TRI-FOLD EGG CARTON FOR VARIOUS SIZE JUMBO EGGS
20180273284 ยท 2018-09-27
Inventors
Cpc classification
International classification
B65D43/16
PERFORMING OPERATIONS; TRANSPORTING
B65D21/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Tri-fold egg carton has a base and a cover each having a complementary matrix of egg receiving cells such that, when the cover is assembled on top of the base, the complementary cells encapsulate each egg in an individual cell pocket (see FIGS. 3-5). Each base cell and cover cell includes a central dome and first and second radially spaced apart circumferential hinges that surround the central dome, and lie radially inward of a lowermost standing ring, enabling the dome to move up and down above the plane of the standing ring (in the height direction of the closed carton) between multiple positions to accommodate jumbo eggs of varying dimensions (height and width) to hold them securely in their respective cell pocket. The base and cover further include full height cell posts with mating surfaces that engage in the assembled state. The carton further includes a lid which fits over the cover (of the assembled cover and base), in a secure and locked position
Claims
1. A tri-fold plastic egg carton comprising: a base, and a cover hingedly connected to one edge of the base for pivoting between open and closed positions, the base and cover each having a complimentary rectilinear matrix of cells that together form a rectilinear matrix of cell pockets for holding individual eggs when the cover is closed over the base; a lid hingedly connected to another edge of the base for pivoting between open and closed positions, wherein when the cover and base are in the closed position the lid can be closed over the cover to form an assembled carton; each cell pocket is sized to hold any different size variations of a jumbo egg, of from 2.50 to 3.00 ounces per egg, in an oriented or a non-oriented direction in the base cell; each cell of the base and lid having a bottom wall comprising: a lowermost peripheral standing ring defining a base plane; a recessed wall portion disposed radially inwardly from the peripheral standing ring and defining a central recessed area above the base plane, the recessed wall portion including a central dome in a concave out position in a relaxed state, a first circumferential hinge disposed radially outwardly of and surrounding the central dome, and a second circumferential hinge disposed radially outwardly of and surrounding the first hinge, the first and second hinges being in a contracted position in a relaxed state, wherein each of the upper and lower hinges are movable between their contracted position to one or more extended positions to move the central dome up and down in the central recessed area while remaining above the base plane while the central domes of the base cell and cover cell engage opposing ends of a jumbo egg of the different size variations and orientations.
2. The egg carton of claim 1, wherein the carton has a 26 matrix of the cell pockets formed by a complementary 26 matrix of cells in each of the base and cover, and the carton is a solid sheet of clear polyester.
3. The egg carton of claim 2, wherein the bottom wall has a thickness in a range of about 0.013 to about 0.022 inches
4. The egg carton of claim 1, wherein each cell has an arcuate, outwardly bowed sidewall portion sized to receive a major cell diameter of a jumbo egg in a range of about 1.75 to about 2.06 inches, and the cell pocket is configured to hold a jumbo egg in a height range of 2.461 to 2.750 inches, between the central domes of the base cell and cover cell.
5. The egg carton of claim 1, wherein each cell has a sidewall and the sidewalls of two adjacent cells form a cell divider which prevents contact between eggs in the adjacent cells.
6. The egg carton of claim 1, the non-hinged peripheral edges of the lid, cover and base each having a lip edge, the lip edges of the cover and base mating when the cover is closed over the base, and the lip edge of the lid being disposed over the mating lip edges of the cover and base when the lid is closed over the cover.
7. The egg carton of claim 1, wherein the assembled carton has a length of from about 11.62 to about 12.00 inches, a width of from about 3.95 to about 4.00 inches and a height of from about 2.62 to about 3.125 inches.
8. The egg carton of claim 1, wherein the assembled carton is filled with jumbo eggs of the different size variations and orientations.
9. A stack comprising a plurality of assembled egg cartons of claim 7 arranged in a stack.
10. The stack of claim 9, further comprising a container holding the stack.
11. The stack of claim 11, wherein the container holds a full case or half case of the egg cartons.
12. The egg carton of claim 1, wherein the plastic is one or more of polyester, polyethylene, polylatic acid, and polystyrene, including polymers, copolymers, mixtures and blends thereof.
13. The egg carton of claim 1, wherein the carton comprises a solid sheet of clear polyester.
14. The egg carton of claim 1, wherein the carton comprises a foamed sheet of polystyrene.
15. The egg carton of claim 1, wherein the lid has four sidewalls and four corners connecting the sidewalls and has structural reinforcements provided in each sidewall and corner.
16. The egg carton of claim 1, wherein the carton has a 26 matrix of cell pockets formed by a complementary 26 matrix of cells in each of the base and cover.
17. A method of assembling the egg carton of claim 1, including filling each base cell with the jumbo eggs, closing the cover over the base and the lid over the assembled cover and base, wherein the hinges and domes of the base and cover cells accommodate the different size variations and orientations of the jumbo eggs in the cell pockets.
18. A tri-fold plastic egg carton comprising: a cell base and a cell cover hingedly connected to one edge of the cell base for pivoting between open and closed positions, the base and the cover having respective peripheral edges that mate with each other in the closed position, and each of the base and the cover having a complimentary 26 matrix of cells that, when the cover is closed over the base, the cells of the cover and base are aligned and form a 26 matrix of cell pockets for holding individual eggs, each cell having a bottom wall and a sidewall extending upwardly from the bottom wall to form a corresponding one of the cells, a cell post formed at an intersection of four adjacent cells as an extension of the sidewalls of the four adjacent cells and having a central mating surface, wherein when the cover is in the closed position over the base the central mating surfaces of the cell posts of the base and cover mate with one another, a lid hingedly connected to another edge of the base for pivoting between open and closed positions, wherein when the cover and base are in the closed position the lid can be closed over the cover to form an assembled carton; each cell pocket is sized to hold any different size variations of a jumbo egg, of from 2.50 to 3.00 ounces per egg, in an oriented or a non-oriented direction in the base cell; the bottom wall of each base and cover cell comprising: a lowermost peripheral standing ring defining a base plane; a recessed wall portion disposed radially inwardly from the peripheral standing ring and defining a central recessed area above the base plane, the recessed wall portion including a central dome in a concave out position in a relaxed state, a first circumferential hinge disposed radially outwardly of and surrounding the central dome, and a second circumferential hinge disposed radially outwardly of and surrounding the first hinge, the first and second hinges being in a contracted position in a relaxed state, wherein each of the upper and lower hinges are movable between their contracted position to one or more extended positions to move the central dome up and down in the central recessed area while remaining above the base plane while the central domes of the base cell and cover cell engage opposing ends of a jumbo egg of the different size variations and orientations.
19. The egg carton of claim 18, wherein the carton is a solid sheet of clear polyester and the bottom wall has a thickness in a range of about 0.013 to about 0.022 inches.
20. The egg carton of claim 19. wherein each cell has an arcuate, outwardly bowed sidewall portion sized to receive a major cell diameter of a jumbo egg in a range of about 1.75 to about 2.06 inches
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The drawings depict various embodiments of the invention wherein:
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DETAILED DESCRIPTION
[0054]
[0055]
[0056] As shown in
[0057] In addition to the hinged lid 20 and base 30, the carton 10 includes a cover 50 connected via a front hinge 51 to the base 30, the front hinge 51 being disposed along the front longitudinal edge 31f of the base, opposite the rear hinge 21 connecting the lid to the opposing rear longitudinal edge 31r of the base. The cover has a 26 matrix of cover cells 140 configured to align with and fit over the 26 matrix of base cells 40, forming a 26 matrix of cell pockets 8. To close the carton, the hinged cover 50 is rotated about front hinge 51 (see arrow A1 in
[0058] As described above, the tri-fold egg carton has a 26 matrix of base cells 40 and a 26 matrix of cover cells 140 which, when assembled one on top of the other, encapsulate each egg in an individual cell pocket 8 (see
[0059] In one example (see
[0060] Returning to the overall carton design as shown in
[0061] In each of the four corners 25 of the lid, where a sidewall 23 joins an end wall 24, there are three shoulder portions all of which increase the mechanical strength (stiffness) of the lid. The shoulder portions also produce a gap between the lip edges of two open stacked upper and lower cartons, enabling an operator to insert a finger in the gap to separate the two cartons, or enabling a picker of an automated handling equipment to separate the open stacked cartons.
[0062] In addition to the two hinge connections 21, 51 at the rear and front longitudinal edges 31r, 31f of the base 30, the remaining top edges of the base, cover and lid have at their perimeter a flat trim lip edge 37, 57, 27 respectively. Each lip edge has a flat peripheral surface lying generally in a plane parallel to the base plane BP on which the lowermost base portions of the base cells rest. The peripheral surfaces form supporting surfaces, which engage in planar relation, to strengthen the carton against compressive forces applied in the height direction to the closed carton, such as when multiple cartons are stacked in a display case, in a shipping case, and other instances when multiple cases or containers (each holding a stack of cartons) are stacked one on top of the other.
[0063] There will now be provided a more detailed description of the cell and post structure of the base and cover which, when assembled, form the array of cell pockets each holding an individual egg.
[0064] As shown in
[0065] The cover 50 has a complimentary 26 matrix of cells 140 that, together with the base cells 40, form the cell pockets 8 for protecting each egg in an individual cell pocket. The complementary features of the cover cells are referenced by a 100 number series corresponding to the respective features of the base cells (e.g., base cell 40 has sidewall 41 and cover cell 140 has sidewall 141).
[0066] The cells 40 that collectively form the base 30 have lowermost standing ring surfaces 49 that are substantially co-planar and lie substantially within a common plane BP on which the carton rests. This allows the planar bottom of one carton to be mechanically stacked or deposited on top of the uppermost planar lid surface 22 of another carton (see
[0067] The bottom wall 47 (see
[0068] The cell sidewall 41 has a lower portion 41 L which is substantially linear (planar) and tapers upwardly and outwardly with respect to the standing ring 49 (in base plane BP); the lower portion 41L includes a plurality of spaced apart axial grooves 80 extending upwardly (in the H direction) for strengthening the cell sidewall. A middle portion 41 M of the sidewall is arcuately curved (bowed) outwardly to accommodate the ovoid shape and maximum egg diameter MED of a jumbo egg. A third upper portion 41 U of the sidewall comprises a sidewall extension that forms a sidewall of a cell post 60, which further engages and secures the egg in the cell pocket. Each sidewall extension 41 U follows the ovoid contour of an egg disposed in the cell and extends to the full height of the plane in which the trim perimeter 37 of the base lies. The cover cell 140 has the same three sidewall portions 141L, 141M and 141U. As a result, a pair of base and cover cells is adapted to receive any of the various sized and oriented jumbo eggs (form 2.50 to 3.00 ounces per egg) in the cell pocket with the maximum egg diameter MED engaging one or more of the mid or upper portions of the cover or base sidewalls, while the top and bottom ends of the egg sit on or in the opposing domes 45, 145 of the opposing cell bottoms walls 47, 147 (which form the interior top and bottom surfaces of the respective cell pocket).
[0069] A cell post 60 is formed at each intersection (i.e., cross-hair (+)) of four adjacent (22 matrix of) cells 40 in the base 30, the cell post comprising the extensions 41U of the intersecting sidewalls 41 of the four adjacent cells, and having a top planar cell post wall 61 disposed substantially in the same plane as the uppermost base perimeter 37 (see
[0070] The cells 40, 140, cell posts 60, 160 and cell dividers 43, 143 are dimensioned to allow each cell pocket to hold a jumbo size egg having a major cell diameter in a range of about 1.75 to about 2.06 inches, and an egg height in a range of 2.461 to 2.750 inches, in either an oriented or unoriented position. In the present embodiment, the assembled carton holds 12 jumbo eggs in a 26 matrix of cell pockets and has an overall length L of from about 11.62 to about 12.00 inches, a width W of from about 3.95 to about 4.18 inches, and height H of from about 2.62 to about 3.125 inches.
[0071] Multiple such filled egg cartons 10 may be enclosed in outer containers (also referred to as cases or wire baskets) in various stacking patterns, e.g., in parallel or in a cross stacking arrangement, wherein successive vertical layers are disposed transverse to the adjacent layer. The container dimensions may be increased (over standard size container dimensions, e.g., for full case (30 dozen) of half case (15 dozen)) to accommodate a large carton footprint.
[0072] Alternatively, a standard size half case rectilinear container 230 as shown in
[0073] The teachings of this disclosure can be applied to forming different sized egg cartons, e.g., having a 22, 23, 24, 25, 26, 35, 36, 45 and 46 matrix of cell pockets.
[0074] In various embodiments, the plastic material of the egg carton is preferably one or more of polyester (e.g., polyethylene terephthalate (PET)), polyolefin (e.g., polyethylene (PE), or polypropylene (PP)), poly(lactic acid (PLA), or polystyrene (e.g., polystyrene foam), including homopolymers, copolymers, mixtures and blends thereof, and including virgin and reclaimed (recycled) materials.
[0075] In the present embodiment, the carton 10 is integrally formed from a sheet of molded plastic material, e.g., a clear solid sheet of polyester, such as polyethylene terephthalate (PET). The sheet from which the carton is integrally molded can then be shaped (formed) by a molding process, e.g., pressure forming with a plug assist in a mold to form the shaped lid, base and cover portions, including the lip edge, and then removing (trimming) any remaining portions of the sheet to form an integral carton.
[0076] 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.