WO2013116387A2

WO2013116387A2 - Packaging system for eggs or sets of multiple objects

Info

Publication number: WO2013116387A2
Application number: PCT/US2013/023923
Authority: WO
Inventors: Geoffrey VON DER AHE
Original assignee: Von Der Ahe Geoffrey
Priority date: 2012-01-30
Filing date: 2013-01-30
Publication date: 2013-08-08
Also published as: WO2013116387A3

Abstract

A carton for a plurality of eggs or objects includes a tray with a top rim and a plurality of cells. The cells form a seating surface for the eggs such that the eggs are fully seated below the top rim with no portion of the eggs extending above the top rim of the carton. The carton includes a lid disposed on the tray and sealing the tray. The lid is arranged and configured to receive custom printed matter thereon. The lid may be transparent, translucent, or opaque. A plurality of supports is disposed in the tray to separate the objects therein and to provide vertical support for the lid. The lid is resealable to the tray, adhesively coupled to the tray, adhesively sealed over the carton or may be provided in the form of a resealable lid. A plurality of breathing air holes or pockets is defined in the tray or lid. After sealing the lid to the tray, the lid forms a tamper proof seal. The tray or lid is composed of environmentally compatible material.

Description

[01] PACKAGING SYSTEM FOR EGGS OR SETS OF MULTIPLE

OBJECTS

[02] Related Applications

[03] The present application is related to U.S. Provisional Patent

Application, serial no. 61/592564, filed on Jan. 30, 2012, and U.S. Provisional Patent Application, serial no. 61/749903, filed on January 7, 2013,which are incorporated herein by reference and to which priority is claimed pursuant to 35 U.S.C. § 1 19.

[04] Background

[05] Field of the Technology

[06] The disclosure generally relates to the field of packaging, and more particularly, relates to palletized packaging of perishable or frangible goods in the food industry (for example, eggs).

[07] Description of the Related Art

[08] Over the years there have been many improvements made to egg trays (e.g. modifications rendering the tray tamper proof, reduction of dry goods storage, use less material, or the ability to see through the tray). However, most of these improvements have not become commercially viable or accepted for various identifiable design disadvantages. The result is that the majority of egg packaging is still made with a clamshell design made out of molded pulp or polystyrene foam. [09] There are several problems with how eggs are currently packaged.

First, most egg packaging requires egg producers to preprint the cartons with the customer's trade dress and keep massive amounts of inventory in dry goods storage. This is very expensive for the egg producer. Second, the vast majority of egg cartons also allow consumers to open the carton and inspect eggs and in so doing allows the eggs to be handled or tampered with in an uncontrolled manner. This poses a food safety issue and a theft issue as customers can easily switch eggs or adulterate them. Third, when eggs break inside of clamshell egg cartons, they tend to spill or leak through the material leavingan undesirable spill residue and creating liability for slip and falls or bio-contamination of the package.

[10] Brief Summary

[11] An aspect of the invention involves the recognition that a need exists for an improved egg packaging that would allow the egg producer to maintain the same filling process and allow the retailer to merchandise the eggs the same way, while reducing the amount of material used and improving inventory management of dry goods storage. At the same time, an improvement is also needed in conventional packaging by making the package tamper resistant, allowing it to contain spillage and making it easier for the consumer to view and access the eggs. The ability to access conventional cartons and switch eggs is a distinct disadvantage to conventional packaging that needs to be solved. [12] The various embodiments of the packaging system described herein provide some or all the following benefits:

1 . Reduces costs to the egg producer by simplifying inventory management;

2. Reduces costs to egg producer by reducing the amount of dry goods storage necessary;

3. Reduces costs to egg producer by improving de-nesting of stacked empty cartons in the automated filling lines over that compared to conventional molded pulp and polystyrene;

4. Provides a tamper resistant package that is safer for consumers than conventional packaging;

5. Provides a see-through design that makes it more convenient for the consumer to inspect eggs before purchasing;

6. Provides a design so that any broken eggs are contained within the tray, thereby reducing the cost and mess associated with clean-up;

7. Provides customers with continuing access to the eggs which allows an easier view of how many eggs are remaining as compared to conventional packaging;

8. Reduces expensive corrugate associated with shipping by providing some kind of design that is strong enough to avoid or reduce the need to include shipping a corrugate;

9. Provides a packaging design that is visually appealing to the consumer; and 10. Provides a packaging design that fits both regular and extra- largeeggs.

[13] Accordingly, disclosed herein is an egg carton for packaging eggs using an automated assembly line. According to some embodiments described herein, the packaging includes an opaque, transparent or translucent plastic tray with top edges and a plurality of cells defined therein. The eggs are fully seated or positioned in the cells and inside the carton with no portion of any egg extending above the top edges of the tray. A transparent or translucent plastic lid is disposed on the tray and fully seals the eggs within the tray. The top lid is arranged and configured to receive custom printed matter thereon so that the egg carton is universal with respect to all suppliers of eggs. A plurality of supports for the lid is disposed in the tray to separate the eggs therein and to provide vertical support for the lid when the sealed and loaded egg cartons are shipped or palletized.

[14] In one embodiment, the cartontray has a low coefficient of friction and a tray shape to inhibit sticking when the carton trays are placed in a nested configuration (for example, as loaded into the automatic egg-filling line). The low coefficient of friction and the tray shape reduce mechanical or frictional engagement of one tray with the other and allow for de-nesting of a stacked plurality of carton traysin the assembly line process.

[15] In one arrangement, the transparent or translucent lid is a film adhered to the tray. In another arrangement, the lid is re-sealable to the cartontray. In another arrangement, the film and tray are transparent, translucent or opaque. In yet a further arrangement, the tray has side walls and includes a plurality of transparent, flat windows defined in the side walls of the carton tray.

[16] In yet another arrangement, the egg carton includes a plurality of breathing air holes or slots defined in the tray or lid. The air slots permit air flow therethrough when the lid is disposed on and seals the tray.

[17] In yet a further arrangement, the lid is tamper proof by being secured to the tray and affixed thereto such that separation of the lid from the tray permanently destroys affixation thereto, leaving unambiguous evidence of opening of the lid.

[18] In an another arrangement, the trayand/or lid is composed of environmentally compatible material consisting of the group of polylactide (PLA), high-density polyethylene (HDPE), polyethylene terephthalate (PET) or low- density polyethylene (LDPE). However, the scope of the invention includes the option of providing a tray and/or lid composed of molded pulp fiber or polystyrene foam.

[19] In a further arrangement, the carton further includes ribbing longitudinally defined into the surface of the cells of the plastic tray to provide rigidity and strength to the carton, where the supports are chamfered dividing walls between the cells, the supports including smooth chamfered relief surfaces drafted inwardly to define a vertical chamfered upper surface of each support to facilitate de-nesting. In one embodiment, each support has a faceted upper end with a flat, horizontal apex. [20] The illustrated embodiments also include a method of providing packaging for eggs in an automated fill line comprising the steps of providing a universal carton tray with a top edge rim into which a plurality of cells are defined therein and in which cells the eggs are fully seated or positioned inside the carton tray with no portion of any egg extending above the top edge rim of the tray; filling the carton tray with eggs in the automated line; andadhering a customized lid attached to the rim of the tray and sealing the eggs within the tray. The top lid is arranged and configured to receive custom printed matter thereon so that the egg carton is universal with respect to all suppliers of eggs.

[21] In one embodiment, the method further includes the step of stacking the filled cartons vertically on each other to be shipped or palletized. A plurality of supports for the lid is disposed in the tray to separate the eggs therein and to provide vertical support for the lid when sealed.

[22] In one embodiment, the method further includes the step of robotically de-nesting a stacked plurality of carton trays from each other prior to filing the universal carton tray. The carton tray is made from a low coefficient of friction material and has a shape to prevent sticking when the carton trays are placed in a nested configuration. The low coefficient of friction and the cartontray shape eliminate mechanical or frictional engagement and allow for de-nesting of a stacked plurality of carton trays in the assembly line process.

[23] The method further includes the step of adhering a corresponding distinguishable customized lid to the rim of each carton processed in a plurality of parallel automated assembly lines. The parallel lines allow for t a plurality of distinguishable customized filled and sealed egg cartons to be produced simultaneously.

[24] In an alternative embodiment, the egg carton includes a plastic tray with top edges characterized by an peripheral horizontal bonding flange, and a plurality of cells defined therein into which cells the eggs are fully seated inside the tray; a film affixed to the bonding flange sealing the eggs within the tray; anda plurality of vertical supports for the lid defined in the tray to provide vertical support for the film, where the supports have an open release shape.

[25] In one arrangement, thefilm is tamper proof by being adhered to the bonding flange such that separation of the lid from the tray permanently destroys affixation thereto, leaving unambiguous evidence of opening of the film.

[26] In yet a further arrangement, the supports are chamfered dividing walls between the cells. The supports including smooth chamfered relief surfaces drafted inwardly to define a vertical chamfered upper surface of each support to facilitate de-nesting. Each support has a faceted upper end with a flat, horizontal apex.

[27] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC § 1 12(6), are not to be construed as necessarily limited in any way by the construction of "means" or "steps" limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents. In the case where the claims are expressly formulated under 35 USC § 1 12(6), they are to be accorded full statutory equivalents under 35 USC § 1 12(6). The disclosure can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.

[28] Brief Description of the Drawings

[29] Figs. 1 a— 1 h are various perspective views and side plan views of the trayof the carton according to an embodiment of the packaging system disclosed herein, which are shown in enlarged scale in Figs. 5a - 5f.

[30] Fig. 2 is a partial cross-sectional view of the tray of the carton, taken alongline 2-2 of Fig. 1 b.

[31] Fig. 3 is a perspective view of an embodiment showing a transparent lid being peeled away from the upper rim of the carton of Figs. 1 a - 1 h.

[32] Fig. 4 is a perspective view of an embodiment showing a transparent lid in an exploded view over the upper rim of the carton of Fig. 3.

[33] Fig. 5 is a perspective view of an embodiment showing an opaque lid being peeled away from the upper rim of the carton of Figs. 1 a- 1 h.

[34] Fig. 6 is a top perspective view of a carton tray of an additional embodiment of the packaging system with eighteen (18) cells, without its top film seal.

[35] Fig. 7 is a bottom perspective view of the carton tray of Fig. 6.

[36] Fig. 8a is a front side view of the carton tray of Fig. 6. [37] Fig. 8b is a top plan view of the carton tray of Fig. 6.

[38] Fig. 8c is a bottom plan view of the carton tray of Fig. 6.

[39] Fig. 8d is a left side view of the carton tray of Fig. 6 (and the right side view is identical to the left side view).

[40] Fig. 9 is a top perspective view of a carton tray of an additional embodiment of the packaging system with twelve (12) cells, without its top film seal.

[41] Fig. 10 is a bottom perspective view of the carton tray of Fig. 9.

[42] Fig. 1 1 a is a front side view of the carton tray of Fig. 9.

[43] Fig. 1 1 b is a top plan view of the carton tray of Fig. 9.

[44] Fig. 1 1 c is a bottom plan view of the carton tray of Fig. 9.

[45] Fig. 1 1 d is a left side view of the carton tray of Fig. 9 (and the right side view is identical to the left side view).

[46] The disclosure and its various embodiments can now be better understood by turning to the following detailed description of the embodiments which are presented as illustrated examples of the embodiments defined in the claims. It should be expressly understood that the embodiments as defined by the claims may be broader than the illustrated embodiments described below.

[47] Detailed Description of the Preferred Embodiments

[48] References will now be made to the drawings wherein like numerals refer to like parts throughout. Figs. 1 a— 1 h illustrate an egg carton 10 according to some preferred embodiments of the present disclosure. In the illustrated embodiments, the egg carton 10 can include a carton tray 12 and a lid 14. In one embodiment, the carton tray 12 can be integrally formed to include an upper portion 17 supporting a peripheral upper rim 16, as best depicted in Fig. 1 d, and a plurality of egg cells 18, as best depicted in Fig. 1 e. In one illustrated embodiment, the carton tray 12 can include 18 egg cells arranged in three rows of six cells. In another embodiment, the carton tray 12 can include 12 egg cells arranged in two rows of six cells. It should be appreciated that the various embodiments shown are for illustration purposes and the carton tray 12 can include a different number and configuration of egg cells and the sizing of the egg cells can be varied in modified embodiments.

[49] The carton tray 12 can be made out of conventional foam or paper carton materials or any other rigid or soft synthetic or natural materials or other similar lightweight packaging materials as is known to those skilled in the art. In one preferred embodiment, the carton tray 12 can be made of molded plastic. In one arrangement, the carton tray 12 can be preferably thermally formed. In other arrangements, however, the carton tray 12 can be formed from any

manufacturing process as is known in the art to create packaging materials, including rotational molding, injection molding, thermoforming, casting, extrusion, pressing, rolling, machining, and the like.

[50] In one embodiment, the upper portion 17 and egg cells 18 can be sized such that each egg is fully seated or disposed within the enclosure of the carton tray 12. In such an embodiment, no portion of the eggs resides above the top edge of the upper portion 17 of the carton tray 12. In another embodiment, a clear, translucent or opaque lid 14 can be disposed over the carton tray 12 and can be adhered to the upper rim 16, as best shown in Fig. 5. In one

embodiment, the combined depth of the upper portion 17 and the egg cells 18 are selected such that the depth approximates the vertical length of the eggs disposed in the carton 10. In such an embodiment, vertical movement of the eggs in the carton 10 can be prevented and/or substantially limited to prevent and/or reduce damage to the eggs if the carton 10 is inverted.

[51] In another arrangement, the top of each egg can extend above the egg cells 18 and is supported by adjacent separating supports 20, best illustrated in Fig. 1 d. The supports 20 and egg cells 18 can form an enclosing structure for each egg such that contact between eggs is prevented and each egg is restricted from large movements even when the carton 10 is subjected to jarring motions. In one embodiment, the supports 20 do not contact the eggs. In another embodiment, the supports 20 can provide vertical load support to aid in stacking a plurality of cartons 10. In such an embodiment, all of the load can be carried by the supports 20 and upper rim 16 of the carton tray 12 such that no vertical forces or loads are applied to the eggs when the cartons 10 are vertically stacked. In some embodiments, a plurality of air holes 22 can be formed through the upper portion 17 of the carton tray 12, as best illustrated in Fig. 1 b, to provide a breathable containment for the eggs, as discussed below. In yet another embodiment, the egg cells 18 form a receiving surface for the lower portion of each egg. [52] Fig. 2 illustrates a cross sectional view of the carton tray 12 through section line 2-2 of Fig. 1 b, according to one embodiment, depicting the profile of the bottom portion of the egg cells 18. In one embodiment, a predefined relief 24 can be circumferentially provided in the bottom portion of the egg cells 18. The bottom portion of the egg cells 18 can also include a centering button 26 to provide for retention of the end of the egg in the center of the egg cells 18. In one embodiment, the predefined relief 24 and the centering button 26 can function in combination to seat and support the eggs (not illustrated). When a plurality of carton trays 12 are stacked for automated filling in an assembly line, relief 24 can be contoured to allow for ready release or de-nesting of each carton from the stack.

[53] In one preferred embodiment, the carton trays 12 can be composed of a plastic with a low coefficients of friction, such as polytetrafluoroethylene (PTFE), or any other material as is known in the art to prevent sticking when the materials are placed in a nested configuration. In another arrangement, the tray or lid is composed of environmentally compatible material consisting of the group of polylactide (PLA), high-density polyethylene (HDPE), polyethylene

terephthalate (PET) or low-density polyethylene (LDPE). Such an embodiment can be used on fill lines in an automated assembly line to reliably de-nest stacked carton trays 12 and prevent jamming, line stoppages, and assembly line bottlenecking. In one embodiment, the stacked carton trays 12 can have a coefficient of friction as low as 0.04. In yet another embodiment, as described below, the lid 14 can be quickly and reliably sealed to the carton in automated assembly processing to prevent disruption of the packaging process. .

[54] Figs. 3 and 4 illustratethe lid 14 disposed on the carton tray 12 according to one preferred embodiment. As described above, the lid 14 can be opaque, translucent, or transparent for viewing the contents inside of the carton. The lid 14 can be sized to match the profile of the rim 16 and can be sealed to the carton tray 12. In one embodiment, the lid 14 can be a transparent film or any other packaging material as in known in the art that is transparent and can form a sealing surface. In another embodiment, the lid 14 can be adhesively or thermally sealed to the rim 16 around the entire perimeter for a complete seal. In yet a further embodiment, the lid 14 can be adhesively sealed to rim 16 by a single use bond, or alternatively may be a resealable adhesive. In an alternative arrangement, the lid 14 can be a resealable inference fit plastic lid, such as those used in conjunction with disposable and/or reusable plastic drinking cups and food containers.

[55] In one embodiment, the lid 14 can be a plain transparent top, or more preferably printed with the information, branding and packaging graphic designs for the egg supplier and/or retailer for whom the cartons 10 are being provided. The carton tray 12 can be designed to be universal such that different suppliers can use the same carton tray 12 and utilize different branding on the lid 14 to uniquely identify their products. Such an embodiment can allow for faster batch processing in automated assembly lines as only the lid 14 requires changing from one supplier to the next. Such an embodiment can also reduce material storage and handling costs by reducing the need for warehouses stored with different inventories of cartons for multiple egg suppliers.

[56] In one embodiment, the assembly of the lid to the tray in an assembly line process can be accomplished as follows. Prior to assembly of the filled and sealed egg cartons, the material for the lid can be placed on large converter rollers. Following a step where the trays are filled with eggs, the material for the lid can be rolled onto the filled trays using industrial automation equipment as is known to those in the art. As discussed in more detail below, the top of the tray 12 can include a rim 16 with an outer flange 15 or flat bonding surface which is sufficiently wide to facilitate sealing of the lid 14 over the top side of the tray 12. After the lid material has been placed on the filled trays, the outer flange of the rim 16 can be used as an edge to seal the lid 14 over the top side of the tray 12 and to prepare the carton for shipment to distributers or retailers. In one embodiment, prior to assembly, the lid material on the rollers can include pre-printed information specific to a particular egg supplier, distributer and/or retailer including branding, logos, trademark, nutritional information and other information. By applying specific product information in a step after the trays have been filled, the trays can be a generic universal component that may be used in the egg cartons sent to many different retailers, suppliers or distributors. As such, the eggs for different retailers, suppliers or distributors can be processed in an automated assembly line using the universal tray described herein. Changeovers between different batches of eggs to be sent to a different retailer, suppliersor distributors can be accomplished by switching the pre-printed lid material on the rollers. Such an embodiment can reduce batch processing times as only the lid material is changed from one batch to the next. The more bulky and cumbersome tray material can be kept constant between batches. Additionally, such an embodiment can also reduce material storage and handling costs by reducing the need for warehouses stored with different inventories of cartons for multiple egg suppliers, distributers, and/or retailers. In an alternative embodiment, prior to assembly of the sealed cartons, the lid material can be a generic universal roll of material. Pre-printed identifying information for each egg supplier, distributer or retailer can be applied to the carton as a label (e.g. an adhesive backed label) either before, during, or after the generic universal lid material is sealed to the universal trays.

[57] Fig. 5 illustrates the lid 14 disposed on the carton tray 12 according to one preferred embodiment. As depicted in Fig. 5, the lid 14 can be opaque and fully covered by a printed pattern or graphics as previously described. As described more fully with respect to Fig. 1 , the supports 20, as depicted in Figs. 4 and 5, serve not only to separate the eggs in the carton tray 12, but also provide vertical support for the lid 14 for any loads place thereon.

[58] The forgoing description of the prior embodiments should be recognized to also apply to the following additional embodiments, unless understood otherwise from the following description. Figs. 6 - 1 1 d illustrate additional embodiments of a carton packaging system. As previously described, the illustrated carton trays can include eighteen cells for eggs or other packaged items. Also as previously described, the cartontrays can be sized and configured to accommodate any number of cells. In one preferred embodiment, the carton trays can be sized to accommodate twelve cellsas illustrated in Figs. 9— 1 1 d. Other than the number of cells, the following description of the carton illustrated in Figs. 6 - 8d should apply equally to the carton illustrated inFigs. 9— 1 1d.

[59] With reference to Fig. 6, in one arrangement, the carton tray 12 can include ribbing 28 incorporated at least on the exterior surface of the carton. In one form, the ribbing 28 can extend generally along the height of the cell 18 with a convex profile extending outward from the cell 18. In some embodiments of the carton tray 12, and especially in those embodiments of the carton tray 12 that have a generally uniform wall thickness, the ribbing 28 can result in elongated concave grooves onthe interior surface of each cell 18. In some arrangements, the ribbing can also be incorporated into the internal dividers 20.

[60] In embodiments where the carton tray 12 is made of a transparent material, the exterior of the carton tray 12 can also includes windows 30, which are generally flat panels that extend between adjacent cells18. The windows 30 and the cellsl 8 can be drafted slightly (e.g., skewed inwardlyor away from the vertical line of each cell 18) to ease separation or de-nesting of the trays or cartons 12 when stacked. The window 30 can permit visual inspection of the contents of the carton 12 as well as can strengthen the carton to resist bending and/or twisting.

[61] In one arrangement, as best illustrated in Fig. 6, the carton tray 12 can include a bridge 38a, 38b at the bottom of each window 30. The bridges 38a, 38b each provide a flat surface reinforcing the bottom portion of window 30and bridge the space between adjacent cells and the corresponding window 30 The bridges 38a and 38b are distinguishable in shape, however, in the illustrated configuration. In the illustrated arrangement, bridge 38b extends further toward its corresponding adjacent support 20 than does bridge 38a before being reduced in height above the bottom of the cartontray 12, as shown by stepped down surface 40 of bridge 38a. In the illustrated arrangement of Fig. 6, bridge 38b is disposed at the middle window 30 of the three windows 30 along the side of the carton tray12 with bridges 38a being disposed on the end windows 30 along the long side of the carton tray 12. On the opposing side of carton tray12, the arrangement is reversed, namely bridge 38a is disposed to the middle window 30 of the three windows 30 along the side of the carton 12 with bridges 38b being disposed on the end windows 30 on the long side of the carton tray 12. Similarly, on the ends of the cartontray 12, bridge 38a is disposed at the base of one of the two end windows 30 with bridge 38b being disposed at the base of the other of the two end windows 30.

[62] As depicted in Figs. 6, the top of the carton tray12 can include a rim

16 with an outer flange 15 or flat bonding surface. The rim 16 is sufficiently wide to facilitate sealing or adhering the lid 14 (e.g., a plastic or film layer, possibly transparent) over the open top side of the cartontrayl 2. The outer flange 15of the rim 16 extends around the outer circumference of the rim 16. Thecarton tray12 can also include a plurality (e.g., two to four) air pockets or slots 32 at a plurality of locations spaced around the rim 16. The air slots 32 enhance air flow though the packaging system. In addition or in thealternative, the plastic or film layer 14 can also include perforations (e.g., perforations formed by laser) toenhance air flow through the packaging system.

[63] In one embodiment, the overall width of the carton tray 12preferably is greater than 6 inches and lessthan 6.5 inches, and more preferably equal to around 6.25 inches ± 0.05 inch. These dimensions have been

foundadvantageous for the packaging of eggsand can be used with the embodiments described herein. In illustrated embodiments, loading of the cells 18 with large or extra-large eggs can be accommodated without alteration of the carton tray12. In some embodiments, the eggs are intended to be loaded with their longitudinal axis approximately parallel with the vertical axis of symmetry of each cell 18. These dimensions, however, should not be understood as limitations on all embodiments described herein.

[64] As best illustrated in Figs. 6 and 8b, the carton tray 12 can include a plurality of upwardly extending internal dividers 21 with supports 20, which define in part the separate cupsor cells 18. The supports 20 can be disposed at the intersection of the internal dividers 21 and can be formed by at least two sets 21 a, 23a of upwardly extending surfaces, of the internal dividers 21 and the cell walls 23. The cell walls 23 define in part the cells 18 adjacent the supports 20. The degree of vertical orientation of the corresponding surfaces 21 a, 23a of the internal dividers 21 and the cell walls 23 can differ from each other. In one embodiment, the surfaces 23a of cell walls 23 can have a steeper vertical profile than that of the surfaces 21 a of the internal dividers 21 . In other words, the draft angle of the surfaces 21 a of the dividers 21 is shallower (i.e., more horizontal )than the draft angle of the surfaces 23a of the cell walls near the top of the supports 20. For example, the draft angle of the divider surfaces 21 a can be approximately 75°, relative to horizontal, whereas the draft angle of the cell wall surfaces 23a can be approximately 87°, relative to horizontal. The shallower draft angle of the dividers 23 aid in the release of the carton tray 12 from a stack of carton trays 12 during the assembly process.

[65] In another embodiment, a least a portion of each internal divider 21 extends upwardly to a height above a bottom surface 33 of each cell that is higher than the equatorial diameters of the eggs, when the eggs are fully seated in the cells. In another embodiment, a portion of each internal divider 21 can extend upwardly to a height that is substantially coplanar with the rim 16. In yet a further embodiment, each internal divider 21 can vary in thickness such that each divider 21 is thicker near an intersection with other dividers 21 than at a location closest to a center of an adjacent cell.

[66] In one preferred embodiment, at least one of the cells 18 includes a cell wall 23 having a portion that extends from the bottom surface 33 of the cell 18 to the rim 16. In the illustrated embodiment shown in Fig. 6 that shown an array of cells having a length of 6 cells long and 3 cells wide, each cell 18 that is disposed along the length includes a cell wall 23 of which a portion extends to the rim 16. Additionally, each cell along the length has ribbing 28 that extends from the bottom surface 33 to the rim 16.

[67] In another embodiment, the upper end of eachsupport 20 can include a generally flat surface 34 that is generally coplanar with the rim 16. The support 20 can include a multi-sided chamfer (e.g., an 8-sided chamfer) that forms a transition between intersecting dividers and the support top end 34. This support configuration aids in stacking the filled cartons 12 (once sealed with the film layer), enhances the overall rigidity and strength of the carton 12, andhelps keep the eggs in their respective cells 18. Each cell 18 hasa seatingsurfacethat forms a lower portion of the cell 18. The cell 18 of Figs. 6 - 1 1 d can have a wider draft angle than that of the cell 18 shown in Fig. 2, which results in a wider dimension at the lower portion of the cell 18 to accommodate extra large eggs.The cell wall 23 of each cell 18 extends upwardly from a bottle surface 33 at a first draft angle β1 and then transitions through steeper draft angles to assume a more vertical orientation. That is, the draft angle is shallower at the lower section of each cell 18 and becomes steeper as the cell wall 23

approaches the rim 16. Near the rim 16, the draft angle β2 is substantially steeper than the draft angel β1 near the bottom surface 33. For example, the draft angle β1 can be approximately 50°, relative to horizontal, while the draft angle β2 can be approximately 87°, relative to horizontal. In the illustrated embodiment, this transition is smoothed so as to provide an generally

continuous, arcuate profile, and more preferably a generally parabolic profile. Additionally, in the illustrated embodiment, the variation of draft angle is symmetrical on all sides of the cell 18. The varying draft angle allows the carton tray 12 to receive extra-large eggs while maintaining an overall width sufficiently narrow to fit within existing automated egg processing lines (for example, having a width not exceeding 6 ½ inches (16.5 cm)). Additionally, the shallower draft angle (i.e., a more horizontaldraft angle) aids in the release of a carton tray 12 from a stack of carton trays 12 during the automated filling process.

[68] Thus, the draft angle of each cell as defined in part by its corresponding supports 20 and dividers 23can return to a more vertical orientation in the upper portion of each cell 18 to reduce overall carton width notwithstanding the wider dimension in the lower portion of cell 18. Additionally, the cellsl 8 can be separated by a slightly larger dimension or width of supports 20and dividers 21 to provide a greater spacing between the cells 18 to accommodate the larger eggs and to provide better strength and plastic manufacturability of supports 20. The draft angle can be carried up into the dividers21 to a point which generally corresponds with the mid-section of the egg when placed in the cell 18. From this pointupwards, each dividers21 can have side surfaces with substantially steeper draft angles (e.g., approaching90 degrees or vertical). As a consequence, each divider 21 can have a varying width from their lower section to their upper section, as noted above. The lower section of each divider 21 can bewider than the upper section. Overall, however, the dividers 21 can be wider than the embodiments of Figs. 1 a - 5. This can be best seen by comparing Fig.8b to Fig. 1 a, where supports 20 are shown in relative scale as thinner vertical supports than the wider chamfered supports 20 of Figs. 6— 1 1 d. A similar comparison of the width of supports 20 can be seen in the interior views of Fig. 3 compared to that of Fig. 6. The embodiment of Figs. 6 - 1 1 d as a consequence of the ribbed and chamfered inner structure, best illustrated in Figs. 6 and 9, provide sturdier vertical support when the filled cartons 12 are stacked and provide more reliable and easier de-nesting when the unfilled stacked cartons 12 are robotically loaded onto an automated fill line.

[69] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the embodiments. Therefore, it must be understood that the illustrated

embodimentshave been set forth only for the purposes of example and that they should not be taken as limiting the claims.

[70] The cartontray 12 is shown in the illustrated embodiments as a preformed containment for the eggs. It is to be understood, however, that the carton tray 12 can also be constructed of a pliable, non-stick, molded material that is selectively formed around an array of the eggs. Thus, the material of the carton tray12 can be molded in place around the eggs, e.g. molded around the lower portion of the eggs with the upper portion of carton 10 molded to a predetermined form as illustrated above.

[71] Further, the objects in the carton are not necessarily limited to eggs, but may include any fragile food element or other type of object, fragile or not.

[72] Therefore, it must be understood that the illustrated

embodimentshave been set forth only for the purposes of example and that it should not be taken as limiting the embodiments as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the embodimentscan include other combinations of fewer, more and/or different elements described above. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the embodiments is explicitly contemplated as within the scope of the embodiments.

[73] The words used in this specification to describe the various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.

[74] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed

combination may be directed to a subcombination or variation of a

subcombination.

[75] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.

[76] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the embodiments.

Claims

WHAT IS CLAIMED IS:

1 . An egg carton for packaging eggs using an automated assembly line comprising:

a tray including a top rim, a plurality of cells and at least one sidewall tapering upwardly from the cells to the top rim, wherein the cells form a seating surface for said eggs such that said eggs are fully seated below the top rim of the tray;

a lid disposed on the tray to fully seal the eggs within the tray, wherein the lid is arranged and configured to receive custom printed matter thereon; and a plurality of supports disposed in the tray, wherein the supports separate the eggs therein and provide vertical support for the lid when a sealed egg carton is placed in a stacked configuration;

wherein the tray has a low coefficient of friction and open release shape such that a stacked plurality of unloaded and unsealed trays can be de-nested in an assembly line without sticking.

2. The egg carton of Claim 1 , wherein the lid is transparent.

3. The egg carton of any of Claims 1 or 2, wherein the tray is transparent.

4. The egg carton of any of Claims 1 -3, wherein the lid is a film adhesively affixed to the tray.

5. The egg carton of any of Claims 1 -4, wherein the lid is re-sealable to the tray.

6. The egg carton of any of Claims 1 -5, further comprising a plurality of breathing air pockets in the tray permitting air flow therethrough when the lid is disposed on and sealed to the tray.

7. The egg carton of Claim 6, wherein the air pockets are disposed on the top rim of the tray.

8. The egg carton of any of Claims 1 -7, further comprising a plurality of breathing air pockets in the lid permitting air flow therethrough when the lid is disposed on and sealed to the tray.

9. The egg carton of any of Claims 1 -8, wherein the lid is affixed to the tray such that separation of the lid from the tray permanently destroys affixation thereto, leaving unambiguous evidence of opening of the lid and providing a tamper proof package.

10. The egg carton of any of Claims 1 -9, wherein the lid is composed of environmentally compatible material consisting of the group of polylactide (PLA), high- density polyethylene (HDPE), polyethylene terephthalate (PET) or low-density polyethylene (LDPE).

1 1 . The egg carton of any of Claims 1 -10, wherein the tray is composed of environmentally compatible material consisting of the group of polylactide (PLA), high- density polyethylene (HDPE), polyethylene terephthalate (PET) or low-density polyethylene (LDPE).

12. The egg carton of any of Claims 1 -1 1 , further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

13. The egg carton of any of Claims 1 -12, wherein the supports have a faceted upper end with a flat, horizontal apex.

14. The egg carton of any of Claims 1 -13, wherein the supports are

chamfered and formed in part by dividing walls between the cells, the supports including smooth chamfered relief surfaces drafted inwardly to define a vertical chamfered upper surface of each support to facilitate de-nesting.

15. The egg carton of any ofClaims 1 -14, wherein the at least one sidewall of the tray further comprises at least one window.

16. The egg carton of Claim 15, wherein the at least one window is

transparent and permits visual inspection of the contents of the carton tray.

17. The egg carton of Claims 15 or 16, wherein the at least one window provides support to the tray to resist bending.

18. A method of providing packaging for eggs in an automated assembly line comprising:

providing a universal tray including a top rim, a plurality of cells and at least one sidewall tapering upwardly from the cells to the top rim, wherein the cells form a seating surface for said eggs such that said eggs are fully seated below the top rim of the tray;

filling the tray with eggs in the automated assembly line; and adhering a lid to the rim of the tray to fully seal the eggs within the tray, wherein the lid is arranged and configured to receive custom printed matter thereon such that the egg carton is universal with respect to all egg suppliers.

19. The method of Claim 18, further comprising stacking the filled cartons, wherein the tray includes a plurality of supports disposed in the tray to separate the eggs therein and provide vertical support for the lid when the sealed carton is placed in a stacked configuration.

20. The method of any of Claims 18 or 19, further comprising robotically de- nesting a stacked plurality of carton trays from each other prior to providing the universal tray to the automated assembly line, wherein the tray has an open release shape such that a stacked plurality of unloaded and unsealed trays can be de-nested in the assembly line without sticking.

21 . The method of any of Claims 18-20, wherein the lid has a pre-printed customized printed surface.

22. An egg carton for packaging eggs using an automated fill line comprising: a tray with top edges characterized by an peripheral horizontal bonding flange, and a plurality of cells defined therein into which cells the eggs are fully seated inside the tray;

a film affixed to the bonding flange sealing the eggs within the tray; and a plurality of vertical supports for the lid defined in the tray to provide vertical support for the film, where the supports have an open release shape.

23. The egg carton of Claim 22, wherein the film is transparent.

24. The egg carton of any of Claims 22 or 23, wherein the tray is transparent.

25. The egg carton of any of Claims22-24, wherein the film is tamper proof by being adhered to the bonding flange such that separation of the lid from the tray permanently destroys affixation thereto, leaving unambiguous evidence of opening of the film.

26. The egg carton of any of Claims 22-25 further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

27. The egg carton of any of Claims22-26, wherein the supports are chamfered and formed in part by dividing walls between the cells, the supports including smooth chamfered relief surfaces drafted inwardly to define a vertical chamfered upper surface of each support to facilitate de-nesting.

28. The egg carton of any of Claims22-27, wherein each support has a faceted upper end with a flat, horizontal apex.

29. An egg carton for packaging eggs using an automated assembly line comprising:

an opaque, transparent or translucent plastic tray with top edges and a plurality of cells defined therein into which cells the eggs are fully seated or positioned inside the carton with no portion of any egg extending above the top edges of the tray;

the tray having side walls and further comprises a plurality of transparent, flat windows defined in the side walls of the tray, wherein the windows provide an substantially unobstructed view of the contents of the egg carton and wherein the windows provide lateral bending stiffness;

a transparent or translucent plastic lid disposed on the tray and fully sealing the eggs within the tray; and

a plurality of air slots defined through the top edges of the tray permitting air flow therethrough when the lid is disposed on and seals the tray.

30. The egg carton of Claim 29 further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

31 . An egg carton for packaging eggs comprising:

a generally hollow tray including a plurality of cells that are arranged in an array, the cells forming a seating surface for said eggs and are defined in part by a plurality of intersecting dividers such that the eggs are separated from one another by said dividers, and

wherein each divider varies in thickness such that saiddivider is thicker near an intersection with other divider than at a location closest to a center of an adjacent cell.

32. The egg carton of Claim 31 , wherein supports are formed at the intersections of the dividers.

33. The egg carton of any of Claims31 or 32, wherein each support is formed by more than four upwardly extending surfaces.

34. The egg carton of any of Claims31 -33 further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

35. An egg carton for packaging eggs comprising:

a generally hollow tray including a plurality of cells that are arranged in an array, the cells forming a seating surface for said eggs and are defined in part by dividers such that the eggs are separated from one another, and

wherein the dividers vary in thickness such that the thickness of the dividers is largest at the midpoint between four cells.

36. The egg carton of Claim 35 further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

37. A carton for packaging eggs, wherein each egg has an equatorial diameter, comprising:

a generally hollow tray including a plurality of cells that are arranged in an array, each cell forming a seating surface that extends upwardly from a bottom surface of the cell,the bottom surfaces being generally coplanar, the tray further comprising a top rim disposed sufficiently apart from the bottom surfaces of the cells such that, when eggs are positioned in the cells, the eggs are fully seated below the top rim of the tray;and

a plurality of dividers that separate the seating surfaces of adjacent cells, wherein a least a portion of each divider extends upwardly to height above the bottom surfacesthat ishigher thanthe equatorial diameters of the eggs, when the eggs are fully seated in the cells.

38. The carton of Claim 37, wherein at least one of the dividers has a thickness that varies across one or more of the cells.

39. The carton of any of Claims36-37 further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

40. An egg carton for packaging eggs comprising:

a generally hollow tray including a plurality of cells that are arranged in an array, the cells forming a seating surface for said eggs and have a generally cylindrical shape defined by intersecting dividers such that the eggs are separated from one another, and

a plurality of supports disposed at the intersections of the dividers, wherein each support is formed by a plurality of upwardly extending surfaces, wherein the degree of vertical orientation of at least one upwardly extending surface differs from that of another upwardly extending surface.

41 . The egg carton of Claim 40 further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

42. The egg carton of any of Claims40 or 41 , wherein each support is defined by at least a first set of upwardly extending surfaces and a second set of upwardly extending surfaces, and wherein the first set of upwardly extending surfaces has a vertically steeper profile than that of the second set of upwardly extending surfaces.

43. The egg carton of Claim 42, wherein the first set of upwardly extending surfaces defines part of the adjacent cells.

44. The egg carton of any of Claims41 or 42, wherein the second set of upwardly extending surfaces defines upper edges of the intersecting dividers.

45. The egg carton of any of Claims42-44, wherein each support has a faceted upper end with a flat, horizontal apex.

46. The egg carton of Claim 45, wherein the upper end of each support has at least eight facets.

47. An egg carton for packaging eggs comprising: a generally hollow tray including a plurality of cells that are arranged in an array, the cells forming a seating surface for said eggs surface that extends upwardly from a bottom surface of the cell, and are defined in part by a plurality of intersecting dividers such that the eggs are separated from one another by said dividers, and

wherein each divider varies in thickness such that said divider is thicker near an intersection with other divider than at a location closest to a center of an adjacent cell.

48. The egg carton of Claim47, wherein the tray is transparent.

49. The egg carton of any of Claims 47 or 48, further comprising a lid disposed on the tray to fully seal the eggs within the tray, wherein the lid is arranged and configured to receive custom printed matter thereon.

50. The egg carton of Claim 49, wherein the lid is transparent.

51 . The egg carton of any of Claims 49 or 50, wherein the lid is a film adhesively affixed to the tray.

52. The egg carton of any of Claims 49-51 , wherein the lid is re-sealable to the tray.

53. The egg carton of any of Claims47-52, further comprising a plurality of breathing air pockets in the tray permitting air flow therethrough when the lid is disposed on and sealed to the tray.

54. The egg carton of any of Claims 47-53, further comprising a top rim.

55. The egg carton of Claim 54, wherein the top rim is disposed sufficiently apart from the bottom surfaces of the cells such that, when eggs are positioned in the cells, the eggs are fully seated below the top rim of the tray.

56. The egg carton of any of Claims 54 or 55, wherein the air pockets are disposed on the top rim of the tray.

57. The egg carton of any of Claims 47-56, further comprising a plurality of breathing air pockets in the lid permitting air flow therethrough when the lid is disposed on and sealed to the tray.

58. The egg carton of any of Claims 49-57, wherein the lid is affixed to the tray such that separation of the lid from the tray permanently destroys affixation thereto, leaving unambiguous evidence of opening of the lid and providing a tamper proof package.

59. The egg carton of any of Claims 49-58, wherein the lid is composed of environmentally compatible material consisting of the group of polylactide (PLA), high- density polyethylene (HDPE), polyethylene terephthalate (PET) or low-density polyethylene (LDPE).

60. The egg carton of any of Claims47-59, wherein the tray is composed of environmentally compatible material consisting of the group of polylactide (PLA), high- density polyethylene (HDPE), polyethylene terephthalate (PET) or low-density polyethylene (LDPE).

61 . The egg carton of any of Claims47-60, further comprising longitudinal ribs on the surface of the cells of the tray to provide rigidity and strength to the carton.

62. The egg carton of any of Claims 47-61 , wherein supports are formed at the intersections of the dividers.

63. The egg carton of Claim 62, wherein each support is formed by a plurality of upwardly extending surfaces.

64. The egg carton of Claim 63, wherein the degree of vertical orientation of at least one upwardly extending surface differs from that of another upwardly extending surface.

65. The egg carton of Claim 62 or 64, wherein the plurality of upwardly extending surfaces includes at least a first set of upwardly extending surfaces and a second set of upwardly extending surfaces.

66. The egg carton of Claim 65, wherein the first set of upwardly extending surfaces has a vertically steeper profile than that of the second set of upwardly extending surfaces.

67. The egg carton of Claim 66, wherein the first set of upwardly extending surfaces defines part of the adjacent cells.

68. The egg carton of any of Claims 66 or 67, wherein the second set of upwardly extending surfaces defines upper edges of the intersecting dividers.

69. The egg carton of any of Claims 62-68, wherein the supports have a faceted upper end with a flat, horizontal apex.

70. The egg carton of Claim 69, wherein the upper end of each support has at least eight facets.

71 . The egg carton of any of Claims 62-70, wherein each support is formed by more than four upwardly extending surfaces.

72. The egg carton of any of Claims62-71 , wherein the supports are chamfered dividing walls between the cells, the supports including smooth chamfered relief surfaces drafted inwardly to define a vertical chamfered upper surface of each support to facilitate de-nesting.

73. The egg carton of any of Claims 47-62, further comprising at least one sidewall that extends upwardly from a bottom surface of at least one cell.

74. The egg carton of Claim 73, wherein the at least one sidewall extends to the top rim.

75. The egg carton of any of Claims73 or 74, wherein the at least one sidewall of the tray further comprises at least one window.

76. The egg carton of Claim 75, wherein the at least one window is

transparent and permits visual inspection of the contents of the carton tray.

77. The egg carton of Claims 75 or 76, wherein the at least one window provides support to the tray to resist bending.

78. The egg carton of any of Claims 47-77, wherein the bottom surfaces are generally coplanar.

79. The egg carton of any of Claims 47-78, wherein at least a portion of each divider extends upwardly to height above the bottom surfaces that is higher than an equatorial diameter of the eggs, when the eggs are fully seated in the cells.

80. The egg carton of any of Claims 49-79, wherein the lid is a film.

81 . The egg carton of any of Claims 54-80, wherein the top rim further comprises a peripheral horizontal bonding flange.

82. The egg carton of Clainn 81 , wherein the lid is affixed to the bonding flange sealing the eggs within the tray.

83. The egg carton of any of Clainn 47-82, wherein a wall of each cell has a draft angle that varies along its height.

84. The egg carton of Clainn 83, wherein the variation of draft angle is symmetric on all sides of the cell.