Patent Description:
Packaging units for eggs, such as egg cases, containers or cartons, are known in practice and are generally manufactured from a moulded pulp material that originates from cellulose fibres. Such packaging units comprise a bottom part that is provided with compartments for individual products, and a cover part that is often hingedly connected to the bottom part. The products, like eggs, are stored, transported and displayed in these packaging units. An example of such egg case is shown in <CIT> that shows a packaging unit comprising bottom and cover parts that are hingedly connected and that further comprises a lock that is configured for locking the cover part and the bottom part in a closed position of the packaging unit.

<CIT> discloses an egg carton having a bottom and hinged cover.

Often, the products like eggs are placed on a shelf in a shop/supermarket, for example. Potential buyers take the egg case from the shelf for inspections, for example. However, inspection of the products involves opening of the egg case. This requires the potential buyer to manually open the egg case to inspect the products. In addition, this has the risk of damaging the products.

The present invention has for its object to obviate or at least reduce the above stated problems in conventional packaging units, such as egg cases, and to provide a suitable packaging unit enabling convenient display of products.

The present invention provides for this purpose a packaging unit according to claim <NUM> from a moulded pulp material.

The packaging unit according to the invention is manufactured from a moulded pulp material that may originate from soft wood fibres and/or hard wood fibres and/or recycled cellulose fibres and/or other suitable fibres. The packaging unit comprises a bottom part and a cover part that are hingedly connected to each other with a hinge-element, such as a hinge. The bottom part is provided with product holding compartments that are capable of receiving and holding respective products, such as eggs and also similar products like kiwis and tomatoes, for example. Between adjacent compartments one or more cones are provided to give additional support to the packaging unit. In a presently preferred embodiment the bottom part and cover part of the packaging unit comprise a front surface, a back surface, and two side surfaces. In addition, the bottom part comprises a bottom surface and the cover part comprises a top surface.

In a closed position of the packaging unit according to the invention, the bottom part and cover part are locked together with a lock. The lock comprises a first lock element and a second lock element that are provided on the respective bottom and cover part. The cover part is provided with a lock opening and the bottom part is provided with a locking cam that are configured to engage each other in the closed position of the packaging unit.

The packaging unit according to the present invention further comprises at least one bottom front surface and at least one cover display surface. These display surfaces are designed to be shown towards a potential buyer when being stacked on a shelf in a shop or supermarket, for example. Preferably, the front surfaces of the bottom and/or cover part are at least partly providing a display surface. Optionally, also the back surfaces of the bottom and/or cover parts may comprise a display surface. It will be understood that also other designs for the packaging unit can be envisaged, such as a triangular packaging unit wherein one (or two or more) of the sides may provide display surfaces, for example. According to the invention, the at least one display surface comprises a number of display openings, wherein the display openings in the bottom part front surface and the cover part display surface are positioned such that they display the product that is received in the respective compartment.

Providing display openings in the display surfaces enables a potential buyer to view and/or inspect the products without having to open the packaging unit. Furthermore, this even enables the potential buyer to evaluate the products while the products with the packaging unit remain on the shelf. This is less time-consuming for the potential buyer. In addition, this reduces the risk of damaging the products, for example.

As a further advantage, the display openings provide additional cooling for the products. This increases the shelf life of the vulnerable products, like eggs. As an even further advantage, the display openings enable improved drying to enable removal of moisture from the products and/or packaging unit such that weakening of the packaging unit is prevented. Therefore, the packaging unit substantially maintains its strength during storage, transport and display of the products.

The aforementioned advantages are especially relevant for consumer products like eggs. The advantages in relation to the enhanced cooling and/or drying are especially relevant when handling boiled eggs. It is noted that these boiled eggs are sometimes provided with a coloured layer or even a coloured protective layer. The display openings in the packaging unit according to the present invention provide a consumer with a view on the coloured eggs. This improves the overall visual appearance of the packaging unit with the coloured products. In addition, the use of the coloured products renders inspection of the products in relation to cracks etcetera more easy.

According to the invention the display openings in the bottom front surface and cover display surface are aligned.

Aligning the display openings in the respective bottom front surface and cover display surface results in a substantial view of the product in the compartment for a potential buyer, for example. Preferably, the display openings in the bottom front surface and cover display surface are located such that a potential buyer can easily see the product in a compartment.

In a presently preferred embodiment the aligned display openings resemble an egg-shape. The egg-shape provides a pleasant visual appearance for a potential buyer wherein the display openings reflect the shape of the products that are placed and/or can be placed inside the packaging unit. Furthermore, the egg-shape provides substantial strength to the packaging unit as compared to other possible shapes for an opening. More specifically, loads from a stack of packaging units that are placed on top of each other can easily be transferred further without damaging the packaging unit. This will also prevent damaging the products that are packed in the packaging unit.

Preferably, the display opening in the bottom front surface extends over at least <NUM>/<NUM> of the height of the bottom part.

Having the display opening in the bottom front surface extending over at least <NUM>/<NUM> of the height enables an effective egg packing operation. More specifically, fingers or other clamping elements of the packing robot are positioned further into the bottom part (as seen in the vertical direction) before disengaging the egg and may exit the egg compartment (partly) through the opening. Therefore, the "falling distance" of the egg is significantly reduced. This reduces the risk of damaging the egg.

According to the invention the lock of the packaging unit comprises a lock opening and a cam element. In a presently preferred embodiment of the invention, in a closed position, the lock substantially lies behind the front plane of the packaging unit.

By providing the lock substantially behind the front plane of the packaging unit the risk of hooking of cams to other packaging units or other elements is substantially reduced. In a manufacturing process this reduces the risk of a standstill of the operation. Also, this reduces the risk of damaging the cams of the lock. This significantly contributes to reducing the risk of a lock not functioning properly during use.

The lock opening comprises a support surface that is configured for engaging the cam. Providing an additional support surface gives an additional strength to the packaging unit. This additional strength obviates the use of additional moulded pulp material to maintain the strength of the packaging unit with the display openings.

According to the invention the cam element is provided on a flapless front surface of the bottom part. By providing the cam element on a flapless front surface the cam element is actually provided directly on the bottom part. This provides additional strength when the cam engages the support surface of the opening in a closed position of the packaging unit. It will be understood that this also substantially improves the strength of the overall packaging unit.

In a further preferred embodiment of the invention the display surface with the lock comprises a display extension that is positioned substantially below the opening.

Providing a display extension gives a visual indication of the location of the lock. This assists the consumer with locking and unlocking the packaging unit. Furthermore, when closing the packaging unit the display extension provides a so-called seeking function such that the opening in the cover part is guided over the cam element in the bottom part. This renders it easier to close the packaging unit. More specifically, it prevents the cover part being positioned erroneously relative to the bottom part. Therefore, this display extension contributes to the lock security or lock robustness. An even further effect of the display extension is the introduction of a lever function for the lock. This further assists a consumer with the opening of the packaging unit.

The packaging unit comprises a hinge-element, such as a hinge, for hingedly connecting the bottom part and the cover part. Preferably, the hinge-element comprises a cover support part and a bottom support part.

By providing one or more cover support parts and bottom support parts in association with the hinge-element, the strength of the packaging unit is further improved. More specifically, these cover support and bottom support parts prevent shifting of the lid of the cover part in a substantially horizontal direction relative to the bottom part. This provides a more secure stacking.

In a further preferred embodiment of the invention the bottom part comprises a substantially horizontally extending bottom support surface on the display surface, wherein the bottom support surface is configured for engaging the cover part. Preferably, the cover part comprises a substantially horizontally extending cover support surface that is also provided close to or at the display surface and is configured for engaging the bottom support surface. Providing a bottom support surface and more preferably a combination of the bottom support surface and cover support surface provides additional strength to the packaging unit. This reduces the risk of damaging to the packaging unit and/or the product therein.

In a further preferred embodiment of the invention at least some of the cones are provided with one or more openings and are configured to enable a gas stream, such as an air stream, to pass through the openings.

The cone (partly) separates adjacent compartments and preferably supports the product(s). The cone may comprise a cone-element and/or equivalent separator between adjacent compartments. Providing an opening in the cone enables a gas flow, preferably an air flow, through the cone. In the manufacturing process this significantly contributes to the drying process of the packaging unit. Therefore, the drying of the packaging unit is significantly improved. In addition, the drying operation of the packaging unit is more controlled and/or gradually performed. The improved drying increases the strength of the packaging unit without increasing the required amount of material and/or reduces the amount of material, while maintaining the strength of the packaging unit.

A further effect of providing the cones of the packaging units with one or more openings is the reduced overall weight of the packaging unit. This reduces the material costs, and may reduce drying costs and/or may improve handling of the packaging unit. For example, for a standard egg package the weight reduction may amount to about <NUM> gram.

As a further effect of providing the cones of the packaging unit with one or more openings is the reduction in product damage during storage, transport and/or display. This is specifically relevant for vulnerable products like eggs. The increased strength of the packaging unit therefore reduces product loss.

In a presently preferred embodiment of the invention the openings have an effective diameter in the range of <NUM>-<NUM>, preferably in the range of <NUM>-<NUM>, more preferably in the range of <NUM>-<NUM>, and most preferably in the range of <NUM>-<NUM>.

Experiments showed that providing openings with an effective diameter, or opening size, in the mentioned range achieves an increased strength due to the improved drying operation. The openings are preferably shaped as a circle having a diameter. This diameter corresponds to the effective diameter. It will be understood that other shapes for an opening are also possible. For example, the opening may be an ellipse. In such case the effective diameter corresponds to the diameter of a circular opening having an equal opening surface.

In a presently preferred embodiment of the invention at least some of the openings are provided at or close to the top of the cone. Providing at least some of the openings at or close to the top of the cone achieves an effective drying operation. This further enhances the strength of the packaging unit.

In a further preferred embodiment of the invention the hinge of the packaging unit comprises an indent.

By providing an indent the connection between the cover part the bottom part is improved and denesting is further improved.

Preferably, the cover part comprises a substantially planar top surface. Such planar top surface assists in providing the potential buyer or consumer with information about the product, for example. Furthermore, this also enables providing a printing area on the inner side of the top surface. This enables providing the consumer with additional information about the product, for example.

In a presently preferred embodiment of the invention, the moulded pulp material comprises an amount of natural fibres.

Additionally, or alternatively, the moulded pulp material comprises an amount of a biodegradable material, such as an aliphatic polyester.

The application of natural fibers and/or biodegradable material in a packaging unit from a moulded pulp material is described in <CIT> of the same applicant. The use of natural fibers and/or biodegradable material results in packaging units that are substantially MOSH and/or MOAH free, and/or are (home) compostable. These materials are preferably applied in combination with one or more of the aforementioned features, especially one or more of the support surfaces, display extension, support surface, and support parts. Such combination provides additional strength to the packaging units providing more possibilities to use alternative materials without reducing the behavior of the packaging units.

The present invention further relates to a method for packing products like eggs according to claim <NUM>, the method comprising the steps of providing a packaging unit as described above, and placing therein one or more of the products.

Such method provides the same effects and advantages as described with respect of the packaging unit.

The present invention further relates to a method for manufacturing a packaging unit from a moulded pulp material according to claim <NUM>, the method comprising the steps of:.

Such method provides the same effects and advantages as described with respect to the packaging unit.

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:.

Packaging unit <NUM> (<FIG>) comprises bottom part <NUM> and cover part <NUM>. Bottom part <NUM> comprises front part/surface <NUM>, first side surface <NUM>, second side surface <NUM>, back surface <NUM>, and bottom surface <NUM>. Cover part <NUM> comprises top surface <NUM>, front surface <NUM>, first side surface <NUM>, second side surface <NUM>, and back surface <NUM>. Hinge <NUM> connects back surfaces <NUM>, <NUM> of bottom part <NUM> and cover part <NUM>, respectively.

In a closed position of packaging unit <NUM> (<FIG>) front surfaces <NUM>, <NUM> of bottom part <NUM> and cover part <NUM> respectively, are connected using lock <NUM>. Lock <NUM> comprises cam element <NUM> in bottom part <NUM> and opening <NUM> in cover part <NUM> (<FIG> and <FIG>).

Compartments <NUM> are provided in bottom part <NUM> and are capable of holding product P, such as an egg. Between compartments <NUM> there are provided a number of cones <NUM> that extend upwardly. In the illustrated embodiment cones <NUM> are provided with opening or hole <NUM>.

Height H<NUM> of packaging unit <NUM> (<FIG>) is considered at the corner of bottom part <NUM>. Bottom display opening <NUM> extends over a height H<NUM>-H<NUM> in bottom part <NUM>.

In the illustrated embodiment, hinge <NUM> comprises a number of hinge parts <NUM>. In this illustrated embodiment hinge parts <NUM> are aligned and are interrupted by cover display opening <NUM> and bottom display opening <NUM> (<FIG>) that together define display opening <NUM> (<FIG>). In the illustrated embodiment display opening <NUM> has a shape resembling an egg. It will be understood that other shapes can also be envisaged in accordance to the present invention.

Hinge parts <NUM> comprise a cover support part <NUM> that in a closed position of packaging unit <NUM> engages bottom support part <NUM> (<FIG>). Furthermore, bottom part <NUM> comprises bottom support surface <NUM> and cover part <NUM> comprises cover support surface <NUM> (<FIG>). In a closed position of packaging unit <NUM> bottom support surface <NUM> engages cover support surface <NUM>.

In the illustrated embodiment providing opening <NUM> to cone <NUM> provides a type of ventilation channel <NUM> inside of cone <NUM> (<FIG>). Furthermore, in this illustrated embodiment cam <NUM> is provided with a top surface <NUM> that engages support surface <NUM> of lock opening <NUM> in a closed position of packaging unit <NUM> (<FIG>).

As illustrated, lock <NUM> preferably remains substantially behind front surface <NUM> (<FIG>) defined by edges <NUM> of bottom part <NUM> and cover part <NUM> that emphasise display openings <NUM> and provide additional strength to packaging unit <NUM>. In the illustrated embodiment hinge <NUM> further comprises indent <NUM> with side edges <NUM> (<FIG>). Individual compartments <NUM> are separated from each other by walls or ribs <NUM> and cones <NUM>.

Packaging unit <NUM> further comprises edge <NUM> (<FIG>) to provide additional support to packaging unit <NUM>. Display extension <NUM> (<FIG>) extends in a substantially downward direction from opening <NUM>. On the inside of top surface <NUM> there is provided print area <NUM> (<FIG>). The moulded pulp material is optionally provided with natural fibres <NUM> (<FIG>) and/or a biodegradable material. Optionally, natural fibres <NUM> can be allowed to remain visible on packaging unit <NUM>, <NUM>.

In the illustrated embodiment packaging unit <NUM> comprises product receiving compartments <NUM> provided in two rows of five compartments <NUM>. It will be understood that other configurations can also be envisaged in accordance to the invention. For example, packaging unit <NUM> (<FIG>) comprises cover part <NUM> and bottom part <NUM> with a number of display openings <NUM> enabling a visual view of products P. It will be understood that other designs can also be envisaged in accordance to the present invention.

Alternative packaging unit <NUM> (<FIG>) has bottom part <NUM> and cover part <NUM>, and comprises more locks <NUM> with cams <NUM> and openings <NUM>. In the illustrated embodiment the number of locks is equal to the number of egg compartments <NUM> in the front row of packaging unit <NUM> minus one. This improves the locking between bottom part <NUM> and cover part <NUM>. Height H<NUM> of packaging unit <NUM> (<FIG>) is considered at the corner of bottom part <NUM>. Bottom display opening <NUM> extends over a height H<NUM>-H<NUM> in bottom part <NUM>.

When manufacturing packaging unit <NUM>, <NUM> 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 AKD, ASA and/or other sizing components. In the illustrated embodiment, packaging unit <NUM>, <NUM> is moulded in a moulding operation and then dried. The dried packaging units <NUM>, <NUM> are then used to pack products P by placing one product P in respective compartment <NUM> to provide a packaging unit that is filled with products P and ready for storage, transport and/or display. Such packaging units enables a potential buyer to inspect products P while packaging unit <NUM>, <NUM> remains on the shelf, for example.

Claim 1:
Packaging unit (<NUM>,<NUM>, <NUM>) from a moulded pulp material, the packaging unit comprising:
- a bottom part (<NUM>, <NUM>, <NUM>) with product receiving compartments (<NUM>, <NUM>) for holding respective products (P), and a number of cones (<NUM>) that are provided between the compartments, and having at least one bottom front surface (<NUM>); and
- a cover part (<NUM>, <NUM>, <NUM>) that is hingedly connected to the bottom part with a hinge-element (<NUM>), and having at least one cover display surface,
wherein the packaging unit comprises a lock (<NUM>, <NUM>) for locking the bottom and cover parts in a closed position,
wherein the bottom front surface (<NUM>) and cover display surface (<NUM>) comprise a number of display openings (<NUM>, <NUM>) that are positioned to display the product in the respective compartment,
wherein the display openings (<NUM>,<NUM>) in the bottom front surface (<NUM>) and cover display surface (<NUM>) are aligned,
wherein the lock comprises a lock opening (<NUM>, <NUM>) and a cam element (<NUM>, <NUM>),
characterised in that the cam element is provided on a flapless surface of the bottom front surface (<NUM>) directly on the bottom part and
wherein the lock opening comprises a support surface (<NUM>) that is configured for engaging the cam element.