US3260441A - Egg carton and blank therefor - Google Patents

Description

y 2, 1966 I M. KOLTZ ETAL 3,260,441

EGG CARTON AND BLANK THEREFOR Filed p 21, 1964 3 Sheets-Sheet 1 E9 INVENTORS l. Morton KOLTZ Jack B. ROZEN A TTORNEY July 12, 1966 1. M. KOLTZ ETAL EGG CARTON AND BLANK THEREFOR 3 Sheets-Sheet 2 Filed Sept. 21, 1964 INVENTORS l. Morton KOLTZ Jack B. ROZEN WLaQ r W ATTORNEY I. M. KOLTZ ETAL EGG CARTON AND BLANK THEREFOR July 12, 1966 5 Sheets-Sheet 3 Filed Sept. 21, 1964 INVENTORS Morton KOLTZ Jack B. ROZEN ATTORNEY United States Patent 3,260,441 EGG CARTON AND BLANK THEREFOR Irving Morton Koltz, Montreal, Quebec, and Jack Benjamin Rozen, Chomedey, Quebec, Canada, assignors to POP Design Consultants of Canada Ltd., Montreal,

Quebec, Canada Filed Sept. 21, 1964, Ser. No. 397,716 14 Claims. (Cl. 229-28) This invention relates to egg cartons.

For ease of handling and for their protection, eggs, during their retail distribution and marketing, are invariably packed in sixes or dozens in cardboard cartons. The cartons employed are conventionally produced from one-piece scored and cut blanks by means of folding operations. The blanks, when erected, provide a pocket for each egg. Many millions of egg cartons are required annually and, as each carton is only used once, large quantities of board are devoted to the production of egg cartons. In view of the number of cartons, a small saving in the amount of board required for each carton results in a considerable saving in the amount of board required per annum with immediately apparent economies.

It is an object of the present invention to provide an egg carton which is formed from a blank having a smaller area than the blanks required for heretofore proposed cartons of comparable size while at the same time ensuring that the carton affords superior protection for the eggs contained therein.

A further object of the invention is to provide an egg carton which does not rely for its stability entirely on the interlocking action between various parts of the carton but which has a stable, permanent joint.

Yet another object of the invention is to provide a carton which can be erected from a blank by hand or by using a simple tool. Such a carton can be distributed, in blank form, to the poultry stations and can be erected readily without the necessity of providing complicated equipment at the poultry stations. Once the cartons have been erected and filled by the poultry farmer they are immediately ready for forwarding to the retailer: the eggs consequently do not have to be shipped while unprotected with the consequent risk of breakage.

The invention will now be described in greater detail with reference to the accompanying drawings in which:

FIGURE 1 is a perspective view of an egg carton according to the present invention,

FIGURE 2 is a top plan View of part of the carton of FIGURE 1,

FIGURE 3 is a section on the line 33 of FIGURE 2,

FIGURE 4 is an end view of the carton of FIG- URE 1,

FIGURE 5 is a section on the line 55 of FIG- URE 2,

FIGURE 6 is a longitudinal section of the egg carton according to the present invention,

FIGURE 7 is a plan view of the blank from which the egg carton is produced,

FIGURE 8 is a view of one side of the blank of FIGURE 7 after the blank has been folded,

FIGURE 9 is an end view of the blank of FIGURE 8,

FIGURE 10 is a View of the blank of FIGURE 8 with the blank turned through 180 about the bottom edge thereof as viewed in FIGURE 8, 1

FIGURE 11 is a section similar to that of FIGURE 5 but showing one pocket only and an egg in the pocket, and

FIGURE 12 is a view of a modified part of the blank of FIGURE 7.

' The carton which forms the subject of the present invention is illustrated in FIGURE 1 and is generally designated by the reference 10. It is believed that the construction of the carton will more readily be understood from a description of the blank, generally indicated at 11, from which the carton is produced, and from a description of the manner in which the blank is folded and glued to form the carton, than from a description of the carton construction per se. The following description is set out in accordance with this idea.

To facilitate the description, the top to bottom dimension of the blank, as viewed in FIGURE 7, will be considered to be the length of the blank, and the left to right dimension its width. Lines running top to bottom in FIGURE 7 are thus longitudinal and lines running across the blank are transverse. The blank 11 from which the carton is produced is a mirror image about its longitudinal centerline and is almost a mirror image about the transverse line AA. The part of the blank below the transverse line AA, as viewed in FIGURE 7, differs from the part of the blank above that line in that it is somewhat longer and its free edge has a modified shape to be described hereinafter.

The blank 11, of board of suitable thickness, effectively includes seven areas or panels 12 to 18, the boundaries of which are constituted by the transverse edges of the blank and by perforated, zig-zagging lines 19 to 24 extending across the blank. The panel 12 is strip-like in form and is bounded by one transverse edge of the blank 11 and by the line 19. The line 19 is part of, and forms one boundary of, a pattern of score lines and cuts which is repeated six times across the Width of the blank. This pattern is contained in the area 13. The line 20 is part of, and forms the other boundary of this pattern. The pattern includes two spaced apart straight perforated lines 26 and 27 which extend transversely of the blank, and a series of perforated lines 28 which run longitudinally of the blank between the lines 26 and 27. These lines 26 to 28 together define a series of six rectangles 29, and the lines 26 and 27 in conjunction with the lines 19 and 20 respectively, define a series of triangles. Each triangle is divided into three parts by two out lines 30 and 31. The cut lines 30 and 31 and part of the lines 19, 26 and 20, 27 define small five-sided tabs. The tabs 32 are only attached to the remainder of the blank on two of their five sides as those parts of thelines 26 and 27 which form the sides of the tabs 32 are out rather than perforated.

Each rectangle is divided into two equal flaps 29A by by a cut 33 extending in the direction of the length of the blank. Further lines 34, formed partly by cutting and partly by perforating, are provided on each side of the line 23 and together define a tear drop shape. The middle portion of each line 34 is perforated and the end portions of each line 34 are cut. This arrangement results in the formation of small tabs 29B.

Adjacent rectangles share a common perforation line 28 with the exception of the middle pair of rectangles whose bounding perforation lines are spaced from one another somewhat in the direction of the width of the blank thereby to form a bar 35.

The middle part of the blank, that is the part immediately on each side of the line AA, includes a pair of parallel perforated lines 36 and 37 extending transversely of the blank. Longitudinally extending perforated lines 38 which join the lines 36 and 37, and longitudinally extending cuts 39 which are somewhat longer than lines 38 and extend on both sides of lines 36 and 37, are provided in the area 15. These lines 36, 37, 38 and 39 divide the central part of the blank into a number of flaps. The lines 38 and 39 are not equally spaced apart so that there is formed flaps 40 which are of greater width than the remaining flaps 41. Two flaps 40 are at the edges of the blank and the remaining two flaps 40 are centrally of the blank.

The lines 21 and 22, together with the lines 36 and 37, define a series of triangles which are each divided into two parts by one of the lines 39. Each line 39 has a small cutout 42 at the center thereof, and star-like cuts 43 on each side of each cutout 42.

As the panel 16 is similar to the panel 14, and the area 12 is similar to the area 13, neither the area 17 nor the panel 16 will be described in detail. However, it should be noted that the area 17 includes two transverse perforated lines 44 and 45.

The panel 18 differs from the panel 12 in that the panel 18 is somewhat larger than the panel 12 and includes, along the transverse edge of the blank, a series of six cutouts 46. Each cutout 46 is narrower at its mouth than at its closed end and the edge 47 which forms the closed end of the cutout 44 is triangular in shape with its apex pointing towards the open end of the cutout.

The manner in which the blank 11 is folded and glued to form the egg carton 10 will now be described. The first step is to fold the blank about the lines 26 and 44 so that the panel 12, and the panel 18 and area 17, overlie the remainder of the blank. The surface of the panel 12 which is now uppermost, that is, the surface which is not visible in FIGURE 7, is then coated with adhesive and the panel is folded once more, this fold being about the line 36. This results in the coated surface of the panel 11 coming into contact with the surface of the panel 18 which, upon the panel being folded about the line 44 becomes the uppermost one. The panels 12 and 18 are pressed into engagement with one another so that they become firmly adhered together. The blank then assumes the form illustrated in FIGURES 8, 9 and 10. From FIGURE 9 it will be seen that the blank can now be considered to be a collapsed sleeve having three 180 bends therein. The lines 26, 44 and 36 coincide with these bends. All three bends are then opened out into 90 bends so that the blank assumes the form of a rectangular sleeve which is divided into two parts by a vertical Wall constituted by the panels 12 and 18. The panel 12 extends alongside the panel 18 for a short way from the top of the panel 18 but terminates considerably above the lower edge of the panel 18.

As described, the provision of the perforated lines 26, -27 and 28 and the cuts 33 gives rise to a number of flaps 39A which are joined to one another along one of the lines of perforations 28. This will readily be seen from FIGURE 7. The next stage in the erection of the carton is to press each one of these flaps 29A inwardly by bending them about the separating lines 28. The effect of pressing down on the flaps 29A is to open up two rows of six holes elongated in the direction of the width of the carton. Each hole is of sufiicient size to have an egg pushed therethrough into the interior of the carton. The holes formed are referenced 48 in FIGURE and one hole 48 is also visible in FIGURE 11. The flaps 40 and 41 of the blank are pressed upwardly towards the interior of the carton and simultaneously the central parts of adjacent fiaps 40 and 41 are squeezed towards one another about the lines 38 so that each fold line 38 effectively becomes a 180 bend and the adjacent flaps 40, 41 at their central parts, lie in face-to-face contact. The cuts 43 form points of Weakness along the edges of the flaps 40 and 41 and enable the middle portions of the these flaps, that is, the portions between the pairs of cuts 43, to be squeezed towards one another without unduly displacing the parts of the flaps which are outside the cuts 43. In this condition the free edges of the flaps 40 and 41 can be entered in the cutouts 46, and when these flaps are released the natural tendancy which they have to spring apart about the fold lines 38 presses these flaps into firm engagement with the side walls of the cutouts 46. The tapering configuration of each cutout 46 prevents the two flaps entered therein from leaving the cutout and the shaped end walls 45 enter and interlock with the cutouts 42 thereby improving the stability of the connection between the panel 18 and the flaps 40 and 41.

At the time that the flaps 29B are pressed inwardly the small tabs 32 are unaffected by this action as they are separated from the flaps 29B by the cuts which form parts of the lines 26 and 27. Consequently, as the panels 12, 14, 16 and 18 to which the tabs 32 are attached take up vertical positions When the carton is erected, these tabs 32 also take up vertical positions and as shown in FIGURE 11 project upwardly above the level of the eggs contained within the carton thereby to protect the eggs from damage when the cartons are stacked. Thus the carton 10, as illustrated in FIGURE 1, includes two spaced apart side walls 14 and 16, a number of upwardly open V-shaped lower ribs composed of the flaps 40 and 41 and forming the bottom of the carton, a central wall structure composed of the panels 1 2 and 18, and a top composed of a number of downwardly open upper V- shaped ribs formed by the flaps 29A. Each upper rib is in two parts, each part extending from one side wall to the central wall structure. The transverse lower and upper ribs are spaced apart longitudinally of the carton and the upper and lower ribs are staggered so that the spaces between the lower ribs are all vertically below the spaces between the upper ribs so that each lower rib and the two upper ribs above the spaces immediately to each side of said lower rib form a pair of side-by-side egg receiving cells.

FIGURE 11 illustrates the manner in which the tabs 29B cooperate with an egg seated in one of the cells of the carton. These tabs 29B are deformed as the egg is pushed into the carton through the hole 46, and due to their natural resiliency, remain in engagement with the egg, to maintain the egg in a fixed position Within the carton.

FIGURE 12 illustrates a slightly modified form for the panels 29A and tabs 29B. In this arrangement the free edge of each fiap 29A has adjacent thereto a pair of score lines 49, the score lines 49 defining, with the free edge of the flap 29A, a triangular configuration which is split in two by a out line 50 substantially normal to the free edge and extending from the free edge to the junction between the lines 49.

We claim:

1. A multicellular carton erected from a one-piece blank and comprising first and second spaced apart side walls extending longitudinally of the carton, a plurality of first ribs spaced apart longitudinally of the carton and together forming a bottom for the carton, said first ribs being integral with said side walls and extending transversely across the carton from said first side wall to said second side wall, a central wall structure having top and bottom edges and extending longitudinally of the carton between said side walls, said bottom edge and said first ribs being secured together, and a plurality of second ribs spaced apart longitudinally of the carton and together forming a top for the carton, said second ribs each being integral with one of said side walls and with said central wall structure and each extending between one of said side walls and said central wall structure, and the second ribs being staggered with respect to said first ribs whereby spaces between adjacent first ribs are each immediately below second ribs, each first rib and those second ribs which are immediately above the spaces on each side of that first rib defining a pair of cells sideby-side in the transverse direction of the carton.

2. A carton according to claim 1 in which each first rib is of upwardly open V-shape and includes two sloping panels joined together along a fold line.

3. A carton according to claim 2 in which said second ribs include downwardly sloping panels.

4. A carton according to claim 3 in which each of said second ribs, apart from those second ribs at the longitudinal extremities of the carton, is of downwardlyopen V-shaped consisting of two panels joined together along a fold line, and said second ribs at said extremities each consists of a single downwardly sloping panel.

5. A multicellular carton erected from a one-piece blank and comprising two spaced apart side walls extending longitudinally of the carton, a plurality of first ribs spaced apart longitudinally of the carton and together forming a bottom for the carton, each first rib being of upwardly open V-shape, being integral with said side walls and extending transversely of the carton therebetween, a central wall structure extending longitudinally of the carton between said side walls and having a lower edge in which a plurality of cutouts are formed and which cutouts receive and retain said first ribs, and a plurality of second ribs spaced apart longitudinally of the carton and together forming a top for the carton, said second ribs each being integral with one of said side walls and with said central wall structure and each extending between one of said side walls and said central Wall structure, and the second ribs being staggered with respect to said first ribs whereby spaces between adjacent first ribs are each immediately below second ribs, each first rib and those second ribs which are immediately above the spaces on each side of that first rib defining a pair of cells side-by-side in the transverse direction of the carton.

6. A carton according to claim 5 in which each of seid cutouts has a mouth coinciding with said edge, and an end wall, the cutouts each tapering from said mouth to said end Wall.

7. A carton according to claim 6 in which each first rib includes two panels which slope upwardly and away from one another and are joined at their lower edges along a fold line.

8. A multicellular carton erected from a one-piece blank and comprising two spaced apart side walls extending longitudinally of the carton, a plurality of first ribs spaced apart longitudinally of the carton and together forming a bottom for the carton, said first ribs being integral with said side walls, and extending transversely of the carton between said side walls, a central wall structure extending longitudinally of the carton between said side walls and consisting of a first central wall and a second central wall which are adhered together, said first central wall being of greater height than said second central wall and having a lower edge to which said first ribs are secured, and a plurality of second ribs spaced apart longitudinally of the carton and together forming a top for the carton, each second rib being in two aligned parts one of which is integral with a first of said side wall and with said first central wall, and the other of which is integral with a second of said side walls and with said second central wall, and the second ribs being staggered with respect to said first ribs whereby spaces between adjacent first ribs are each immediately, below second ribs, each first rib and those second ribs which are immediately above the spaces on each side of that first rib defining a pair of cells side-by-sicle in the transverse direction of the carton.

9. A carton according to claim 8 in which each of said first and second central walls is joined to the associated rib parts along a zig-zagging fold line.

10. A blank for a multicellular carton of the type having two longitudinally extending side walls, a bottom structure, a top structure, and a central wall structure extending longitudinally of the carton between said side walls and dividing the carton into two parts, the blank being substantially rectangular in shape and having transverse and longitudinal edges, and consisting, in series between said transverse edges, of a first panel bounded by a first fold line and by one of said transverse edges and adapted to form part of said central wall structure, a second panel bounded by said first fold line and a second fold line, said second panel being cut and scored to define a side-by-side series of pairs of flaps transversely of the blank, the flaps of each pair being joined together along a fold line and adjacent pairs being separated by out lines whereby said pairs of fiaps can be pressed out of the plane of the blank to form downwardly open V- shaped ribs forming part of said top structure, a third panel adapted to form one of said side walls and bounded by said second fold line and by a fold score line, a fourth panel bounded by said third fold line and by a fourth fold line, said fourth panels being cut and scored to define a side-by-side series of pairs of flaps transversely of the blank, the fiaps of each of these pairs being joined together along a fold line and adjacent pairs being separated by cut lines whereby these pairs of fiaps can be pressed out of the plane of the blank to form upwardly open V-shaped ribs adapted to constitute said bottom of the carton, a fifth panel bounded by said fourth fold line and a fifth fold line, said fifth panel being adapted to form a second side wall for the carton, a sixth panel bounded by said fifth fold line and by a sixth fold line, the sixth panel being cut and scored to define a side-by-side series of pairs of flaps transversely of the blank, the flaps of each pair being joined together along fold lines and adjacent pairs being separated by cut lines whereby these pairs can be pressed out of the plane of the blank to form downwardly open V-shaped ribs forming part of said top structure, the V-shaped ribs of the second and sixth panels being aligned longitudinally of the blank, and being staggered with respect to the V- shaped ribs of said fourth panel, and a seventh panel bounded by said sixth fold line and by the other transverse edge of the blank, said seventh panel being adapted to be adhered to said first panel to constitute said central wall structure, said other transverse edge being adapted for connection to the central parts of said ribs.

11. A blank according to claim 10 in which said other transverse edge includes a series of cutouts having mouths which coincide with that edge, and end walls, the cutouts tapering such that they are wider at their mouths than at their end walls.

12. A blank according to claim lit, in which each of the flaps of the second and sixth panels has, adjacent its free edge, a pair of score lines defining with the free edge, a triangular configuration split in two by a out line substantially normal to said free edge and extending from the free edge to the junction between said pair of score lines.

13. A blank according to claim 10, wherein said first through sixth fold lines each consist of first and second perforated lines, each first perforated line being straight and each second perforated line zigzagging, the first and second perforated lines together defining six rows of triangles extending transversely of the blank are formed.

14. A blank according to claim 10, wherein said first, second, fifth and sixth fold lines each consist of first and second perforated lines, each first perforated line being straight and each second perforated line Zig-zagging, the first and second perforated lines together defining four rows of triangles, the rows extending transversely of the blank, and each triangle being slit into three parts by two cut lines thereby to provide tabs which project upwardly when the carton is erected.

References Cited by the Examiner FOREIGN PATENTS 7/1964 Great Britain.

GEORGE O. RALSTON, Primary Examiner.

Claims (1)

1. A MULTICELLULAR CARTON ERECTED FROM A ONE-PIECE BLANK AND COMPRISING FIRST AND SECOND SPACED APART SIDE WALLS EXTENDING LONGITUDINALLY OF THE CARTON, A PLURALITY OF FIRST RIBS SPACED APART LONGITUDINALLY OF THE CARTONS AND TOGETHER FORMING A BOTTOM FOR THE CARTON, SAID FIRST RIBS BEING INTEGRAL WITH SAID SIDE WALLS AND EXTENDING TRANSVERSELY ACROSS THE CARTON FROM SAID FIRST SIDE WALL TO SAID SECOND SIDE WALL, A CENTRAL WALL STRUCTURE HAVING TOP AND BOTTOM EDGES AND EXTENDING LONGITUDINALLY OF THE CARTON BETWEEN SAID SIDE WALLS, SAID BOTTOM EDGE AND SAID FIRST RIBS BEING SECURED TOGETHER, AND A PLURALITY OF SECOND RIBS SPACED APART LONGITUDINALLY OF THE CARTON AND

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