GB2606560A

GB2606560A - Protective packaging for items

Info

Publication number: GB2606560A
Application number: GB2106844.0A
Authority: GB
Inventors: Coles Christopher
Original assignee: Anglian Bespoke Corrugated and Packaging Ltd
Current assignee: Anglian Bespoke Corrugated and Packaging Ltd
Priority date: 2021-05-13
Filing date: 2021-05-13
Publication date: 2022-11-16
Anticipated expiration: 2041-05-13
Also published as: GB2606560B; GB2606560A8; GB202106844D0

Abstract

Protective packaging 100 comprising a first part 110 formed of a first layer 102 defining a first surface, a second layer 104 defining a second surface, and a first core 106 extending therebetween; and a second part 112 formed of a third layer 102 defining a third surface, a fourth layer 104 defining a fourth surface, and a second core 106 extending therebetween. A recess 116 is formed in the first surface by a portion of the first core 106 having been compressed in a direction from the first surface to the second surface. A further recess 118 is formed in the third surface by a portion of the second core 106 having been compressed in a direction from the third surface to the fourth surface. The first and second recesses 116, 118 are opposing, contiguous recesses forming a cavity. The first and second parts may be joined by a hinge 114. The core structure may comprise a cellular structure, and may comprise a honeycomb or prismatic columnar structure.

Description

PROTECTIVE PACKAGING FOR ITEMS

FIELD OF THE INVENTION

The present invention relates to packaging, including but not limited to protective packaging for fragile goods, such as eggs.

BACKGROUND

Fragile goods often require specialised or bespoke packaging for protection during handling and transit. Such packaging may comprise, for to example, air packaging, bubble wrap, foam packaging, moulded polymer packaging, moulded polystyrene, or polystyrene pieces.

SUMMARY OF THE INVENTION

The present inventors have realised that existing conventional packaging whose shape conforms with that of an object to be packaged, e.g. packaging which is vacuum moulded or injection moulded or thermo-plastically moulded, tends to be difficult or costly to manufacture. The present inventors have further realised that such existing conventional packaging tends to be susceptible to breakage under load.

The present inventors have further realised that existing conventional packaging whose purpose is to provide protection to an object therewithin tends to be excessively cumbersome or heavy.

The present inventors have further realised that existing conventional packaging, in particular protective packaging, tends to be environmentally unsustainable to manufacture or dispose of.

The cost and duration of manufacture of the liner thus tends to be reduced. This is contrary to many existing conventional methods for producing packaging comprising a honeycomb core, which tend to avoid deforming the -2 -prismatic or columnar cavities, i.e. tend to avoid incision and/or compression of the core.

The present inventors have further realised that forming a cavity within the protective packaging by compressing or crushing a honeycomb core tends 5 to allow the process to be carried out using pre-formed conventional honeycomb sheets.

The present inventors have therefore recognised that it is desirable to provide protective packaging which is simultaneously cost-effective to manufacture and distribute, robust under load, thermally insulating to improve to the longevity of perishable or heat-sensitive goods, and formed entirely of environmentally-sustainable materials, e.g. biodegradable or recyclable or recycled materials.

In a first aspect, there is provided a protective packaging for packaging an item, the packaging comprising a first part and a second part. The first part is formed of a first layer defining a first surface of the first part. The first part is further formed of a second layer defining a second surface of the first part. The first part is further formed of a first core structure extending between the first layer and the second layer. The second part is formed of a third layer defining a third surface of the second part. The second part is further formed of a fourth layer defining a fourth surface of the second part. The second part is further formed of a second core structure extending between the third layer and the fourth layer. The first part comprises a first recess formed in the first surface. The first recess is formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface. The second part comprises a second recess formed in the third surface. The second recess is formed by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface. The first part and the second part are configured such that the first recess and the second recess are opposing, contiguous recesses which together form a cavity of the packaging.

At least some of the first surface may contact the third surface. -3 -

The first core structure may be a cellular structure comprising a plurality of cells substantially sealed by the first layer and the second layer. The second core structure may be a cellular structure comprising a plurality of cells substantially sealed by the third layer and the fourth layer.

Each of the cellular structures may be a structure selected from the group of structures consisting of a honeycomb structure and a prismatic columnar structure.

The first part may be hingedly attached at a first end to the second part. The hinged attachment may connect the first layer to the third layer. The 10 first layer and the third layer connected by the hinged attachment may define a single unitary layer.

One or both of the first surface and the third surface may be elastically deformable.

The packaging may comprise one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.

There may be at least one of: a discontinuation in the first surface at a perimeter of the first recess; and a discontinuation in the third surface at a perimeter of the second recess.

The first segment may be secured to the second segment via a fastening means.

The fastening means may be disposed at a second end of the packaging opposite the first end.

The fastening means may be a fastening means selected from the group of fastening means consisting of: a tab, an adhesive, a pin, a sleeve, and an outer packaging or sleeve.

In a second aspect, there is provided a method for packaging an item. The method comprises providing a first part of a protective packaging. The first part is formed of a first layer defining a first surface of the first part. The first part -4 -is further formed of a second layer defining a second surface of the first part. The first part is further formed of a first core structure extending between the first layer and the second layer. The first part comprises a first recess formed in the first surface. The first recess is formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface. The method further comprises providing a second part of the protective packaging. The second part is formed of a third surface defining a third surface of the second part. The second part is further formed of a fourth surface defining a fourth surface of the second part. The second part is further to formed of a second core structure extending between the third surface and the fourth surface. The second part comprises a second recess formed in the third surface. The second recess is defined by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface. The method further comprises inserting the item into the first recess. The method further comprises bringing at least some of the third surface into contact with the first surface such that the first recess and the second recess are opposing, contiguous recesses. The first recess and the second recess are opposing, contiguous recesses which together form a cavity within which the item is disposed.

Bringing at least some of the third surface into contact with the first surface may include bringing at least some of the third surface parallel with the first surface.

The first part may be attached by a hinge, at a first end of the first part, to the second part, the hinge connecting the first layer to the third layer. Bringing at least some of the third surface into contact with the first surface such that the first recess and the second recess are opposing, contiguous recesses may include rotating the second part, from a position in which it is aligned and lies flush with the first part, relative to the first part about the hinge.

The first core structure may be a cellular structure comprising a plurality of cells substantially sealed by the first layer and the second layer. The second core structure may be a cellular structure comprising a plurality of cells substantially sealed by the third layer and the fourth layer. -5 -

The cellular structure may be a structure selected from the group of structures consisting of a honeycomb structure and a prismatic columnar structure.

The method may further comprise thereafter securing the first segment to 5 the second segment via a fastening means.

In a third aspect, there is provided an egg box for packaging an egg, the egg box comprising a first part and a second part. The first part is formed of a to first layer defining a first surface of the first part. The first part is further formed of a second layer defining a second surface of the first part. The first part is further formed of a first core structure extending between the first layer and the second layer. The second part is formed of a third layer defining a third surface of the second part. The second part is further formed of a fourth layer defining a fourth surface of the second part. The second part is further formed of a second core structure extending between the third layer and the fourth layer. The first part comprises a first recess formed in the first surface. The first recess is formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface. The second part comprises a second recess formed in the third surface. The second recess is formed by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface. The first part and the second part are configured such that the first recess and the second recess are opposing, contiguous recesses which together form a cavity of the egg box.

In a fourth aspect, there is provided packaging containing an item, the packaging comprising a first part and a second part. The first part is formed of a first layer defining a first surface of the first part. The first part is further formed of a second layer defining a second surface of the first part. The first part is further formed of a first core structure extending between the first layer and the second layer. The second part is formed of a third layer defining a third surface -6 -of the second part. The second part is further formed of a fourth layer defining a fourth surface of the second part. The second part is further formed of a second core structure extending between the third layer and the fourth layer. The first part comprises a first recess formed in the first surface. The first recess is formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface. The second part comprises a second recess formed in the third surface. The second recess is formed by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface. The first to part and the second part are arranged such that the first recess and the second recess are opposing, contiguous recesses which together form a cavity of the packaging. The item is disposed in the cavity.

In a fifth aspect, there is provided a method for manufacturing protective packaging. The method comprises providing a sheet of material comprising a first layer defining a first surface, a second layer defining a second surface opposing the first surface, and a core structure extending between the first layer and the second layer. The method further comprises forming a first recess in the first surface. The core structure comprises a cellular structure comprising a plurality of cells substantially sealed by the first layer and the second layer.

Forming the first recess in the first surface includes compressing a first portion of the core structure in a direction from the first surface to the second surface.

The method may further comprise making an incision or cut through the first surface at a perimeter of the first recess, thereby to form a discontinuation in the first surface at the perimeter of the first recess.

The method may further comprise forming a second recess in the first surface, wherein forming the second recess in the first surface includes compressing a second portion of the core structure in a direction from the first surface to the second surface. The method may further comprise forming a slit or cut through the core structure and the second surface between the first recess and the second recess, thereby to form a hinge in the first layer between the first recess and the second recess. -7 -

The method may further comprise making an incision or cut through the first surface at a perimeter of the second recess, thereby to form a further discontinuation in the first surface at the perimeter of the second recess.

The method may further comprise forming a first recess in the first surface. Making an incision or cut through the first surface at the first recess may be performed by a machine die or press.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view (not to scale) of a protective packaging in an open configuration; Figure 2 is a process flow chart showing certain steps of a process for packaging an egg within the protective packaging; Figure 3 is a perspective view (not to scale) of the protective packaging in transition from the open configuration to a closed configuration; Figure 4 is a side view (not to scale) of the protective packaging housing an egg in the closed configuration; Figure 5 is process flow chart showing certain steps of a process for producing a part of the protective packaging; and Figure 6 is a side view (not to scale) of the part of the protective 20 packaging having been formed by a machining tool.

DETAILED DESCRIPTION

It will be appreciated that relative terms such as above and below, horizontal and vertical, top and bottom, front and back, and so on, are used herein merely for ease of reference to the Figures, and these terms are not limiting as such, and any two differing directions or positions and so on may be implemented rather than truly above and below, horizontal and vertical, top and bottom, and so on. -8 -

Figure 1 is a perspective view (not to scale) of a protective packaging 100 in an open configuration.

The protective packaging comprises a sheet of material. The sheet comprises a first layer 102 and a second layer 104 opposing the first layer 102.

The sheet further comprises a core 106 sandwiched between the first layer 102 and the second layer 104. In this embodiment, the core 106 is a honeycomb core of cellulose fibre material. The honeycomb core includes prismatic or columnar cavities or cells defined by partitioning walls.

In this embodiment, the first layer 102 and second layer 104 are flat sheets. The first layer 102 and the second layer 104 are substantially parallel to each other. In the sandwiched arrangement of this embodiment, the first layer 102 and the second layer 104 abut, and lie substantially perpendicular to, the partitioning walls of the honeycomb core 106. As such, the first layer 102 and second layer 104 may be considered to be closures of the prismatic or columnar cavities within the honeycomb core 106.

In this embodiment, a slit 108 is formed in the second layer 104 and the core 106. The slit 108 is a slit or cut which extends perpendicular to the direction in which the second layer 104 extends. The slit 108 separates or bisects the protective packaging 100, thereby to define a first segment 110 and a second segment 112. In this embodiment, the first segment 110 is connected to the second segment 112 at a hinge 114 formed by the first layer 102. The second segment 112 is configured to rotate relative to the first segment 110, from a position in which it is aligned and lies flush with the first segment 110, in a closing direction about the hinge 114.

The first segment 110 comprises a first recess 116. The first recess 116 is a recess, depression, or indentation formed in the first segment 110. The first recess 116 is formed in the first layer 102 and core 106 of the first segment 110, i.e. in an upper surface of the first segment 110.

The second segment 112 comprises a second recess 118. The second recess 118 is a recess, depression, or indentation formed in the second segment 112. The second recess 118 is formed in the first layer 102 and the -g -core 106 of the second segment 112, i.e in an upper surface of the second segment 112.

In this embodiment, both the first recess 116 and the second recess 118 are sized and shaped to receive an egg.

In this embodiment, each of the first layer 102, the second layer 104, and the core 106 is formed of a cellulose fibre material.

As will be described further for the embodiments below, a portion of the core 106 of the sheet of material is at least to some degree compressed or crushed, in a direction parallel to the core's partitioning walls, during manufacture. Prior to being compressed or crushed, the core 106 is relatively rigid and resistant to compression under load. In contrast, the crushed portion of the core 106 is, to a greater extent than prior to being compressed or crushed, elastic or compressible. In other words, compression of the core 106 during manufacture desirably alters the load-bearing properties of the packaging. In particular, the increased elasticity or compressibility of the compressed core 106 provides improved protection and/or shock absorption to the packaged goods.

In this embodiment, a length of the first segment 110, in a direction 120 parallel to the first layer 102 and second layer 104, is approximately 11 cm. In 20 other embodiments, the length may be, for example, between 5 cm and 60 cm, for example between 10 cm and 20 cm.

In this embodiment, a width of the first segment 110, in a direction 122 parallel to the first layer 102 and the second layer 104 and perpendicular to its length, is approximately 10 cm. In other embodiments, the width may be, for 25 example, between 5 cm and 60 cm, for example between 10 cm and 20 cm.

In this embodiment, a thickness of the first segment 110, in a direction from the first layer 102 to the second layer 104, i.e. in a direction perpendicular to the length and width, is approximately 3 cm. In other embodiments, the thickness may be, for example, between 0.6 cm and 10 cm, for example between 2 cm and 5 cm.

-10 -In this embodiment, the second segment 112 is substantially the same size as the first segment 110. In other embodiments, however, one or more of the dimensions of the second segment 112 may differ from that of the first segment 110.

Figure 2 is a process flow chart showing certain steps of a process 200 for packaging an egg within the protective packaging 100.

It should be noted that certain of the process steps depicted in the flowchart of Figure 2 and described below may be omitted or such process steps may be performed in differing order to that presented below and shown in Figure 2. Furthermore, although all the process steps have, for convenience and ease of understanding, been depicted as discrete temporally-sequential steps, nevertheless some of the process steps may in fact be performed simultaneously or at least overlapping to some extent temporally.

At step s202, protective packaging, e.g. the protective packaging 100, is provided in the open configuration. It will be apparent that the process 200 may apply to other embodiments of the present invention described below.

At step s204, an egg is placed within the first recess 116 of the first segment 110 of the protective packaging 100 in the open configuration.

At step s206, the protective packaging 100 is manipulated into a closed configuration. Specifically, the second segment 112 is rotated in the closing direction relative to the first segment 110 about the hinge 114. A view of the protective packaging 100 during its closure, i.e. following execution of step s204 and during execution of step s206, is provided in Figure 3.

Figure 3 is a perspective view (not to scale) of the protective packaging 100 in transition from the open configuration to the closed configuration, thereby to house the egg 300.

Rotation of the second segment 112 in the closing direction relative to the first segment 110 about the hinge 114 is indicated in Figure 3 by arrows and the reference numeral 302. When the second segment 112 is rotated such that the first layer 104 of the second segment 112 is brought in to contact with the first layer 104 of the first segment 110, the first recess 116 and the second recess 118 form opposing, contiguous recesses. The opposing, contiguous recesses 116, 118 form a cavity which houses the egg 300 within the protective packaging 100. The protective packaging 100 in the closed configuration, i.e. following execution of step s206, is shown in Figure 4.

The protective packaging 100, by virtue of the hinged connection between the first and second segments 110, 112, may be considered an integral protective packaging, or a "clam-shell" shaped protective packaging.

Figure 4 is a side view (not to scale) crosse section of the protective to packaging 100 housing the egg 300 in the closed configuration.

In the closed configuration, the first layer 102 of the first segment 110 contacts the first layer 102 of the second segment 112. In this embodiment, in the closed configuration, the first recess 116 and the second recess 118 are opposing, contiguous recesses which form a cavity in which the egg 300 in housed. At each perimeter of the respective recessed portions of the first and second segments 110, 112, there is a discontinuation in the first layer 102.

In this embodiment, when the egg 300 is received by the cavity of protective packaging 100 in the closed configuration, one or more voids are formed between the egg 300 and each of the first segment 110 and the second segment 112.

Advantageously, in the closed configuration, the one or more voids tend to provide improved thermal insulation to the protective packaging 100, i.e. to reduce a rate of heat transfer to or from the egg 300.

Advantageously, in the closed configuration, the one or more voids tend 25 to provide space for storage of additional goods other than the egg 300 within the cavity.

Advantageously, in the closed configuration, the honeycomb core 106 tends to provide rigidity and strength under load to the protective packaging 100, thereby to prevent or mitigate damage to the egg 300, e.g. due to inverting, jostling, or otherwise mishandling the packaging during handling or transit.

-12 -Advantageously, in the closed configuration, the discontinuation in the first layer 102 around the perimeter of the cavity tends to provide improved shock absorption. Specifically, while the core 106 is rigid under forces parallel to the partitioning walls of the prismatic or columnar cavities, i.e. perpendicular to the first and second layers 102, 104, it deforms more readily under forces perpendicular to said partitioning walls. In particular, perpendicular forces applied by the egg 300 on the core 106, e.g. during jostling of the protective packaging 100, tend to at least partially deform the core 106. Thus, a force imparted on the egg 300 during jostling of the protective packaging 100 tends to be reduced.

Advantageously, in the closed configuration, the closed prismatic or columnar cavities of the honeycomb core 106 tend to provide improved thermal insulation to the protective packaging 100, i.e. to reduce a rate of heat transfer to or from the egg 300.

Advantageously, while having the above-described beneficial rigidity, strength and shock-absorption characteristics, the protective packaging 100 tends, by virtue of the cavities formed within the core 106 and the cavity formed by the recesses 116, 118, to be relatively lightweight compared to conventional packaging. This tends to provide for improved ease of transport of the packaging and improved ergonomics for assembly-line packaging of goods and/or for customers unpackaging goods.

Referring again to Figure 2, the process 200 may optionally further comprise, following execution of step s206, securing the first segment 110 relative to the second segment 112. The protective packaging 100 may thereby be secured in the closed configuration. In this embodiment, this may be accomplished by fastening or otherwise coupling the first segment 110 to the second segment 112, for example, at ends of the first and second segments opposite the hinge 114. The first and second segments 110, 112 may be secured together by any appropriate securing means. The securing means may comprise a tab formed in or one segment 110, 112 that is configured to be received by a slot formed in the other of the segments 110, 112. The securing means may comprise an adhesive. The securing means may comprise a pin.

-13 -The securing means may comprise an outer sleeve which wraps around the first segment 110 and the second segment 112. The securing means may comprise an outer packaging, e.g. a box, within which the protective packaging 100 is contained. The end at which the packaging may be fastened or otherwise coupled is indicated by the reference numeral 400 in Figure 4.

In this embodiment, the first segment 110 is hingedly connected to the second segment 112. In other embodiments, the first segment 110 is not attached, i.e. is separate, from the second segment 112. Accordingly, such other embodiments may be considered non-integral protective packaging or two-part protective packaging. In such two-part embodiments, the protective packaging is closed, e.g. at step s206, by inverting the second segment 112 and placing it atop the first segment 110 such that the first recess 116 and the second recess 118 form a cavity for housing the egg 300. In such two-part embodiments, securing the protective packaging in the closed configuration may be accomplished by fastening or otherwise coupling the first segment 110 to the second segment 112, at one or both of the opposing ends of the packaging, e.g. by any of the fastening means described above.

In the embodiments described above, at a perimeter of the recessed portion of the first segment 110, there is a discontinuation in the first layer 102 at each perimeter of the respective recessed portions of the first and second segments 110, 112. In other embodiments, there is no discontinuation in the first layer 102 at one or both perimeters of the respective recessed portions of the first and second segments 110, 112. For example, the first layer 102 may be sufficiently elastic as to deform to form the first recess 116 and/or the second recess 118 without being sheared or severed along the length or width of said layer.

Figure 5 is a process flow chart showing certain steps of a process 500 for producing a part of the protective packaging of the above embodiments, for example the first segment 110 or the second segment 112.

It should be noted that certain of the process steps depicted in the flowchart of Figure 5 and described below may be omitted or such process steps may be performed in differing order to that presented below and shown in -14 -Figure 5. Furthermore, although all the process steps have, for convenience and ease of understanding, been depicted as discrete temporally-sequential steps, nevertheless some of the process steps may in fact be performed simultaneously or at least overlapping to some extent temporally.

At step s502, a sheet of material is provided. In this embodiment of the process 500, the sheet is formed of cellulose fibre material. The sheet is in accordance with the above embodiments, i.e. comprises a first layer 102, a second layer 104 opposing the first layer 102, and a honeycomb core 106 sandwiched between the first layer 102 and the second layer 104.

At step s504, a recess is formed in the sheet of material. In this embodiment, the recess is a recess or indentation or depression in accordance with the first recess 116 of the protective packaging 100. In particular, in this embodiment, there is, at a perimeter of the recess, a discontinuation in the first layer 102. In other embodiments, there is no discontinuation in the first layer 102.

Thus, in this embodiment of the process 500, forming the recess includes forming the discontinuation in the first layer 102. Specifically, step s504 includes making an incision or cut through the first layer 102 at the recess. In this embodiment, step s504 also includes making an incision or cut part-way through the core 106, thereby to define an edge or side of the recess. In other embodiments in which there is no discontinuation in the first layer 102, step s504 does not include making an incision or cut part-way through the core 106.

In this embodiment of the process 500, step s504 is performed by a machining tool comprising a die. The die stamps or presses the first layer 102 and core 106 of the protective packaging, thereby to form the recess.

Forming the recess at step s504 includes compressing or crushing or otherwise deforming a portion of the core 106, thereby to bring a portion of the first layer 102 towards the second layer 104. In this embodiment, the portion of the first layer 102 moved towards the second layer 104 is defined by the discontinuation in the first layer 102. In embodiments in which there is no discontinuation in the first layer 102, the portion of the first layer 102 moved -15 -towards the second layer 104 is defined by a perimeter of the recess or indentation or depression.

Optionally, in embodiments in which a discontinuation is intended to be made in the first layer 102, the machining tool may comprise a sharp edge integrally formed with, or coupled, to the die. In such embodiments, the sharp edge is used to make the incision or cut in the first layer 102.

Further details of a machining tool and a stamping process for forming a recess using the machining tool are shown in Figure 6 and described in more detail later below.

Optionally, the method 500 may comprise forming a slot in the sheet of material. The slot forms a part of a fastening means of the protective packaging. For example, the slot may be for receiving a tab or a pin.

Optionally, the method 500 may comprise forming a further part of the fastening means. For example, the further part may be a tab or a pin.

The process 500 is, in this embodiment, specifically a method of making a part of the protective packaging 100. Thus, the above embodiment of the process 500 may be considered a method for producing embodiments of the protective packaging in which the first segment 110 is an identical copy of the second segment 112, e.g. the two-part embodiments described above.

It should be apparent that other embodiments of the method 500 may be for producing the clam-shell protective packaging 100 of the above embodiments. Such other embodiments are hereinafter referred to as "methods for producing a clam-shell protective packaging". In methods for producing a clam-shell protective packaging, the method 500 further comprises forming a further recess in the sheet of material. The further recess is a recess or indentation or depression in accordance with the second recess 118 of the protective packaging 100. In some embodiments, there is, at a perimeter of the further recess, a discontinuation in the first layer 102. In some other embodiments, there is no discontinuation in the first layer 102.

-16 -In methods for producing a clam-shell protective packaging, the method 500 further comprises forming a slit or cut through the second layer 104 and the core 106, in accordance with the slit 108 of the above embodiments. The slit or cut is disposed between the recess and the further recess. The slit forms a hinge in the first layer 102, in accordance with the hinge 114 of the protective packaging 100 of the above embodiments. The positions of the recess and the further recess relative to the hinge are such that, when the sheet of material is folded, the recess and further recess are opposing, contiguous recesses which form a cavity for housing fragile goods, e.g. an egg.

Figure 6 is a schematic illustration (not to scale) showing further details of the machining tool 600 and the formation of the recess in the sheet of material using the machining tool 600.

The machining tool 600 comprises a die 601 for stamping the sheet of material. The die 601 has a shape associated with, e.g. matching, the desired shape of the first recess 116. The edge or side 602 of the first recess 116 may be formed by shearing of the first layer 102 upon stamping by the die 601. Alternatively, a sharp edge 604 may be integrally formed with, or coupled to, the die 601, and may assist in forming the edge or side 602 of the first recess 116 The sharp edge 604 may be a continuous protrusion around the entire perimeter of a lower surface of the die 601, or one or more distinct protrusions at the perimeter of the lower surface of the die 601. Alternatively, the sharp edge 604 may be a cutter or cutting tool integrally formed with, or coupled to, the die 601, or a cutter or cutting tool separate from the die 601.

In this embodiment, the sharp edge 604 protrudes or juts from the lower surface such that it is the first point of contact between the machining tool 600 and the sheet of material. The sharp edge 604 may comprise a different material than that of the die 601. The sharp edge 604 may be retractable relative to the lower surface of the die 601.

Referring again to Figure 5, at step s504, the die 601 is moved towards the elongate sheet in a direction 606, thereby to form the first recess 116 in the -17 -first layer 102 and core 106. The incision or cut made through the first layer 102 during step s504 may be made before or during formation of the recess. In embodiments in which the machining tool 600 comprises a sharp edge, said sharp edge is used to make the incision or cut. In other embodiments, for example in some embodiments in which the machining tool 600 does not comprise a sharp edge, the incision or cut through the first layer 102 during step s504 is formed by the die forcibly piercing or puncturing the first layer 102 and core 106.

As is shown in Figure 6, forming the recess at step s504 includes compressing or crushing or otherwise deforming a portion of the core 106. This tends to be contrary to conventional methods for producing packaging comprising a honeycomb core. Conventionally, it is generally recognised that deformation of the prismatic or columnar cavities in the core may detrimentally affect structural properties of the material. However, the present inventors have realised that compressing or crushing on a limited portion of the material to create spec for transporting goods does not significantly affect structural properties and indeed, surprising, may provide for improved protection of the goods. For example, the crushed portion of the core may be somewhat elastic and thus tends to provide for improved shock absorption. The present inventors have further realised that, advantageously, forming the recess in the protective packaging by crushing the core tends to facilitate the process being carried out using pre-formed conventional honeycomb sheets. The cost and duration of manufacture of the liner thus tends to be reduced.

Compressing or crushing a portion of the core, as opposed to cleanly cutting or incising a recess within the core, tends to minimise or mitigate associated structural weakness around the periphery of the recess. The protective capability of the packaging thus tends to be improved.

In the above embodiments, the first segment is a first part of the protective packaging. The second segment is a second part of the protective packaging.

-1 8 -In some of the above embodiments, e.g. the clam-shell embodiments, the sheet of material is common to both segments. In other embodiments, e.g. the two-part embodiments, the sheet forming the first segment is separate from the sheet forming the second segment. The first layer of the sheet belonging to the first segment may be considered a first layer of the protective packaging.

The first layer of the sheet belonging to the second segment may be considered a third layer of the protective packaging distinct from the first layer. The second layer of the sheet belonging to the first segment may be considered a second layer of the protective packaging. The second layer of the sheet belonging to to the second segment may be considered a fourth layer of the protective packaging distinct from the second layer. The core of the sheet belonging to the first segment may be considered a first core structure of the protective packaging. The core of the sheet belonging to the second segment may be considered a second core structure of the protective packaging.

The first layer of the protective packaging may be considered a first surface of the first segment. The second layer of the protective packaging may be considered a second surface of the first segment. The third layer of the protective packaging may be considered a third surface of the second segment. The fourth layer of the protective packaging may be considered a fourth surface of the second segment.

In the above embodiments, the protective packaging is for packaging an egg. In other embodiments, the protective packaging is for packaging fragile goods other than an egg. For example, the protective packaging may be used to package food, or fragile consumer goods, or medical supplies, or construction materials.

In the above embodiments, the protective packaging comprises two recesses forming a single cavity, thereby to package a single egg. In other embodiments, the protective packaging comprises more than two recesses, thereby to form multiple cavities to package multiple eggs. For example, the protective packaging may comprise four recesses, or six recesses, or eight recesses, or ten recesses, or twelve recesses.

-1 9 -In the above embodiments, the first layer is formed of a cellulose fibre material. In other embodiments, the first layer is formed of one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.

In the above embodiments, the second layer is formed of a cellulose fibre material. In other embodiments, the second layer is formed of one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.

In the above embodiments, the core is formed of a cellulose fibre material. In other embodiments, the core is formed of one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.

Advantageously, the protective packaging tends to be at least partially recyclable, or made at least partially of recycled material. For example, in some embodiments, the entirety of the protective packaging is recyclable. A volume of waste packaging, and a volume of non-recyclable waste, thus tends to be reduced.

In the above embodiments, the protective packaging comprises two segments. In other embodiments, the protective packaging comprises a number of segments other than two, for example three, for example four. In these other embodiments, the protective packaging may comprise one or more further hinges connecting respective segments.

In the above embodiments, the protective packaging is a standalone packaging, optionally comprising a sleeve or outer packaging for fastening. In other embodiments, the protective packaging is disposed within an outer protective packaging.

Claims

-20 -CLAIMS1. Protective packaging for packaging an item, the packaging comprising: a first part; and a second part; wherein the first part is formed of a first layer defining a first surface of the first part, a second layer defining a second surface of the first part, and a first core structure extending between the first layer and the second layer; the second part is formed of a third layer defining a third surface of the second part, a fourth layer defining a fourth surface of the second part, and a second core structure extending between the third layer and the fourth layer; the first part comprises a first recess formed in the first surface, the first recess being formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface; the second part comprises a second recess formed in the third surface, the second recess being formed by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface; the first part and the second part are configured such that the first recess 20 and the second recess are opposing. contiguous recesses which together form a cavity of the packaging.
2. The packaging of claim 1, wherein at least some of the first surface contacts the third surface.
3 The packaging of claim 1 or 2, wherein: the first core structure is a cellular structure comprising a plurality of cells substantially sealed by the first layer and the second layer; and/or -21 -the second core structure is a cellular structure comprising a plurality of cells substantially sealed by the third layer and the fourth layer.
4. The packaging of claim 3, wherein each of the cellular structures is a structure selected from the group of structures consisting of a honeycomb structure and a prismatic columnar structure.
5. The packaging of any of the preceding claims, wherein the first part is hingedly attached at a first end to the second part.
6. The packaging of claim 5, wherein the hinged attachment connects the first layer to the third layer.
7. The packaging of any of the preceding claims, wherein one or both of the first surface and the third surface is elastically deformable.
8. The packaging of any of the preceding claims, wherein the packaging comprises one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.
9. The packaging of any of the preceding claims, wherein there is at least one of: a discontinuation in the first surface at a perimeter of the first recess, and a discontinuation in the third surface at a perimeter of the second recess.
10. The packaging of any of the preceding claims, wherein the first segment is secured to the second segment via a fastening means.
11. The packaging of claim 10 when dependent on claim 5 or 6, wherein the fastening means is disposed at a second end of the packaging opposite the first end.
12. The packaging of claim 10 or 11, wherein the fastening means is a fastening means selected from the group of fastening means consisting of: a tab, an adhesive, a pin, a sleeve, and an outer packaging.
13. A method for packaging an item, the method comprising: providing a first part of a protective packaging, the first part being formed of a first layer defining a first surface of the first part, a second layer defining a second surface of the first part, and a first core structure extending between the first layer and the second layer, the first part comprising a first recess formed in the first surface, the first recess being formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface; providing a second part of the protective packaging, the second part being formed of a third surface defining a third surface of the second part, a fourth surface defining a fourth surface of the second part, and a second core structure extending between the third surface and the fourth surface, the second part comprising a second recess formed in the third surface, the second recess being defined by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface; inserting the item into the first recess; bringing at least some of the third surface into contact with the first surface such that the first recess and the second recess are opposing, contiguous recesses which together form a cavity within which the item is disposed.
14. The method of claim 13, wherein bringing at least some of the third surface into contact with the first surface includes bringing at least some of the third surface parallel with the first surface.
15. The method of claim 13 or 14, wherein: the first part is attached by a hinge, at a first end of the first part, to the second part, the hinge connecting the first layer to the third layer; and bringing at least some of the third surface into contact with the first surface such that the first recess and the second recess are opposing, contiguous recesses includes rotating the second part, from a position in which it is aligned and lies flush with the first part, relative to the first part about the hinge.
16. The method of any of claims 13 to 15, wherein: the first core structure is a cellular structure comprising a plurality of cells substantially sealed by the first layer and the second layer; and the second core structure is a cellular structure comprising a plurality of cells substantially sealed by the third layer and the fourth layer.
17. The method of any of claims 13 to 16, wherein the cellular structure is a structure selected from the group of structures consisting of a honeycomb structure and a prismatic columnar structure.
18. The method of any of claims 13 to 17, the method further comprising, 25 thereafter: securing the first segment to the second segment via a fastening means.
19. An egg box for packaging an egg, the egg box comprising: -24 -a first part; and a second part; wherein the first part is formed of a first layer defining a first surface of the first part, a second layer defining a second surface of the first part, and a first core structure extending between the first layer and the second layer; the second part is formed of a third layer defining a third surface of the second part, a fourth layer defining a fourth surface of the second part, and a second core structure extending between the third layer and the fourth layer, the first part comprises a first recess formed in the first surface, the first recess being formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface; the second part comprises a second recess formed in the third surface, the second recess being formed by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface; the first part and the second part are configured such that the first recess and the second recess are opposing. contiguous recesses which together form a cavity for receiving an egg.
20. Packaging containing an item, the packaging comprising: a first part; and a second part; wherein the first part is formed of a first layer defining a first surface of the first part, a second layer defining a second surface of the first part, and a first core structure extending between the first layer and the second layer; the second part is formed of a third layer defining a third surface of the second part, a fourth layer defining a fourth surface of the second part, and a second core structure extending between the third layer and the fourth layer; -25 -the first part comprises a first recess formed in the first surface, the first recess being formed by a first portion of the first core structure having been compressed in a direction from the first surface to the second surface; the second part comprises a second recess formed in the third surface, 5 the second recess being formed by a second portion of the second core structure having been compressed in a direction from the third surface to the fourth surface; the first part and the second part are arranged such that the first recess and the second recess are opposing, contiguous recesses which together form a cavity of the packaging; and the item is disposed in the cavity.
21. A method for manufacturing protective packaging, the method comprising: providing a sheet of material, the sheet of material comprising a first layer defining a first surface, a second layer defining a second surface opposing the first surface, and a core structure extending between the first layer and the second layer; and forming a first recess in the first surface; wherein the core structure comprises a cellular structure comprising a plurality of cells substantially sealed by the first layer and the second layer; and forming the first recess in the first surface includes compressing a first portion of the core structure in a direction from the first surface to the second surface.
22. The method of claim 21, the method further comprising: making an incision or cut through the first surface at a perimeter of the first recess, thereby to form a discontinuation in the first surface at the perimeter of the first recess.
23. The method of any of claims 21 or 22, the method further comprising: forming a second recess in the first surface, wherein forming the second recess in the first surface includes compressing a second portion of the core structure in a direction from the first surface to the second surface and forming a slit or cut through the core structure and the second surface between the first recess and the second recess, thereby to form a hinge in the first layer between the first recess and the second recess.to
24. The method of claim 23, the method further comprising: making an incision or cut through the first surface at a perimeter of the second recess, thereby to form a further discontinuation in the first surface at the perimeter of the second recess.
25. The method of claim 22 or any claim dependent on claim 22, wherein both forming a first recess in the first surface and making an incision or cut through the first surface at a perimeter of the first recess is performed by a machine die or press