Carton

Abstract

A carton 10 is provided for storing comestibles, particularly eggs, therein. There is a lower carton portion 16 and an upper carton portion 14 hingeably engaged with the lower carton portion 16 to fo

Description

The present invention relates to a carton for, but not limited to, carrying comestibles. The invention further relates to a method of forming a carton. In the art, typical comestible packaging uses excessive adhesive, non-recyclable components or is formed of a shape that is either not fit for purpose or unduly wastes manufacturing material. Furthermore, current comestible packaging can still leave fragile foodstuffs damaged by not providing sufficient rigid or resilient protection. Traditional egg boxes are formed of single layer pieces which make them inherently weaker and easy to rip. Furthermore, they are not easily stackable due to their egg-shaped moulded bases and are often covered by a finishing sealant to increase their overall resilience and durability, which makes them less easy to recycle. As such, it is an object of the present invention to obviate or substantially obviate the above-mentioned problems. According to a first aspect of the invention, there is provided a carton comprising: a lower carton portion; and an upper carton portion hingeably engaged with the lower carton portion to form a lid therefor; each of the upper and lower carton portions having a non-rectilinear geometry; each of the upper and lower carton portions having side walls which interleave with one another to form a three-dimensional receiving area for a comestible; and the upper and lower carton portions being formed from a unitary net. This is advantageous as it provides a carton that can be formed of a single piece of material that provides both a comestible receiver part and a lid therefor. The unitary net and the hinge engagement also permits a user to open and close the carton without removing any parts or necessitating separate components. Optionally, the carton may have non-rectilinear geometry that may be polygonal and may have more than five sides and the non-rectilinear geometry may be hexagonal. This is beneficial as polygonal geometry provides a carton that is substantially stronger than alternative shapes. Having more than five sides, specifically six sides, is beneficial to carrying specific goods such as a plurality of single comestibles such as eggs or fruits. Eggs in particular are shaped to be received in a more secure manner when in a hexagonal carton. Preferably, the carton may be formed from cardboard, paperboard, or another pulpbased material. This is beneficial as not only are cardboard, paperboard, and other pulp-based materials strong, durable, and lightweight, but are also ecologically friendly, recyclable and are naturally biodegradable. As such, these materials mean the cartons will not be processed into landfill waste and the manufacturing materials can be recycled. As a further benefit, this leads to a reduced carbon footprint during manufacture and after. Optionally, the side walls may comprise interleavable receiver slots and tabs and the side walls may comprise first side walls being foldable to define the said receiver slots therein and second side walls comprising the said tabs; the first side walls may comprise hinged inner and outer wall portions which fold to define the said receiver slots; the inner wall portion may comprise a locator nub receivable in a corresponding locator to hold the inner and outer wall portions adjacent to one another when folded. This is advantageous as it provides a means in which the walls of the carton can be secured. The receiver slots provide a space for the receiver tabs to insert, providing a secure upstanding wall, whilst the hinged part of the inner and outer wall portions allow the separate inner and outer wall portions to come together to form a stronger and more secure double-layered wall. This is also improved by the locator nub and corresponding locator which holds this double-layered wall into the upstanding position and adjacent to one another. This helps provide rigidity and durability to the carton. Preferably, in the unitary net, the tabs may abut the outer wall portions of first side walls, to minimise material waste. This is advantageous as it improves the overall eco-friendly nature of the product and also lowers the overall carbon footprint of the manufacturing process. Optionally, the first and second side walls may alternate around a perimeter of the upper and lower carton portions and a hinge of the carton may be provided on a second side wall. This is advantageous as it provides a way to separate the carton into two parts that come together as one strong unitary part. Specifically, it allows for different types of walls around the perimeter of the carton to serve different functions. For example, second side walls provide a hinge, to connect the upper carton portion and lower carton portion, which act as a lid and a body. Additionally, first side walls provide a means to increase overall stability and strength of the carton. Preferably, at least one second wall of the upper or lower carton portion may comprise a closure tab, and the other of the upper or lower carton portion may comprise a tab receiver for closing the carton. This is advantageous as it provides a way of securing shut the carton to hold comestibles or other items within the space provided by the upper carton portion and the lower carton portion. Optionally, the closure tab or tab receiver may comprise a finger hole for assisting with removing the closure tab from the tab receiver. This is beneficial as it aids with user accessibility. The finger hole helps the user remove the closure tab without necessitating any damage or deformation to the carton by providing manipulatable access to said closure tab from the tab receiver. Preferably, the side walls may interleave without the need for adhesive or an additional fastener. This is advantageous as it increases simplicity by allowing the carton to be formed from a unitary net without necessitating any adhesive or other separate parts. It also reduces the need for any additional parts that may be needed to act as fasteners and reduces the cost of assembly by not requiring anything extra. Furthermore, it reduces the complexities associated with recycling after use as there is only one unitary material to recycle rather than additional fasteners or adhesives that would need separating during the recycling process. Optionally, the carton may further comprise an insert receivable in the lower carton portion to create distinct compartments therein. This is advantageous as it provides a way to carry comestibles within the carton without any undue movement which could cause damage to said comestibles. Preferably, the insert may be formed from a unitary net. This is advantageous as it allows the insert to be formed and useable without the need for other fasteners or adhesives and increases the simplicity of assembly. It is preferably discrete from the main carton so that the carton can be used with or without the insert. Optionally, the insert may be formed from cardboard, paperboard, or another pulp-based material. This is advantageous as it improves the overall eco-friendly nature of the product and also lowers the overall carbon footprint of the manufacturing process. Furthermore, it allows the product to be recycled. Preferably, the insert may have a complementary non-rectilinear geometry to the carton. This is beneficial as it allows the insert to securely fit within the receiving area of the carton. A complementary geometry also means that it is more able to stay within the carton and not fall out and does not require any undue bending or force to secure therein. Optionally, the insert may include at least one upstanding partition formed to create the said distinct compartments; the or each upstanding partition may extend from a centre of the non-rectilinear geometry to an edge of the non-rectilinear geometry; the at least one upstanding partition may be formed by folding of the insert at a plurality of folds therein; and the insert is assembleable without the need for adhesive or an additional fastener. This is advantageous as it provides a strong support for the inside of the carton, and also keeps the comestibles stored within the distinct compartments separate from each other. The fact it extends from the centre to an edge means that the strengthening support is provided across the whole perimeter of the carton. The plurality of folds that form the upstanding partitions and the lack of adhesive means that the insert remains strong and fulfils its purpose without the need for additional components. This also prevents issues with downstream recycling. Optionally, the carton may be an egg box. This is beneficial as it provides a specific embodiment of a carton specifically designed for the safe storage and carriage of eggs. According to a second aspect of the invention, there is provided a method of forming a carton, the method comprising the steps of: a] providing a unitary net which defines a lower carton portion and an upper carton portion which is hingeably engaged therewith, each of the upper and lower carton portions having a non-rectilinear geometry; and b] interleaving side walls of the upper and lower carton portions to form a three-dimensional receiving area for a comestible, the upper carton portion forming a lid for the lower carton portion. This is advantageous as it provides a step-by-step method of how to create the carton with a lower carton portion acting as a comestible receiving area and an upper carton portion acting as a lid. According to a third aspect of the invention a carton comprising: a base and a plurality of side walls which interleave with one another to form a three-dimensional receiving area for a comestible; the base having a non-rectilinear geometry; and the base and a plurality of side walls being formed from a unitary net. This is advantageous as it provides a carton for storing comestibles of a specific shape and formed from a single piece of material rather than multiple components. The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a plan view of a carton in accordance with the first aspect of the invention in an assembled and open condition; Figure 2 shows a perspective view of the carton of Figure 1 in the open condition; Figure 3 shows a plan view of the carton of Figure 1 in a closed condition; Figure 4 shows a perspective view of the carton of Figure 3 in the closed condition; Figure 5 shows a perspective view of the underside of the carton of Figure 4; Figure 6 shows a plan view of the net of the carton of Figure 1; Figure 7 shows a plan view of an insert suitable for use with a carton in accordance with the first aspect of the invention, in a folded condition; Figure 8 shows a plan view of the net of the insert of Figure 6; and Figure 9 shows a plan view of the carton of Figure 2 with the insert of Figure 7. With reference to Figures 1 to 5, there is shown a carton, referenced globally at 10, suitable for storing one or more comestible goods therein, such as eggs. A unitary net 12 is illustrated in Figure 6. The unitary net 12 feature means that all parts of the carton 10 can be formed from one single piece of material and this also permits assembly of the carton 10 only by folding and does not require any adhesive or other affixing agent. The carton 10 comprises an upper carton portion 14 and a lower carton portion 16 that are hingeably engaged at a carton hinge portion 18 which is a single hinged fold that connects the upper carton portion 14 and the lower carton portion 16 together. In the depicted embodiment, the carton 10 has hexagonal geometry. One side wall of each of the upper carton portion 14 and the lower carton portion 16 is formed by the carton hinge portion 18, which has upper and lower hinge walls 18u, 181. Furthermore, this embodiment specifically utilises cardboard as the material of choice. However, the carton 10 could be made from other types of material such as paperboard, or another pulp or fibre-based material. The upper carton portion 14 has three first upper side walls 20u which alternate with two second upper side walls 22u. The lower carton portion 16 has three first lower side walls 20I which alternate with two second lower side walls 22I. The upper side walls 20u, 22u, and the lower side walls 20I, 22I alternate around a perimeter of the upper carton portion 14, and the lower carton portion 16, respectively. The upper side walls 20u, 22u collectively meet at a lid portion 24, and the lower side walls 20I, 22I collectively meet at a base portion 26, thereby respectively forming the upper carton portion 14 and the lower carton portion 16. The upper carton portion 14 forms a lid in-use for the lower carton portion 16. The first upper and lower side walls 20u, 20I each are formed having an inner wall portion 28 and an outer wall portion 30. The inner wall portion 28 is foldable along a first-side-wall fold 32 which, in-use permits hinged movement of the inner wall portion 28 from an outer facing condition, to an inner facing condition, whereby the inner wall portion 28 is then positioned adjacent and parallel to the outer wall portion 30, thereby forming a double side wall 34. The structure of the pre-folded side walls is most readily seen in the net 12 shown in Figure 5. The inner wall portion 28 of the first upper and lower side walls 20u, 20I comprises a locator nub 36 which is complementarily-shaped to one of a plurality of locators 38 which are formed on each of the lid portion 24 and the base portion 26. The formation of the double side walls 34 leaves a void space between the inner wall portion 28 and the outer wall portion 30 which forms receiver slots 40 on both ends of the double side wall 34. As most clearly visible in the net 12 shown in Figure 6, tabs 42 are formed as substantially triangular wings that extend from sides of the second upper and lower side walls 22u, 22I and the upper and lower hinge walls 18u, 181. The tabs 42, in the net 12, physically abut the adjacent first upper and lower side walls 20u 20I, to minimise material wastage, and the tabs 42 and upper and lower side walls 20u, 20I are separated during cutting of the net 12. The other two second upper wall portions 22u each have a closure tab 44a extending therefrom, which is in-use received by two closure tab receivers 46 in the base portion 26 of the lower carton portion 16, respectively formed as slots in the base portion 26. There are also finger holes 48 for assisting with fixing and releasing the closure tabs 44a from the closure tab receivers 46. This is shown in detail in Figures 3 and 4. Specifically, there is a clearance space where the finger holes 48 have been cut. The closure tab receivers 46 are formed on the fold where the two second lower side walls 22I join the base portion 26. When folded and assembled, the upper carton portion 14 and the lower carton portion 16 both have six corner folds 50. Specifically, the closure tabs 44a are each attached to a tab body 44b which, when the closure tabs 44a are in-use inserted into the tab receivers 46 in a use condition, each tab body 44b folds over at a tab fold 44c to become adjacent with each of the second lower side walls 22I. This only occurs when the lower carton portion 16 is together with the upper carton portion 14 in a closed condition. When the carton is in a closed condition, the closure tabs 44a are inserted into the tab receivers 46, thereby preventing the upper carton portion 14 and the lower carton portion 16 from coming apart. Overhang material 52 formed in the formation of the locators 38 for the locator nubs 36 is visible in these images, particularly in Figures 3 to 5. This overhang material is proud of the lid portion 24 and the base portion 26, following folding of the carton 10 into its three-dimensional shape. The first side walls 20u, 20I and second side walls 22u, 22I in this particular embodiment are at an angle between 100° and 120°. In a folded condition, the lid portion 24 and the base portion 26 in this particular embodiment are non-rectilinear. The first side wall 20u, 20I, second side walls 22u, 22I and the base portion 26 of the lower carton portion 16 form an insert receiver region 54. The top edges of the double side walls 34 are indicative of the first-side-wall folds 32. In the closed condition, the upper carton portion 14 abuts the lower carton portion 16 to provide a lid therefor. Figure 7 shows an insert 56 in a folded use condition, with its corresponding unitary net 13 shown in Figure 8. The unitary net 13 construction allows it to be assembled from only one piece of material. Furthermore, it also means that no adhesive or additional affixing agent is required. The insert 56 in this specific embodiment is formed as a hexagonal shape, so as to be complementary to the geometry of the carton 10. The insert 56 is shown as being formed from cardboard but may also be formed from paperboard or another pulp or fibre-based material. There is a plurality of partition folds 58 and partition faces 60 which are linked by a plurality of insert bases 62. There is also an inner aperture 64. The partition faces 60 are linked by a plurality of partition folds 58 which are foldable to create upstanding partitions 66. The upstanding partitions 66 are upstanding relative to the insert base 62 which forms a compartment 68 between two upstanding partitions 66. The partition folds 58 are folded to create the upstanding partitions 66 which are triangular prisms. The inner aperture 64 provides clearance to allow the concertina of partition folds 58 to come together, with at least two partition faces 60 brought closer and adjacent when folded in-use. The inner aperture 64 gets narrower as a result of this. The upstanding partitions 66 are upstanding, and extend from the centre of the hexagonal geometry to an edge of the geometry. That is, the upstanding partitions 66 cover the whole width and length of the lower carton portion 16. The upstanding partitions 66 also have two ends 70a, 70b at the end of each upstanding partition 66 which includes one outward-facing end 70a, and one inward-facing end 70b. The inward-facing end 70b faces inwardly to the inner aperture 64. There is also a locator nub 36 clearance section 72, which allows space for the protruding locator nub 36 into the corresponding locator 38, even if the insert is rotated. Figure 9 shows the carton 10 with the insert 56 received within the insert receiver region 52. The insert bases 62 of each compartment 68 strengthens each compartment 68 by providing a double layer parallel to the lower carton portion 16. In this condition, the outward-facing ends 70a of the upstanding partitions 66 physically abut corner folds 50 in the lower carton portion 16 to increase the rigidity of the insert 56. When the insert 56 is in a use condition within the insert receiver region 52 of the lower carton portion 16, the inner aperture 64 is in its narrowest condition. The insert 56 when folded and in-use with the insert receiver region 52 forms a hexagonal shape that is shape-matched to receiving the dimensions of an egg or other spheroid comestible. The insert bases 62 are formed to have different areas so that the insert bases 62’ which align with the finger holes 48 do not obscure the said finger holes 48. When the insert 56 is in a use condition in the carton 10 in the correct orientation, as demonstrated in Figure 8, then the insert bases 62’ having a smaller area provide clearance for the finger holes 48 when the insert 56 is in the insert receiver region 52. Whilst the embodiments shown have focused on eggs being the primary comestible being held, this does not preclude an embodiment where the carton does not comprise an insert, and instead receives a single larger comestible. Alternatively, there may be an insert that is provided to aid in receiving a single larger comestible. An example of this could be holding a prepared hamburger or similar on-the-go food items. Whilst the carton is shown in the exemplary embodiment as being hexagonal, it may be that there are a different number of sides and faces and thus, the carton may comprise a different shape. Whilst the insert is shown as a hexagonal shape, forming six compartments for receiving six unitary comestibles, it may be envisaged that an alternative polygonal or non-polygonal shape is used. Herein is provided a carton for the carrying and / or storage of comestibles, preferably for, but not limited to, eggs, fruits, or other small unitary comestible goods. The carton comprises a non-rectilinear, polygonal shape that may be of at least five sides, and an insert for receiving and stabilising the movement of a comestible therein. The words ‘comprises / comprising’ and the words ‘having / including’ when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps, or components, but do not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The embodiments described above are provided by way of examples only, and various 5 other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.

Claims

1. A carton comprising:a lower carton portion; andan upper carton portion hingeably engaged with the lower carton portion to form a lid therefor;each of the upper and lower carton portions having a non-rectilinear geometry;each of the upper and lower carton portions having side walls which interleave with one another to form a three-dimensional receiving area for a comestible; andthe upper and lower carton portions being formed from a unitary net.

2. A carton as claimed in claim 1, wherein the non-rectilinear geometry is polygonal and has more than five sides.

3. A carton as claimed in claim 2, wherein the non-rectilinear geometry is hexagonal.

4. A carton as claimed in any one of the preceding claims, wherein the carton is formed from cardboard, paperboard, or another pulp-based material.

5. A carton as claimed in any one of the preceding claims, wherein the side walls comprise interleavable receiver slots and tabs.

6. A carton as claimed in claim 5, wherein the side walls comprise first side walls being foldable to define the said receiver slots therein and second side walls comprising the said tabs.

7. A carton as claimed in claim 6, wherein the first side walls comprise hinged inner and outer wall portions which fold to define the said receiver slots.

8. A carton as claimed in claim 7, wherein the inner wall portion comprises a locator nub receivable in a corresponding locator to hold the inner and outer wall portions adjacent to one another when folded.

9. A carton as claimed in claim 7 or claim 8, wherein, in the unitary net, the tabs abut the outer wall portions of first side walls, to minimise material waste.

10. A carton as claimed in any one of claims 6 to 9, wherein the first and second side walls alternate around a perimeter of the upper and lower carton portions.

11. A carton as claimed in any one of claims 6 to 10, wherein a hinge of the carton is provided on a second side wall.

12. A carton as claimed in any one of claims 6 to 11, wherein at least one second wall of the upper or lower carton portion comprises a closure tab, and the other of the upper or lower carton portion comprises a tab receiver for closing the carton.

13. A carton as claimed in claim 14, wherein the closure tab or tab receiver comprises a finger hole for assisting with removing the closure tab from the tab receiver.

14. A carton as claimed in any one of the preceding claims, wherein the side walls interleave without the need for adhesive or an additional fastener.

15. A carton as claimed in any one of the preceding claims, further comprising an insert receivable in the lower carton portion to create distinct compartments therein.

16. A carton as claimed in claim 15, wherein the insert is formed from a unitary net.

17. A carton as claimed in claim 15 or claim 16, wherein the insert is formed fromcardboard, paperboard, or another pulp-based material.

18. A carton as claimed in any one of claims 15 to 17, wherein the insert has a complementary non-rectilinear geometry to the carton.

19. A carton as claimed in any one of claims 15 to 18, wherein the insert includes at least one upstanding partition formed to create the said distinct compartments.

20. A carton as claimed in claim 19, wherein the or each upstanding partition extends from a centre of the non-rectilinear geometry to an edge of the non-rectilinear geometry.

21. A carton as claimed in claim 19 or claim 20, wherein the at least one upstanding partition is formed by folding of the insert at a plurality of folds therein.

22. A carton as claimed in any one of claims 15 to 21, wherein the insert is assembleable without the need for adhesive or an additional fastener.

23. A carton as claimed in any one of claims 15 to 22, wherein the carton is an egg box.

24. A method of forming a carton, the method comprising the steps of:a] providing a unitary net which defines a lower carton portion and an upper carton portion which is hingeably engaged therewith, each of the upper and lower carton portions having a non-rectilinear geometry; andb] interleaving side walls of the upper and lower carton portions to form a three-dimensional receiving area for a comestible, the upper carton portion forming a lid for the lower carton portion.

25. A carton comprising:a base and a plurality of side walls which interleave with one another to form a three-dimensional receiving area for a comestible;the base having a non-rectilinear geometry; andthe base and a plurality of side walls being formed from a unitary net.

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