerline C1 aligned with the central axis of each lid post, are located and shaped to mate with eggs in the cells on opposing sides of the centerline C1.

(20) As shown in FIGS. 1 and 4, the tray portion 30 of the carton 10 comprises a linear matrix of egg-receiving cells 40, aligned along rows and/or columns of the cell matrix, each cell being formed to receive and accommodate a single egg. Each cell 40 has a sidewall 45 having an inner receiving surface contoured to receive the ovoid shape of an egg. The sidewall 45 extends upwardly from a bottom cell wall 47 (see FIG. 3) to define an open top end of the cell. Two adjourning sidewalls 45, 45, between adjacent pairs of cells 40, cooperatively define a cell junction 43. The cell junction 43 preferably includes a rounded upper shoulder portion forming a top edge 48 of the joined sidewalls. The sidewalls 45 are generally flexible to respond to pressure applied during packaging, transportation and/or storage of the eggs.

(21) As show in FIG. 3, sidewall 45 extends upwardly from a cell base wall 47 in the direction of the lid 20. The cells collectively form the base tray 30 such that at least some area of the bottom surfaces 49 of all of the cells of one carton are substantially co-planar to lie substantially within a common plane B. This allows the planar bottom of one carton to be mechanically stacked or deposited on top of the uppermost planar lid surfaces 21 of another carton (see FIGS. 10-11). By force of gravity, the bottom surfaces 49 bear against the top surface 21 to provide a degree of stability against lateral LAT or longitudinal LONG movement due to friction between the top surface 21 and bottom surface 49.

(22) In the first embodiment of FIG. 1, the cell 40 has a generally triangular-shaped cell bottom wall 47, including a curved outermost edge 46a disposed adjacent a longitudinal edge 11a or 11b of the carton. The other two generally straight edges 46b of the bottom wall come together to form at their opposing ends a rounded (truncated) third corner 46c of the triangle. The cell sidewall 45 has sidewall portions a, b, and c which extend upwardly from and generally continue the triangular shape of the base well. More specifically, the sidewall 45 includes: 1) an outwardly curved sidewall portion 45a extending from the curved bottom edge 46a, having substantially the same curvature as edge 46a and gradually increasing in circumferential length moving upwardly toward the top edge 48 of the cell wall; 2) extending from each of the linear side edges 46b, 46b of the triangular bottom, are outwardly curved sidewall portions 45b, 45b that gradually increase in circumferential length moving toward the top edge 48 of the cell wall; and 3) extending upwardly from the rounded third corner 46c of the triangular bottom, a fourth sidewall portion 45c also has a similar rounded contour increasing in length toward the top of the cell wall. The triangular cell bottom and sculpted sidewall surfaces shown in this first embodiment provide improved egg protection by securing the eggs within an individual cell pocket compartment. The cell contour is designed to handle both oriented and non-oriented eggs.

(23) At each intersection of four adjacent (22 matrix of) cells within the tray 30, a cell post 60 is formed as an extension of the merged sidewalls 45 of the four adjacent cells 40. The cell post 60 has a central dome 61 extending axially A by a selected distance T (see FIG. 2) above the upper peripheral edge 31 of the base tray 30. Typically the dome 61 extends a distance of about 0.30 to about 0.50 inches above the upper periphery 31 of the tray 30, the peripheral edge 31 providing a mating surface for the lower peripheral edge 27 of the lid 20. The cell post 60 includes four sidewall extensions 64 arranged in a cross-hair (+) configuration and extending upwardly from the intersecting sidewalls 45 between each pair of the four adjacent cells, i.e., each pair of adjacent cells have sidewalls that merge to form one of the sidewall extensions 64a, b, c, d (see FIG. 4). Preferably, each sidewall extension 64 has a substantially planar ramp surface 65 (see FIGS. 2 and 4-5) preferably forming an uppermost and widest portion W.sub.65 (see FIG. 4) of the intersecting sidewalls 45 of the adjoining adjacent cells. While the cross-hair construction and planar ramps of the adjoining sidewall extensions 64 provide increased compression strength and help maintain the cell posts and lid posts in alignment, the individual sidewalls 45 can yield and flex to protectively hold the various sized eggs against breakage, particularly when exposed to lateral forces.

(24) In the present embodiment, the sidewall extensions 64 are dimensioned, in their relaxed state, to allow each cell to hold up to a jumbo size egg, without expanding the overall egg carton footprint (i.e., length L, width W and height H) of the carton beyond the standard footprint, that a non-jumbo cell size egg carton requires. This feature is described further below.

(25) The planar ramp surfaces 65 of the sidewall extensions are preferably arranged and disposed at an angle X, as shown in FIG. 3, of from about 20 to about 45 degrees relative to the axis A aligned along the height H of the carton. The axis A of a cell post is a line that extends axially down the center of a cell post 60. The cell post is preferably generally tubular in shape and typically hollow. Typically, axis A is disposed laterally (at about 90 degrees) to the planar bottom B of the carton 10. The planar bottom B of the carton (see FIG. 3) lies in a plane that is generally coincident or coplanar with the bottom-most extending surfaces 49 on the underside of the egg cells 40 that comprise the tray 30. The ramp surfaces 65 extend between and form a portion of the wall adjoining adjacent cells at least along a certain length RL of intersecting walls 45 (see FIG. 3). The ramp surfaces 65 extend generally downwardly D from the base of the dome 61. The ramp surfaces 65 provide resistance at least in the axial direction A against downward compressive forces that may be exerted in the downward D direction by a lid post 25 bearing down against a cell post 60 when one carton is stacked on top of another. They also resist side impact forces and help maintain the lid and cell posts in axial alignment (i.e., the central axis of both the lid post and cell post are aligned).

(26) As best shown in FIGS. 4-5, each lid post 25 comprises a downwardly projecting member having four downwardly projecting fingers 70 having inner surfaces 72. The four lid post fingers 70a, b, c, d are arranged in a cross-hair (+) configuration for mating with the four sidewall extensions 64 of a cell post. At the center of the lid post is a recessed crown 75 having a central interior pocket 76 adapted to receive the upwardly projecting dome 61 of the cell post when the lid 20 and tray 30 are in a closed position. The inner surfaces 72 of the fingers 70 are preferably configured to be complementary in contour with the sidewall extensions 64 of the cell post. More preferably, the inner surfaces of the lid post fingers have generally planar ramp surfaces 73 to mate with the ramp surfaces 65 of the cell post when the lid and tray are closed. Preferably, the outer surfaces 77 of the lid posts 25, between each pair of adjacent fingers have a recessed ovoid contour that is complementary to the outside surface of an egg deposited within a cell, and most preferably such that the outer surfaces 77 of the lid posts mate with the outside surface of an egg 4 to protect the egg against lateral LAT or longitudinal LONG movement within a cell when the lid 20 is closed down onto the tray 30.

(27) The complementary lid and cell post ramp surfaces 73, 65 are adapted to engage when compressive forces are present, to resist such forces; as a result, the crown and dome need not actually engage. This helps prevent distortion of the cell post and lid post, which distortion may shift alignment of the lid and base tray and cause excessive loading on the eggs within the cell pockets, leading to egg breakage.

(28) FIGS. 6-9 illustrate a second embodiment of the invention. The second embodiment is similar to the first, but here the egg carton is designed to hold jumbo eggs in a 36 matrix. For ease of reference, corresponding elements in the second embodiment are labeled with reference numbers in a 100 series (e.g., carton 10 in the first embodiment is carton 110 in the second embodiment).

(29) Similar to FIG. 4, FIG. 6 is a top prospective view of the egg carton 110 with the lid 120 and tray 130 in a partially open position, showing the interior of the carton and the contours of the cell pockets 140, cell posts 160 and lid posts 125. Another difference in the second embodiment is that the cell bottom walls are not triangular, but rather the bottom walls 147 are substantially circular, having a substantially circular outer edge 146. Also, the bottom wall is not flat but rather includes an outermost annular projecting edge ring 146a, forming the lowermost surface of the carton 110 which lies in bottom plane B. Radially inwardly of the outer annular ring is a push-up central bottom wall portion 146b and an oppositely disposed outwardly extending central dimple 146c which is contoured to receive one end of the egg 4 in the cell 140.

(30) Following along the circular contour of the outer edge 146a of the bottom wall, the cell sidewall 145 is substantially conical, and increasing in diameter going upwardly toward the upper edge of the sidewall 148. This sidewall structure is adapted to form relatively thinner cell junctions between adjacent cells, compared to the cell junctions of the first embodiment. This allows the carton 110 to accommodate jumbo eggs in a 36 matrix wherein the carton footprint is no greater than a standard (non-jumbo) egg carton footprint for a 36 matrix. The relatively thinner sidewall junctions 164 (compared to the first embodiment) still include the generally planar ramp surfaces 165, 173 on the mating cell and lid posts. Otherwise, the structure of the first and second embodiments is substantially the same.

(31) The second embodiment further includes a pair of opposing raised nubs or projections 180a, 180b disposed along the lateral sidewalls 113a, 113b of the base. The nubs preferably have a flat outer wall adapted to mate with the inner flat surface of the lid sidewall 123, to resist lateral movement of the lid on the base. Here, the pair of nubs 180a, 18b are disposed at opposing lateral ends of each row of cell posts. As a result of the nubs, lateral motion of the lid posts 125 and cell posts 160 is further reduced, assisting the posts in maintaining axial alignment. The nubs are optional and may be included in the 26 matrix of the first embodiment.

(32) FIG. 7 is a lateral sectional view, similar to FIG. 2, taken along the lines 7-7 of FIG. 6. Three eggs 4 are shown in dashed lines, resting in the three cells 140 extending laterally across the carton 110. Two lid posts 125 are shown in lid 130 for mating with the two cell posts 160 between each pair of adjacent cells 140.

(33) FIG. 8 is similar to FIG. 3, showing a longitudinal sectional view of the lid and tray in a closed position. The bottom surfaces 149 of the cells lie in the plane B. The complementary planar ramp surfaces 165, 173 of the cell and lid posts 160, 125 are in engagement or are in close proximity thereto.

(34) FIG. 9 is top perspective view of the lid and tray in a partially open position, similar to FIG. 4. This figure best shows the surface contours of the mating cell and lid posts 160, 125.

(35) In the second embodiment, the carton holds 18 jumbo eggs in a 36 matrix of cells and the overall carton has a length of between about 11.62 and about 11.75 inches, a width of between about 5.95 and about 6.00 inches, and a height of between about 2.62 and about 2.75 inches. This is the standard volume footprint of a 36 carton for non-jumbo eggs. Here, due to the increased strength provided by the mating cell and lid post structure, the standard footprint is maintained while accommodating jumbo eggs.

(36) Similarly, in the first embodiment, the carton holds 12 jumbo eggs in 26 matrix of cells and has an overall length of between about 11.62 and about 11.75 inches, a width of between about 3.95 and about 4.00 inches, and a height of between about 2.62 and about 2.75 inches.

(37) FIG. 10 shows one embodiment of a method and system for stacking a plurality of cartons 10. In this example the cartons are stacked on the top planar surface 210 of a pallet 200, typically by a forklift or crane 300. Here, the stacked cartons are shown not enclosed within outer containers. Alternatively, the cartons may be stacked within outer containers such as those shown in FIG. 11, and the containers stacked on top of one another. As shown in FIG. 10, the cartons 10 are stacked vertically in series in direct top to bottom contact, one on top of another, to form a stack 400. Slip sheets 250 are disposed between each substack of 4 cartons in vertical depth. The slip sheets 250 may comprise a flexible sheet of paper, plastic or cloth that can be deposited on and extended across the top surfaces of a horizontal layer of multiple side-by-side (horizontally arranged) cartons.

(38) In other embodiments, the egg cartons are held (e.g., enclosed) in outer containers in various stacking patterns. FIG. 11A shows a full case rectilinear paperboard container 230 holding a 65 array of 30 26 egg cartons 10 stacked in parallel arrangement. The case 230 of FIG. 11A has inner dimensions of about: 23 inches11 inches13 inches. FIG. 11B shows the same full case container 230 holding 30 26 egg cartons 10 stacked in a cross stacking arrangement, wherein successive vertical layers are disposed transverse to the adjacent layer. Alternatively, a half case rectilinear container is provided to hold 15 26 egg cartons, in a 35 carton matrix. In one embodiment the 15-dozen half case container has inner dimensions of about: 11 inches11 inches13 inches. In another embodiment, the 15-dozen half case container has inner dimensions of about: 12 inches11 inches13 inches.

(39) In accordance with previously described embodiments of the invention, wherein a 26 egg carton is provided having a standard footprint but which accommodates jumbo size eggs, the above-described standard full case and half case containers can be used for jumbo size eggs, without increasing the dimensions of the full case or half case containers. Similarly, the 36 egg carton previously described can be accommodated in standard full and half case containers.

(40) In alternative embodiments, the egg cartons 10 can be stacked in wire baskets 232. FIG. 11 C shows parallel stacking of 15 26 matrix cartons in a wire basket 232. FIG. 11 D shows cross stacking of 15 26 matrix cartons in the same wire basket.

(41) In a further embodiment, a 24-dozen rectilinear case container, 2 cartons across in length, 3 cartons in width and 4 cartons in height, has inner dimensions of about: 23 inches11 inches11 inches.

(42) In various embodiments, the plastic material of the egg carton is preferably one or more of polystyrene (e.g., polystyrene foam), polyester (e.g., polyethylene terephthalate (PET)), polyolefin (e.g., polyethylene (PE), polypropylene (PP)), or poly(lactic acid (PLA), including homopolymers, copolymers, mixtures and blends thereof, and including virgin and reclaimed (recycled) materials.

(43) While specific embodiments of the present invention have been shown and described, it will be apparent that many modifications can be made thereto without departing from the scope of the invention. Accordingly, the invention is not limited by the foregoing description.