Patent Publication Number: US-2018029786-A1

Title: Egg carton insert

Description:
TECHNICAL FIELD 
     The present disclosure relates to packaging. Example embodiments related to an insert for improved packaging of eggs in cartons. 
     BACKGROUND 
     An egg carton is a package designed for carrying and transporting whole eggs. Referring to  FIG. 1 , a typical carton  100  used at retail stores is illustrated. The carton  100  may include a bottom  110  comprising an array of dimples  112  connected to each other. The array of dimples  112  may be connected to a bottom rim  114  around the perimeter of the array. Each dimple  112  may be shaped to support the bottom of a single egg. One or more of the regions between any group of four dimples may be formed as a cone  116  that may extend above the plane of the bottom rim  114  to a height not substantially greater than the top of an egg expected to be carried in the carton  100 . The cones  116  may inhibit, but do not prevent, an egg in the carton from contacting eggs in adjoining dimples  102 . 
     The egg carton may include a top  120 . The top  120  may be flexibly connected along a top back edge  128  to a bottom back edge  118  in a manner allowing the top  120  to be closed over the bottom  110 . When the carton is closed, a top rim  124  may be substantially in contact with one or more portions of the bottom rim  114 . Each cone  116  may extend no higher than an inside upper surface of the top  122 . 
     The egg carton may include a flap  130  flexibly connected to a bottom front edge  119  for releasably securing the top  120  in place when the carton  100  is closed. The flap outer surface  136  may abut a top inside front surface  126  when the carton  100  is closed. The flap  130  may include detents  132  sized and shaped to mate with holes  129  formed in the top  120  to releasably secure the top  120  in place when the carton  100  is closed. 
     This egg carton  100  structure may protect eggs against stresses exerted during some forms of transportation and storage by absorbing shock. An egg carton  100  may be manufactured from various materials, including foamed plastics such as polystyrene foam, clear plastic, recycled paper, and molded pulp. 
     While a typical egg carton  100  is illustrated in  FIG. 1 , other variations are known. For example, the flap  130  may comprise three detents  132  for engaging three holes  120  in the top  120 ; the middle cone  116  may be replaced with a divider that extends across both columns of the array of dimples  112 ; and some portion of one or more cones  116  may extend through the top  120 . A typical egg carton  100  can accommodate one dozen eggs—though egg cartons  100  for other amounts, such as four, six, eight, ten, eighteen (for example, comprising three columns of six eggs), are known. 
     Online grocers may allow consumers to order groceries and other products typically found in grocery stores, online. Either the grocer, or a third party, then may deliver the ordered goods to consumers. Often, a variety of mixed good, for example, eggs, bread, milk, and potato chips, are packaged in the same bag or box. 
     SUMMARY 
     In certain example embodiments described herein, an egg carton insert includes an N row by M column array of interconnected domes. Each dome is sized to enclose a top portion of an egg. Each dome is connected to each neighboring dome in the array. The array of domes forms an opening between each group of four adjacent domes. The array is arranged such that each dome corresponds to a dimple of an egg carton into which the insert can be placed. The overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton. 
     In some embodiments, at least one dome defines therein a cutout along a portion of the at least one dome at a long side of the array. In some embodiments, the insert material is molded pulp. 
     In some embodiments, N is at least two and M is at least two. In such embodiments, in each even-numbered column, each odd-numbered dome position is vacant; and in each odd-numbered column, each even-numbered dome position is vacant. 
     In certain example embodiments described herein, a method for packing eggs includes providing an N row by M column egg carton containing a plurality of eggs. An egg carton insert is provided in the form of an N row by M column array of interconnected domes as described above. The array is placed over the eggs such that each dome aligns with a dimple. The egg carton is closed over the eggs and the egg carton insert. 
     In certain example embodiments described herein, an egg carton insert includes a substantially flat elongated rectangle of material. The material is characterized by a length less than the interior length of an egg carton, a width less than the interior width of the egg carton; and a thickness less than one half the height of an egg to be carried in the egg carton. The material defines therein an N row by M column array of through-holes of common diameter, the hole diameter less than the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton. 
     These and other aspects, objects, features, and advantages of the example embodiments will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of illustrated example embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a typical egg carton. 
         FIG. 2  illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein. 
         FIG. 3  illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein. 
         FIG. 4  illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein. 
         FIG. 5  is a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein. 
         FIG. 6  is a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein. 
     
    
    
     DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS 
     Turning now to the remaining drawings, in which like numerals indicate like (but not necessarily identical) elements throughout the figures, example embodiments are described in detail. 
     Overview 
     Delivering eggs purchased from an online retailer in cartons can result very high egg breakage rates, especially if the online retailer uses a common carrier for delivery. Egg breakage rates can increase if the egg carton is delivered in the same overall package, for example a cardboard box, along with heavy products or products packaged in hard-sided containers. A typical egg carton is not designed to withstand the forces likely to be encountered by the eggs being handled like books, clothing, and other goods delivered by common carriers. Even specialty carriers, accustomed to transporting fragile items, can see unacceptable breakage rates. Private testing has shown breakage rates as high as 44% for 6-count and 12-count egg cartons shipped for overnight delivery in outer boxes with other grocery products. 
     Embodiments of the technology disclosed herein include devices, systems, and methods for supplementing a typical egg carton with an insert that can reduce the rate of egg breakage during transport. Some embodiments disclosed herein have demonstrated breakage rates of less than 3%. 
     Example Architectures 
     Referring to  FIG. 2 , and continuing to refer to prior figures for context, a first embodiment of an egg carton insert  200  is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton insert  200  is a six row  202   a - 202   f  by two column  204   a - 204   b  array of domes  210 . While 6×2 is the most common egg carton  100  configuration, the egg carton insert  200  can be sized to any commonly-used N row×M column egg carton  100 , such as 4×4, 6×3, etc. 
     Each dome  210  in  FIG. 2  is shaped and sized to enclose a top portion of an egg. In some embodiments, the dome is shaped and sized to enclose less that the portion of an egg above its largest substantially round cross section. Other dome forms, including a truncated dome with a solid top, a truncated dome with an open top, and a pyramidal dome, can be used. In the example embodiment of  FIG. 2 , each dome  210  includes a substantially cruciform feature  240  that can facilitate orienting each egg top portion in its corresponding dome  210 . Egg carton inserts  200  can be made from other materials, such as foamed plastics, rubber, clear plastic, and felt. 
     Each dome  210  can be connected to each neighboring dome in the array. In the example embodiment of  FIG. 2  representing a pulp insert, each dome  210  is connected to each neighboring dome  210  at the dome edge, including by a small bridge  220 . In other embodiments, each dome  210  can be connected to neighboring domes  210  without the use of a bridge  220 . 
     The array of domes  210  forms an opening  230  between each group of four adjacent domes  210 . Each opening  230  can receive a cone  116  of the egg carton  100 . Inserting a cone  116  into one or more of the openings  230  can provide lateral stability to the combined egg carton  100  and egg carton insert  200 . The loose, but laterally restrained, coupling between the egg carton insert  200  and the egg carton  100  can contribute to the protection of the eggs contained in the egg carton  100 . The egg carton insert  200  is arranged such that each dome  210  corresponds to a dimple  112  of an egg carton  100  into which the egg carton insert  200  can be placed. 
     The overall dimensions of the egg carton insert  200  are such that the egg carton  100  can be closed when the egg carton insert  200  is placed over each egg occupying a dimple  116  of the egg carton  100 . 
     In some embodiments, at least one dome  210  defines therein a cutout  212  along a portion of the at least one dome at a long side of the array. The cutout  212  is oriented substantially parallel to the long side of the array. The cutout  212  can be in the shape of an arch, a rectangle, or other shape for providing clearance for egg carton  100  features that would otherwise impede closing the egg carton  100  over the egg carton insert  200  when the egg carton  100  dimples  112  are holding eggs. 
     Referring to  FIG. 3 , and continuing to refer to prior figures for context, a second embodiment of an egg carton insert  300  is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton insert  300  is a substantially flat 6×2 array of rings  310  defining holes therein. While 6×2 is the most common egg carton  100  configuration, the egg carton insert  300  can be sized to any commonly used N row×M column egg carton  100 . The length of the egg carton insert  300  is less than the interior length of an egg carton  100 . The width of the egg carton insert  300  is less than the interior width of an egg carton  100 . The thickness of the egg carton insert  300  is less than one half the height of an egg to be carried in the egg carton  100 . The overall dimensions of the egg carton insert  300  are such that the egg carton  100  can be closed when the egg carton insert  300  is placed over one egg occupying each dimple  166  of the egg carton  100 . 
     Each ring  310  in  FIG. 3  defines therein a hole  320  shaped and sized to fit over a top portion of an egg placed in an egg carton  100 . In some embodiments, each ring  310  defines a hole  320  therein that is shaped and sized to encircle the egg above its largest substantially round cross section, leaving a portion of the egg projecting through the ring  310 . While the outer portion of the ring  310  illustrated in  FIG. 3  is substantially circular, other ring forms, including various regular polygons and truncated polygons, can be used. The hole  320  formed by each ring  310  is aligned with a corresponding dimple  116  of the egg carton  100 . 
     Each ring  310  is connected to each neighboring ring  310  in the array. In the example embodiment of  FIG. 3  representing a pulp insert, each ring  310  is connected to each neighboring ring  310  at the ring edge. Egg carton inserts  300  can be made from other materials, such as foamed plastics, rubber, clear plastic, and felt. 
     The array of rings  310  forms an opening  330  between each group of four adjacent rings  310 . Each opening  330  can receive a cone  116  of the egg carton  100 . Inserting a cone  116  into one or more of the openings  330  can provide lateral stability to the combined egg carton  100  and egg carton insert  200 . The loose, but laterally restrained, coupling between the egg carton insert  300  and the egg carton  100  can contribute to the protection of the eggs from damage. The egg carton insert  300  is arranged such that each ring  310  corresponds to a dimple  112  of an egg carton  100  into which the egg carton insert  300  can be placed. 
     Referring to  FIG. 4 , and continuing to refer to prior figures for context, a third embodiment of an egg carton insert  400  is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. In the egg carton insert  400  of  FIG. 4 , each odd-numbered ring position of the egg carton insert illustrated in  FIG. 3  in the second column  420  each is vacant, and each even-numbered ring position of the egg carton insert illustrated in  FIG. 3  in the first column  410  is vacant. 
     Example Processes 
     Referring to  FIG. 5 , a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein, is shown. In such methods an N row by M column egg carton containing a plurality of eggs is provided—Block  510 . For example, a 6×2 conventional egg carton  100  as shown in  FIG. 1 , with one egg in each carton dimple  116 , is provided. 
     An N row by M column egg carton insert in the form of an array of interconnected domes is provided—Block  520 . For example, the egg carton insert  200  in the form of a 6×2 array of domes  210  of  FIG. 2  is provided. Each dome  210  is sized to enclose a top portion of an egg. Each dome  210  is connected to each neighboring dome  210  in the array  200 . The array of domes  210  forming an opening  230  between each group of four adjacent domes  210 . The array is arranged such that each dome  210  corresponds to a dimple  116  of the egg carton  100 . The overall dimensions of the egg carton insert  200  are such that the egg carton  100  can be closed when the egg carton insert  200  is placed over one egg occupying each dimple  116  of the egg carton. 
     The array is placed over the eggs such that each dome  210  aligns with a dimple  116 —Block  530 . For example, the edges of the array can be aligned with the bottom rim  112  of the open egg carton  100 . Even an imperfect alignment, up to one half an egg diameter off, between the egg carton insert  200  and the carton  100  containing eggs will create a self alignment. The egg carton, containing the eggs and the egg carton insert  200 , is closed—Block  540 . For example, closing the top  120  and locking the top by aligning detents  132  with holes  139  will further facilitate the self-alignment. 
     Referring to  FIG. 6 , a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein, is shown. In such methods an N row by M column egg carton containing a plurality of eggs is provided—Block  610 . For example, a 6×2 conventional egg carton  100  as shown in  FIG. 1 , with one egg in each carton dimple  116 , is provided. 
     An egg carton insert in the form of a substantially flat elongated rectangle of material is provided—Block  620 . For example, the egg carton insert  300  having a length less than the interior length of the egg carton  100 , a width less than the interior width of the egg carton  100 , and a thickness less than one half the height of an egg in the egg carton  100  is provided. The material defines therein an N row by M column array of through-holes of common diameter. The hole diameter less then the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton. 
     The material is placed over the eggs such that each hole aligns with a dimple  116 —Block  630 . The egg carton, containing the eggs and the egg carton insert  300 , is closed—Block  640 . 
     The example systems, methods, and acts described in the embodiments presented previously are illustrative, and, in alternative embodiments, certain acts can be performed in a different order, in parallel with one another, omitted entirely, and/or combined between different example embodiments, and/or certain additional acts can be performed, without departing from the scope and spirit of various embodiments. Accordingly, such alternative embodiments are included in the technology described herein. 
     Although specific embodiments have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects described above are not intended as required or essential elements unless explicitly stated otherwise. Modifications of, and equivalent components or acts corresponding to, the disclosed aspects of the example embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of the present disclosure, without departing from the spirit and scope of embodiments defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures.