Packaging unit of molded pulp material with a display opening and method for manufacturing such a packaging unit

Abstract

The present invention relates to a packaging unit (2) made of molded pulp material, the packaging unit comprising: a bottom part (4) having product receiving compartments for receiving respective products, and a plurality of cones provided between the compartments and having at least one bottom display surface; and a lid part (6) hingedly connected to the bottom part by a hinge element (26) and having at least one lid display surface, wherein the packaging unit comprises a locking member (28) for locking the bottom part and the lid part in a closed position, wherein the bottom front surface and the lid display surface comprise a plurality of display openings (42, 44, 46), the display openings being positioned to display the products in the respective compartments, wherein the display openings in the bottom front surface and the display openings in the lid display surface are aligned, wherein the locking member comprises a locking member opening (32) and a cam element (30), and wherein the cam element is provided on the flapless front surface of the bottom part.

Description

[0001] The present invention relates to a packaging unit made of moulded pulp material. These packaging units are used for products such as eggs.

[0002] Packaging units for eggs, such as egg cartons, containers or cardboard boxes, are known in practice and are typically made of moulded pulp material derived from cellulose fibres. Such a packaging unit includes a bottom part and a lid part, the bottom part being provided with compartments for individual products, and the lid part is usually hingedly connected to the bottom part. Products such as eggs are stored, transported and displayed in these packaging units. An example of such an egg carton is shown in WO2015 / 160248A1, which shows a packaging unit comprising a bottom part and a lid part connected by a hinge, and further comprising a locking member configured to lock the lid part and the bottom part in a closed position of the packaging unit.

[0003] For example, products such as eggs are usually placed on the shelves of a shop / supermarket. For example, a potential purchaser removes the egg carton from the shelf for inspection. However, inspecting the product involves opening the egg carton. This requires the potential purchaser to manually open the egg carton to inspect the product. In addition, there is a risk of damaging the product.

[0004] It is an object of the present invention to eliminate or at least reduce the above problems in conventional packaging units, such as egg cartons, and to provide a suitable packaging unit that enables convenient display of the product.

[0005] To this end, the present invention provides a packaging unit made of moulded pulp material, wherein the packaging unit according to the present invention comprises:

[0006] - a bottom part having product receiving compartments for receiving respective products, and a plurality of cones provided between the compartments, and having at least one bottom front surface; and

[0007] - a lid part hingedly connected to the bottom part by a hinge element and having at least one lid display surface,

[0008] wherein the packaging unit includes a locking member for locking the bottom part and the lid part in a closed position, and

[0009] wherein at least one of the bottom front surface and the lid display surface includes a plurality of display openings positioned to display the products in the respective compartments,

[0010] wherein the display openings in the bottom front surface are aligned with the display openings in the lid display surface,

[0011] wherein the locking member includes a locking member opening and a cam element, and

[0012] The cam element is provided on the flapless front surface of the bottom part.

[0013] The packaging unit according to the invention is made of molded pulp material, which can be derived from softwood fibers and / or hardwood fibers and / or recycled cellulose fibers and / or other suitable fibers. The packaging unit includes a bottom part and a lid part, which are hingedly connected to each other by a hinge element such as a hinge. The bottom part is provided with a product receiving compartment, which is capable of receiving and accommodating a corresponding product, such as an egg, and in addition, similar products, such as kiwis and tomatoes. One or more cones are provided between adjacent compartments to provide additional support to the packaging unit. In the currently preferred embodiment, the bottom part and the lid part of the packaging unit include a front surface, a rear surface, and two side surfaces. In addition, the bottom part includes a bottom surface, and the lid part includes a top surface.

[0014] In the closed position of the packaging unit according to the invention, the bottom part and the lid part are locked together by a locking member. The locking member includes a first locking member element and a second locking member element, which are provided on the corresponding bottom part and lid part. In the currently preferred embodiment, the lid part is provided with a locking member opening, and the bottom part is provided with a locking cam, which are configured to engage with each other in the closed position of the packaging unit.

[0015] The packaging unit according to the invention further includes at least one bottom front surface and at least one lid display surface. For example, these display surfaces are designed to be shown to potential purchasers when stacked on the shelves of a store or supermarket. Preferably, the front surface of the bottom part and / or the lid part at least partially provides a display surface. Optionally, the rear surface of the bottom part and / or the lid part may also include a display surface. It can be understood that other designs for the packaging unit can also be envisaged, such as a triangular packaging unit, where, for example, one (or two or more) sides can provide a display surface. According to the invention, at least one display surface includes a plurality of display openings, and the display openings in the bottom part front surface and the display openings in the lid part display surface are positioned such that they display the products received in the corresponding compartments.

[0016] Providing display openings in the display surface enables potential purchasers to view and / or inspect the products without having to open the packaging unit. In addition, this even enables potential purchasers to evaluate the products while the products together with the packaging unit are held on the shelf. This is more time-saving for potential purchasers. In addition, for example, this reduces the risk of damaging the products.

[0017] As another advantage, the display opening provides additional cooling for the product. This increases the shelf life of perishable products such as eggs. As a further advantage, the display opening enables enhanced drying to be able to remove moisture from the product and / or the packaging unit, thereby preventing the packaging unit from weakening. Accordingly, the packaging unit substantially maintains its strength during storage, transportation and display of the product.

[0018] The above advantages are particularly applicable to consumer goods such as eggs. When dealing with hard-boiled eggs, the advantages related to enhanced cooling and / or drying are particularly important. It is noted that these hard-boiled eggs sometimes have a colored layer or even a colored protective layer. According to the present invention, the display opening in the packaging unit enables the consumer to observe the colored eggs. This improves the overall visual appearance of the packaging unit with the colored product. In addition, the use of the colored product makes it easier to inspect the product in terms of cracks and the like.

[0019] According to the present invention, the display opening in the bottom front surface and the display opening in the lid display surface are aligned.

[0020] For example, the alignment of the display opening in the bottom front surface and the display opening in the lid display surface causes a potential purchaser to substantially see the product in the compartment. Preferably, the display opening located in the bottom front surface and the display opening in the lid display surface are positioned such that a potential purchaser can easily see the product in the compartment.

[0021] In the presently preferred embodiment, the aligned display openings are egg-shaped. The egg shape provides a pleasant visual appearance for the potential purchaser, where the display opening reveals the shape of the product placed in and / or that can be placed in the packaging unit. In addition, the egg shape provides a considerable strength to the packaging unit as compared to openings of other possible shapes. More specifically, the load from stacked packaging units (placed on top of each other) can be easily further transferred without damaging the packaging unit. This will also prevent damage to the product packaged within the packaging unit.

[0022] Preferably, the display opening in the bottom front surface extends over at least 2 / 3 of the height of the bottom part.

[0023] The display opening in the bottom front surface extends over at least 2 / 3 of the height such that an egg packaging operation can be effectively carried out. More specifically, the fingers or other clamping elements of the packaging robot are further positioned into the bottom part (as seen in the vertical direction) before separating from the egg, and can leave the egg compartment (partially) through the opening. Accordingly, the "drop distance" of the egg is significantly reduced. This reduces the risk of damaging the egg.

[0024] According to the present invention, the locking member of the packaging unit includes a locking price opening and a cam element. In the currently preferred embodiment of the present invention, in the closed position, the locking member is substantially located behind the front plane of the packaging unit.

[0025] By providing the locking member substantially behind the front plane of the packaging unit, the risk of the cam hooking onto other packaging units or other components is significantly reduced. During the manufacturing process, this reduces the risk of operational pauses. In addition, this reduces the risk of damaging the cam of the locking member. This greatly helps to reduce the risk that the locking member does not operate properly during use.

[0026] Preferably, the locking member opening includes a support surface configured to engage with the cam. Providing an additional support surface imparts additional strength to the packaging unit. This additional strength avoids the use of additional molded pulp material to maintain the strength of the packaging unit with a display opening.

[0027] According to the present invention, the cam element is provided on the flapless front surface of the bottom portion. By providing the cam element on the flapless front surface, the cam element is actually directly provided on the bottom portion. When, in the closed position of the packaging unit, the cam engages with the support surface of the opening, this provides additional strength. It can be understood that this also substantially improves the strength of the entire packaging unit.

[0028] In another preferred embodiment of the present invention, the display surface having the locking member includes a display extension substantially located below the opening.

[0029] Providing the display extension gives a visual indication of the position of the locking member. This helps the consumer to lock and unlock the packaging unit. In addition, when closing the packaging unit, the display extension provides a so-called seeking function such that the opening in the lid portion is guided onto the cam element in the bottom portion. This makes it easier to close the packaging unit. More specifically, it prevents the lid portion from being mispositioned relative to the bottom portion. Thus, such a display extension contributes to the security or stability of the locking member. A further effect of the display extension is to introduce a lever function to the locking member. This further helps the consumer to open the packaging unit.

[0030] In another preferred embodiment of the present invention, the packaging unit includes a hinge element, such as a hinge, for hingedly connecting the bottom portion and the lid portion, wherein the hinge element includes a lid support portion and a bottom support portion.

[0031] By providing one or more lid support portions and bottom support portions associated with the hinge element, the strength of the packaging unit is further improved. More specifically, these lid support portions and bottom support portions prevent the cover of the lid portion from moving in a substantially horizontal direction relative to the bottom portion. This provides a safer stacking.

[0032] In another preferred embodiment of the present invention, the bottom portion includes a bottom support surface that extends substantially horizontally on the display surface, wherein the bottom support surface is configured to engage with the lid portion. Preferably, the lid portion includes a lid support surface that extends substantially horizontally, and the lid support surface is also provided close to or at the display surface and is configured to engage with the bottom support surface.

[0033] Providing the bottom support surface, and more preferably, providing a combination of the bottom support surface and the lid support surface, provides additional strength to the packaging unit. This reduces the risk of damaging the packaging unit and / or the product therein.

[0034] In another preferred embodiment of the present invention, at least some of the cones are provided with one or more openings and are configured such that an air flow (e.g., an air stream) can pass through the openings.

[0035] The cones (partially) separate adjacent compartments and preferably support (one or more) products. The cones may include cone elements and / or equivalent partitions between adjacent compartments. Providing openings in the cones allows gas flow (preferably air flow) through the cones. During the manufacturing process, this greatly facilitates the drying process of the packaging unit. Thus, the drying of the packaging unit is significantly improved. In addition, the drying operation of the packaging unit becomes more controlled and / or is performed step by step. The improved drying increases the strength of the packaging unit without increasing the amount of material required and / or reduces the amount of material while maintaining the strength of the packaging unit.

[0036] A further effect of providing one or more openings in the cones of the packaging unit is to reduce the total weight of the packaging unit. This reduces the material cost and can reduce the drying cost and / or can improve the handling of the packaging unit. For example, for a standard egg packaging, the weight reduction may reach about 1 gram.

[0037] A further effect of providing one or more openings in the cones of the packaging unit is to reduce product damage during storage, transportation, and / or display. This is particularly applicable to fragile products such as eggs. Thus, the increased strength of the packaging unit reduces product loss.

[0038] In the currently preferred embodiment of the present invention, the effective diameter of the openings is in the range of 0.5 - 15 mm, preferably in the range of 1.0 - 10 mm, more preferably in the range of 2.0 - 8 mm, and most preferably in the range of 3 - 6 mm.

[0039] Experiments have shown that providing openings with an effective diameter or effective opening size within the above range can achieve enhanced strength due to improved drying operations. The openings are preferably shaped as circles having a diameter. This diameter corresponds to the effective diameter. It should be understood that other shaped openings are also possible. For example, the openings can be oval. In this case, the effective diameter corresponds to the diameter of a circular opening having an equal opening surface.

[0040] In the currently preferred embodiment of the present invention, at least some of the openings are provided at or near the top of the cone. Providing at least some openings at or near the top of the cone enables effective drying operations. This further enhances the strength of the packaging unit.

[0041] In another preferred embodiment of the present invention, the hinge of the packaging unit includes a notch.

[0042] By providing a notch, the connection between the lid portion and the bottom portion is improved, and the denesting is further improved.

[0043] Preferably, the lid portion includes a substantially flat top surface. For example, such a flat top surface helps to provide information about the product to potential purchasers or consumers. In addition, this also enables a printing area to be provided on the inner side of the top surface. For example, this can provide additional information about the product to the consumer.

[0044] In the currently preferred embodiment of the present invention, the molded pulp material includes a certain amount of natural fibers.

[0045] Additionally or alternatively, the molded pulp material includes a certain amount of biodegradable material, such as aliphatic polyesters.

[0046] The use of natural fibers and / or biodegradable materials in a packaging unit derived from a molded pulp material is described in WO 2018 / 067006 A1 of the same applicant. The use of natural fibers and / or biodegradable materials results in the packaging unit being substantially MOSH-free and / or MOAH-free, and / or being (home) compostable. These materials are preferably used in combination with one or more of the above features, particularly in combination with one or more of the support surface, display extension, display surface, and support portion. This combination provides additional strength to the packaging unit, provides more possibilities for using alternative materials without reducing the performance of the packaging unit.

[0047] The present invention also relates to a method for packaging products such as eggs, including the steps of providing a packaging unit as described above and placing one or more products therein.

[0048] This method provides the same effects and advantages as those described with respect to the packaging unit.

[0049] The present invention also relates to a method of manufacturing a packaging unit from molded pulp material, the method comprising the following steps:

[0050] - Preparing the molded pulp material; and

[0051] - Providing a packaging unit according to any one of the embodiments of the present invention.

[0052] This method provides the same effects and advantages as those described with respect to the packaging unit.

[0053] Additional advantages, features, and details of the present invention are elucidated based on a preferred embodiment of the present invention, with reference to the accompanying drawings, in which:

[0054] Figure 1 A packaging unit according to the present invention is shown in a closed position;

[0055] Figure 2 Is shown Figure 1 The packaging unit in is in a position between the fully open position and the fully closed position;

[0056] Figure 3 Is shown Figure 1 And Figure 2 The packaging unit of is in the fully open position;

[0057] Figure 4 Is shown Figures 1-3 A cross-section of the packaging unit of;

[0058] Figure 5 An alternative design of the packaging unit according to the present invention is shown; and

[0059] Figure 6A And Figure 6B An alternative embodiment of the packaging unit according to the present invention is shown.

[0060] The packaging unit 2 ( Figures 1-4 ) comprises a bottom part 4 and a lid part 6. The bottom part 4 comprises a front part / front surface 8, a first side surface 10, a second side surface 12, a rear surface 14, and a bottom surface 16. The lid part 6 comprises a top surface 18, a front surface 20, a first side surface 22, a second side surface 22, and a rear surface 24. A hinge 26 connects the rear surface 14 of the bottom part 4 and the rear surface 24 of the lid part 6 respectively.

[0061] In the closed position of the packaging unit 2 ( Figure 1 ), the front surface 8 of the bottom part 4 and the front surface 20 of the lid part 6 are connected by a locking member 28. In the illustrated embodiment, the locking member 28 comprises a cam element 30 in the bottom part 4 and an opening 32 in the lid part 6 ( Figure 2and Figure 3 )。

[0062] The compartment 34 is provided in the bottom part 4 and is capable of accommodating a product P, such as an egg. A plurality of cones 36 extending upward are provided between the compartments 34. In the illustrated embodiment, the cones 36 are provided with openings or holes 38.

[0063] The height H of the packaging unit 2 1 ( Figure 1 ) is considered at the corners of the bottom part 4. The bottom display opening 44 extends beyond the height H in the bottom part 4 1 -H 2 。

[0064] In the illustrated embodiment, the hinge 26 includes a plurality of hinge parts 40. In the illustrated embodiment, the hinge parts 40 are aligned and interrupted by the lid display opening 42 and the bottom display opening 44( Figure 3 ) and the lid display opening 42 and the bottom display opening 44 together define the display opening 46( Figure 1 ). In the illustrated embodiment, the display opening 46 has a shape similar to an egg. It should be understood that according to the present invention, other shapes can also be envisaged.

[0065] The hinge part 40 includes a lid support part 48 which engages with the bottom support part 50 in the closed position of the packaging unit 2( Figure 4 ). In addition, the bottom part 4 includes a bottom support surface 52 and the lid part 6 includes a lid support surface 54( Figure 2 ). In the closed position of the packaging unit 2, the bottom support surface 52 engages the lid support surface 54.

[0066] In the illustrated embodiment, providing the openings 38 in the cones 36 provides a ventilation passage 56 within the cones 36( Figure 4 ). In addition, in the illustrated embodiment, the cam 30 is provided with a top surface 58 which engages with the upper edge or support surface 60 of the locking member opening 32 in the closed position of the packaging unit 2( Figure 4 ).

[0067] As shown, the locking member 28 preferably remains substantially at the rear of the front surface 62( Figure 4 ), the front surface 62 being defined by the edges 64 of the bottom part 4 and the lid part 6, the edges 64 strengthening the display opening 44 and providing additional strength to the packaging unit 2. In the illustrated embodiment, the hinge 26 also includes a notch 66 having side edges 68( Figure 3 ). The individual compartments 34 are separated from each other by walls or ribs 69 and the cones 36.

[0068] The packaging unit 2 also includes an edge 70( Figure 2), to provide additional support for the packaging unit 2. The extension part 71 is shown Figure 1 ) extends from the opening 32 in a generally downward direction. A printing area 72 is provided inside the top surface 18 Figure 3 ). The molded pulp material is optionally provided with natural fibers 74 Figure 2 ) and / or biodegradable materials. Optionally, the natural fibers 74 may be allowed to remain visible on the packaging units 2, 102.

[0069] In the illustrated embodiment, the packaging unit 2 includes product receiving compartments 34, and the product receiving compartments 34 are arranged in two rows, with five compartments 34 in each row. It should be understood that according to the present invention, other configurations are also conceivable. For example, the packaging unit 102 Figure 5 ) includes a lid portion 104 and a bottom portion 106, and the lid portion 104 and the bottom portion 106 have a plurality of display openings 108, and the display openings 108 enable the product P to be visually inspected. It should be understood that other designs are also conceivable according to the present invention.

[0070] The alternative packaging unit 202 Figures 6A-6B ) has a bottom portion 204 and a lid portion 206, and includes more locking members 228 with cams 230 and openings 233. In the illustrated embodiment, the number of locking members is equal to the number of egg compartments 234 in the front row of the packaging unit 202 minus 1. This improves the locking between the bottom portion 204 and the lid portion 206. The height H of the packaging unit 202 Figure 6A is considered at the corners of the bottom portion 204. The bottom display opening 44 extends beyond the height H in the bottom portion 204 1 -H 1 2 .

[0071] When manufacturing the packaging units 2, 102, the molded pulp material is provided to the mold. Preferably, the molded pulp material includes various additives, such as a certain amount of AKD, ASA, and / or other sizing components. In the illustrated embodiment, the packaging units 2, 102 are molded in a molding operation and then dried. The dried packaging units 2, 102 then package the product P by placing one product P in the corresponding compartment 34, so as to provide a packaging unit filled with the product P and ready for storage, transportation, and / or display. For example, when the packaging units 2, 102 are placed on the shelf, such a packaging unit enables potential purchasers to inspect the product P.

[0072] ​The present invention is in no way limited to its preferred embodiments described above. The rights sought to be protected are defined by the appended claims, and many modifications can be envisaged within the scope of the claims. For example, the locking member 28 can be provided with locking elements of different shapes. In addition, labels can be attached to the packaging units 2, 102. The illustrated packaging unit 2 includes ten product receiving compartments 34. It should be understood that another number of product receiving compartments 34 can also be envisaged according to the present invention. Although the packaging unit 2 is shown as being for eggs, it can also be used for other products, such as, for example, kiwis and tomatoes.

Claims

1. A packaging unit made of molded pulp material, said packaging unit comprising: A bottom part having product receiving compartments for receiving respective products, and a plurality of cones provided between said compartments, and having at least one bottom front surface; and A lid part hingedly connected to said bottom part by a hinge element and having at least one lid display surface, wherein said packaging unit includes a locking member for locking said bottom part and said lid part in a closed position, wherein said bottom front surface and said lid display surface include a plurality of display openings positioned to display the products in the respective compartments, wherein the display openings in said bottom front surface and the display openings in said lid display surface are aligned, wherein said locking member includes a locking member opening and a cam element, wherein said cam element is provided on a flapless front surface of said bottom part, and wherein said locking member opening includes a support surface configured to engage with said cam element.

2. The packaging unit according to claim 1, wherein, the aligned display openings are egg-shaped.

3. The packaging unit according to claim 2, wherein, the display openings in said bottom front surface extend more than 2 / 3 of the height of said bottom part.

4. The packaging unit according to claim 1, wherein, in the closed position, said locking member is substantially located behind the front plane of said packaging unit.

5. The packaging unit according to any one of the preceding claims 1 - 4, wherein, the display surface having said locking member includes a display extension substantially located below said opening.

6. The packaging unit according to any one of the preceding claims 1 - 4, wherein, said hinge element includes a lid support part and a bottom support part.

7. The packaging unit according to any one of the preceding claims 1 - 4, wherein, the bottom part on said display surface includes a bottom support surface extending substantially horizontally and configured to engage with said lid part.

8. The packaging unit according to claim 7, wherein, the lid part on said display surface includes a lid support surface extending substantially horizontally and configured to engage said bottom support surface.

9. The packaging unit according to any one of the preceding claims 1 - 4 and 8, wherein, at least some of said cones are provided with one or more openings configured to allow an air flow such as an air stream to pass through said openings.

10. The packaging unit according to any one of the preceding claims 1 - 4 and 8, wherein, said hinge element includes a notch.

11. The packaging unit according to any one of the preceding claims 1 - 4 and 8, wherein, said lid part includes a substantially flat top surface.

12. The packaging unit according to any one of the preceding claims 1 - 4 and 8, wherein, said molded pulp material includes a certain amount of natural fibers.

13. The packaging unit according to any one of the preceding claims 1 - 4 and 8, wherein, The molded pulp material comprises a quantity of biodegradable material.

14. The packaging unit according to claim 5, wherein, the bottom portion on the display surface includes a bottom support surface extending substantially horizontally, the bottom support surface being configured to engage with the lid portion and the lid portion on the display surface includes a lid support surface extending substantially horizontally, the lid support surface being configured to engage the bottom support surface.

15. The packaging unit according to claim 12, wherein, the molded pulp material comprises a quantity of biodegradable material.

16. A method for packaging a product such as an egg, comprising the steps of: providing a packaging unit according to one or more of the preceding claims and placing one or more of said products therein.

17. A method of manufacturing a packaging unit from molded pulp material, the method comprising the steps of: preparing the molded pulp material; and providing a packaging unit according to any one of claims 1-15.

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