Abstract:
A container for receiving frangible items comprises a sheet of polymer formed into a base portion having a plurality of item-receiving cavities for supporting frangible items. A cover portion has an item-covering concavity for covering the frangible items. A first hinge portion is positioned between a first longitudinal edge of the base portion and the cover portion for rotating the cover portion onto the base portion to hold the frangible items captive in the item-receiving cavities. The first hinge portion comprises a pair of longitudinal grooves formed into the first hinge portion and extending parallel to the first longitudinal edge of the base portion, with a web defined between the longitudinal grooves, and a hinge-reinforcement wall at at least one end of the longitudinal grooves. A fold line is formed in the web and in the hinge-reinforcement wall when the cover portion is rotated onto the base portion.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 12/637,092, filed on Dec. 14, 2009, which claims priority to U.S. Provisional Patent Application No. 61/122,650, filed on Dec. 15, 2008, each of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE APPLICATION 
     The present application relates to containers for receiving frangible objects such as eggs, and to structural components of such containers. 
     BACKGROUND OF THE ART 
     Containers of all kinds have been developed for the transportation and sale of frangible food items such as eggs. As eggs are relatively fragile, the egg containers must protect the eggs from the various manipulations involved from the packaging of the eggs to the consumer&#39;s refrigerator. 
     One significant improvement in egg containers is the use of thermoformed plastics as material for the egg containers. Thermoformed plastics are typically transparent, which allows the eggs to be visible, and are relatively inexpensive to produce. As they can inspect the eggs by seeing through the material of the egg container, the consumers do not need to open the egg container, as is the case with cardboard egg containers, for instance. In the case of cardboard boxes, it may occur that the boxes are not closed properly after inspection. This may cause the breakage of eggs if the improperly closed egg container is subsequently manipulated by another consumer. 
     SUMMARY OF THE APPLICATION 
     It is therefore an aim of the present invention to provide a container for frangible items that addresses issues associated with the prior art. 
     Therefore, in accordance with the present application, there is provided a container for receiving frangible items comprising a sheet of polymer formed into: a base portion having a plurality of item-receiving cavities for supporting frangible items; at least one cover portion having at least one item-covering concavity for covering the frangible items; and a first hinge portion between a first longitudinal edge of the base portion and the cover portion for rotating the cover portion onto the base portion to hold the frangible items captive in the item-receiving cavities, the first hinge portion comprising at least a pair of longitudinal grooves formed into the first hinge portion and extending parallel to the first longitudinal edge of the base portion, with a web defined between the longitudinal grooves, and a hinge-reinforcement wall at at least one end of the longitudinal grooves, a fold line forming in the web and in the hinge-reinforcement wall when the cover portion is rotated onto the base portion. 
     Further in accordance with the present application, there is provided a container for receiving frangible items comprising a sheet of polymer formed into: a base portion having a plurality of item-receiving cavities for supporting frangible items; a cover portion having one item-covering concavity for covering the frangible items, the cover portion having a flat top wall and generally flat peripheral walls defining the at least one item-covering concavity; a first hinge between a first longitudinal edge of the base portion and the cover portion for rotating the cover portion onto the base portion in closing the container to hold the frangible items captive in the item-receiving cavities; and a pair of reinforcement beams formed into the concavity of the top cover portion, the reinforcement beams projecting inwardly from the flat top wall and from opposite peripheral walls of the top cover portion into the concavity, the reinforcement beams being centrally positioned along a longitudinal dimension of the container, a gap being defined in the concavity between ends of the reinforcement beams, with the reinforcement beams being seated on a top surface of the base portion when the container is closed. 
     Still further in accordance with the present application, there is provided a container for receiving frangible items comprising a sheet of polymer formed into: a base portion having a plurality of item-receiving cavities for supporting frangible items, a base peripheral flange defining a periphery of the base portion, and a peripheral hollow curb being positioned inward of the base peripheral flange; a cover portion having one item-covering cavity for covering the frangible items, the cover portion having peripheral walls, and a cover peripheral flange at a bottom of the peripheral walls, to define a periphery of the cover portion; a first hinge between a first longitudinal edge of the base portion and the cover portion for rotating the cover portion onto the base portion in closing the container to hold the frangible items captive in the item-receiving cavities, whereby the base peripheral flange and the cover peripheral flange contact one another, while the peripheral walls of the cover portion and the peripheral hollow curb contact one another, when the container is closed; at least one duct formed into the peripheral hollow curb, the duct being open to an interior of the container when closed; and a ditch formed into at least one of the peripheral flanges for each said duct, and in alignment with the duct to form therewith an air passage between an interior and an exterior of the container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of a two-fold container for frangible items such as eggs; 
         FIG. 2  is a schematic perspective view of a three-fold egg container; 
         FIG. 3  is a perspective view of an egg container showing a cover portion configuration according to an embodiment of the present disclosure; 
         FIG. 4  is an enlarged view of the egg container of  FIG. 3 , illustrating a hinge configuration in accordance with another embodiment of the present disclosure; and 
         FIG. 5  is an enlarged view of the egg container of  FIG. 3 , illustrating an aeration unit. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings and more particularly to  FIG. 1 , a container for frangible items such as eggs is generally shown at  10 . The egg containers described hereinafter are preferably made of transparent or translucent plastics, for instance using a thermoforming process or other molding process. Other materials and/or processes may be used as well. The containers described hereinafter may be used to contain eggs or any other frangible items (e.g., tomatoes). 
     The egg container  10  of  FIG. 1  is a two-fold egg container, as it has two portions hinged to one another. The egg container  10  has a base portion  11  having a plurality of egg-receiving cavities  12  (e.g., six, twelve, eighteen, twenty-four, or any other suitable number), with each cavity  12  supporting an egg. A top cover portion  13  is hinged to the base portion  11  by hinge  14 , in a longitudinal dimension of the egg container  10 . The hinge  14  is generically illustrated in  FIG. 1 , but may have a specific configuration, as described hereinafter. The top cover portion  13  may or may not have egg cavities to cover a top portion of the eggs supported by the egg-receiving cavities  12 . Alternatively, the top cover portion  13  may present a flat top surface as in  FIG. 1 , with or without strengthening components (e.g., arches, posts). Although not shown, mating connectors or any other suitable type of connector are provided on the periphery of the base portion  11  and top cover portion  13  for interlocking them when the egg container  10  is closed. 
     Referring to  FIG. 2 , a three-fold egg container is generally illustrated at  10 ′. The egg container  10 ′ is similar to the egg container  10  of  FIG. 1 , but has an intermediate cover portion  15 . The intermediate cover portion is hinged to the base portion  11  by hinge  16 , in a longitudinal dimension of the egg container  10 ′. The hinges  14  and  16  are preferably on opposite edges of the base portion  11 . The hinges  14  and/or  16  are generically illustrated in  FIG. 2 , but may have a specific configuration, as described hereinafter. The intermediate cover portion  15  typically has egg cavities  17  to cover a top portion of the eggs supported by the egg-receiving cavities  12 . Although not shown, mating connectors or any other suitable type of connector are provided on the periphery of the top cover portion  13  and the intermediate cover portion  15  for interlocking them when the egg container  10 ′ is closed. 
     In order to close the egg container  10 ′, the intermediate cover portion  15  is firstly hinged into contact with the base portion  11 , as illustrated by arrow A. The top cover portion  13  is then hinged onto the intermediate cover portion  15 , as illustrated by arrow B. 
     The egg containers of the present disclosure may contain any suitable number of egg-receiving cavities. One suitable material for the egg containers of the present application is polyethylene terephthalate (PET). PET has many advantages, as this material can be transparent or opaque and can be produced at high volume and at low cost. Wall thicknesses of PET cases in a contemplated embodiment are of 0.0175 inch in thickness, but other thicknesses as low as 0.012 to as high as 0.022 inch are also contemplated, but this thickness may vary for instance once the sheet is formed into the egg container  10 / 10 ′. 
     In one embodiment, referring to  FIG. 3 , the top cover portion  13  has one large concavity  18  having a main flat top wall  19  into which center reinforcement beams  20  are formed to rigidify the center of the top cover portion  13 . The top cover portion  13  has two of the center reinforcement beams  20 , with the beams  20  projecting inwardly from respective peripheral walls  21  of the top cover portion  13 . A gap is formed between the inward ends of the center reinforcement beams  20 . The center reinforcement beams  20  may have rounded end tips  22  (e.g., frustoconical section), an interiorly projecting ridge  23 , and/or ribs  24  (e.g., exteriorly projecting), all of which serve structural functions in strengthening the top cover portion  13 . The center reinforcement members  20  sit on the top surface of the base portion  11  when the container  10  is closed. 
     Referring to  FIGS. 3 and 4 , the hinge  14  is shown having a particular configuration, in the two-fold container  10 . The particular configuration may also be used for the hinge  16  in case of a three-fold container  10 ′( FIG. 2 ), but is described as being used for hinge  14  in two-fold container  10 , for simplicity purposes. 
     The hinge  14  as shown in  FIGS. 4 and 5  is defined in a flat flange section of a width that is permanently deformed when the top cover portion  13  is placed forcibly over the base portion  11  to close the egg container  10 . Typically, a fold line is thermoformed where it is desired to have the hinging movement, using precision tooling such as a knife edge. The fold line is a weakness line, as the plastic sheet is thinner thereat. Accordingly, when manipulating an opened container (e.g., before eggs or frangible items are introduced therein), the container  10 / 10 ′ naturally has a tendency to close. 
     In order to rigidify the hinge  14 , the width of the sheet ( FIG. 5 ) between the base portion  11  and the top cover portion  13  may be increased, to define a hinge portion  30 . A pair of longitudinal grooves  31  and  32  are formed in the hinge portion  30 , and are separated by a web  33 . Flat hinge-reinforcement walls  34  are provided at opposed ends of the longitudinal grooves  31  and  32 . There may be a single one of the flat walls  34 , at either end of the longitudinal grooves  31  and  32 . 
     The flat walls  34  are molded/formed without a fold line and therefore strengthen the container  10 / 10 ′ when in an opened and unfolded condition. The walls  34  are preferably substantially flat prior to a fold line being formed, and are preferably of substantially of uniform thickness as well. The container  10 / 10 ′ is in such opened and unfolded condition prior to its first use. Accordingly, when manipulated, the container  10 / 10 ′ in the opened and unfolded condition remains generally flat (e.g., when manipulated by automated equipment). The top cover portion  13  does not naturally pivot onto the base portion  11  to close the container  10 / 10 ′. 
     When it is desired to close the container  10 / 10 ′, the user or automated equipment may forcibly pivot the top cover portion  13  (and middle cover portion  15  if applicable) onto the base portion  11 . The presence of the longitudinal grooves  31  and  32  will cause a fold line to form therebetween. The bend or fold line in the PET is thus confined to the web  33  between the two longitudinal grooves  31  and  32 , and extends through the flat wall(s)  34 . Because the distance in the flat walls  34  is small compared to the length of the grooves  31  and  32 , the bend in the PET at the hinge  14  remains focused along the line created in the web  33 . The bend is permanent once the egg container  10 / 10 ′ is closed for the first time. 
     In one embodiment, the flat wall(s)  34  has(have) a dimension ranging between 0.25 inch to 2.0 inches, along a longitudinal axis of the hinge portion  30 .  FIG. 5  illustrates more closely the geometry of the two grooves  31 , 32 . The grooves  31  and  32  may be 0.125 inch wide and 0.09 inch deep. The web  33  as contemplated in the shown embodiment may be only 0.03 inch wide. The above dimensions are provided as an example, but any appropriate dimensions are considered. 
     While a single set of grooves  31 , 32  are used longitudinally at the hinge between the top cover portion  13  and the base portion  11 , a different number of groove sets is also contemplated. The flat walls  34  in the hinge  14  allow the angle to be at around  10  degrees between base portion  11  and top cover portion  13 . 
     Referring to  FIG. 5 , an aeration unit for the container  10 / 10 ′ is illustrated. The aeration unit is defined in the base portion  11 . The base portion  11  has a peripheral flange  40  surrounding a peripheral hollow curb  41 . The item-receiving cavities  12  are positioned inwardly from the peripheral hollow curb  41 . The aeration unit defines an air passage for air to enter/exit the container  10 / 10 ′ when closed. For instance, excess humidity in the container  10 / 10 ′ may be exhausted through the aeration unit. 
     The aeration unit features a duct  42  formed into the peripheral hollow curb  41 . Accordingly, when the top cover portion  13  is on top of the base portion  11 , and thus when the peripheral walls  21  are against the lateral surface of the peripheral hollow curb  41 , the duct  42  defines a passage of rectangular section. Other section shapes are considered as well. When the container  10 / 10 ′ is closed, a peripheral flange of the top cover portion  13 , and a peripheral flange of the intermediate cover portion  15 , both sit on the peripheral flange  40  of the base portion  11 . Accordingly, a ditch  43  is defined in the peripheral flange  41 , and merges with the duct  42 . The duct  42  and the ditch  43  concurrently form the air passage. 
     The ditch  43  may alternatively or concurrently be formed into the peripheral flange of the top cover portion  13  in the case of the two-fold container  10 . In the case of the three-fold container  10 ′, ditches  43  may be formed in the peripheral flanges of the top cover portion  13  and of the intermediate cover portion. 
     Referring to  FIG. 5 , a shoulder  44  may be formed to define an upper edge of the duct  42 , to strengthen the hollow curb  41  at the duct  42 . As shown in  FIG. 3 , a plurality of the aeration unit may be provided around the container  10 , and the three faces away from the hinge  14 . 
     It is understood that the preceding is merely a detailed description of some examples and embodiments of the present disclosure, and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure made herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without any undue burden.