CN117580781A - Packaging unit made of molded pulp material with self-aligning elements and method for manufacturing the packaging unit - Google Patents

Abstract

The invention relates to a packaging unit (2) made of molded pulp material, a method for packaging a product and a method for manufacturing such a packaging unit. The packaging unit includes: -a bottom part (4), the bottom part (4) having a product receiving compartment for receiving a respective product, wherein the bottom part has at least a bottom front (8), a bottom rear (14) and two bottom sides (10, 12); a cover part (6), the cover part (6) having at least a cover front (20), a cover top (18) and two cover sides (22, 24); a hinge element (28), the hinge element (28) being for hingedly connecting the lid portion and the bottom portion; and a locking member (30) for locking the bottom portion and the lid portion in a closed position of the packaging unit, and wherein the bottom side and the lid side comprise side edges with self-aligning elements (56).

Description

Packaging unit made of molded pulp material with self-aligning elements and method for manufacturing the packaging unit

The invention relates to a packaging unit made of moulded pulp material (moulded pulp material). These packaging units are used for storing, transporting and/or displaying products such as eggs.

Packaging units for eggs, such as egg cartons, containers or cartons, are known in practice and are typically manufactured from molded pulp material derived from cellulose fibers. Such packaging units comprise a bottom part provided with compartments for individual products and a cover part (cover part), which is usually hingedly connected to the bottom part. Products such as eggs are stored, transported and displayed in these packaging units. An example of such an egg carton is shown in WO 2015/160248 A1, which shows a packaging unit comprising a hingedly connected bottom part and cover part, and further comprising a locking member (lock) configured for locking the cover part and the bottom part in a closed position of the packaging unit.

In handling such a packaging unit, forces act on all sides of the packaging unit, including the rear side of the packaging unit, which is typically provided with a hinge. This may result in the cover portion moving relative to the base portion. This may result in unlocking of the packaging unit if the cover part is moved forward relative to the bottom part, because the opening in the cover part is disengaged from the locking cam in the bottom part. This may occur, for example, when the packaging units filled with the product are transported on an automated packaging machine line. This situation may lead to damage of the product, the packaging unit and/or a stop of the packaging machine production line. In the case of so-called tab-less designs (designs) of packaging units, this effect occurs more frequently, because the product cannot "push" the tab in the forward direction to compensate for the undesired relative movement between the lid and bottom parts of the packaging unit.

It is an object of the present invention to obviate or at least reduce one or more of the above problems of conventional packaging units, such as egg cartons, and to provide a suitable packaging unit capable of conveniently displaying products.

To this end, the invention provides a packaging unit made of molded pulp material, wherein the packaging unit according to the invention comprises:

a bottom portion having a product receiving compartment for receiving a respective product, wherein the bottom portion has at least a bottom front, a bottom surface and two bottom sides;

a lid portion having at least a lid front, a lid top and two lid sides;

a hinge element for hingedly connecting the lid portion and the bottom portion; and

a locking member for locking the bottom part and the cover part in the closed position of the packaging unit, and

wherein the bottom side and the lid side comprise side edges with self-aligning elements.

The packaging unit according to the invention is manufactured from a moulded pulp material, which may be derived from soft and/or hard wood fibres and/or recycled cellulose fibres and/or other suitable fibres. The packaging unit comprises a bottom portion and a lid portion, which are hingedly connected to each other by means of a hinge element, such as a hinge. The bottom portion and the lid portion of the packaging unit each comprise a front surface, a rear surface and two side surfaces. In addition, the bottom portion includes a bottom surface and the cover portion includes a top surface.

For example, the bottom portion is provided with a product containing compartment capable of receiving and containing a respective product (e.g. eggs) and also similar products (e.g. kiwi and tomatoes). Preferably, one or more cone portions (cone) are provided between adjacent compartments to provide additional support to the packaging unit.

Furthermore, the packaging unit preferably comprises a locking member configured for locking the bottom portion and the lid portion in the closed position of the packaging unit. In a presently preferred embodiment, the lock comprises a first locking element (such as a cam element) in the bottom portion and a second locking element (such as an opening) in the cover portion. For example, in the closed position, the locking element engages such that the opening is positioned above the locking cam.

In the closed position of the packaging unit, the side edges of the cover part and the side edges of the bottom part are joined to each other. More specifically, the side edges of the cover portion rest on the side edges of the bottom portion. These side edges extend between the back or rear surface and the front surface of the packaging unit. According to the invention, the side edges comprise self-aligning elements. Such self-aligning elements may include specially shaped or formed elements that allow for such self-aligning effects.

When a load or force acts on the lid top of the lid portion in the closed position of the packaging unit, the lid portion is (further) pushed onto or against the bottom portion and the self-alignment effect between the lid portion and the bottom portion is further enhanced. This even better ensures a correct and optimal positioning of the cover part with respect to the bottom part. This reduces the risk of product damage, damage to the packaging unit and downtime of the automated packaging machine production line, for example.

In addition, it has been shown that the self-aligning element provides additional support for relative movement between the cover portion and the bottom portion in a substantially horizontal direction or in other words in a direction or plane substantially parallel to the top surface of the cover. This effectively prevents the opening in the lid portion from moving onto the locking cam element in the bottom portion resulting in an undesired opening of the packaging unit. This applies to different designs of the packaging unit, including the so-called wingless design of the packaging unit. As previously mentioned, in the vaneless design, the tab with the locking cam element is not pushed forward by the product with the lid portion to compensate for at least a portion of the relative movement between the lid portion and the bottom portion. In fact, the effect of the self-aligning element improves both the non-flap packaging unit and the flap packaging unit.

One advantage of self-aligning elements is increased stability, also when moving on an automatic packaging line. Typically, when one packaging unit is stopped on a packaging line, the next packaging unit is quickly stopped against the other packaging unit with the back. The self-aligning element prevents the lid portion/cover from moving forward and in this way prevents the opening/closing aperture from moving over the closing arc (dock)/cam, which in turn would allow the packaging unit to be opened inadvertently in inconvenient places. Thus, the self-aligning element may prevent damage to the product, the packaging unit and/or a stop of the packaging line. Such a self-aligning element is particularly advantageous for so-called tab-less designs of the packaging unit.

As a further effect of the packaging unit according to the invention, the stability of the bundle of packaging units during transport and storage is significantly improved. In transportation and storage, the packaging units are typically packaged as bundles, which are typically positioned with their side edges. Providing the side edge with a self-aligning element changes the shape of such edge from a straight line or substantially straight line to a more stable shaped edge when positioned with the side edge. This improves storage and transport and reduces the risk of damaging the side edges of the packaging unit during transport and storage.

The self-aligning element is shaped or formed to enable a self-aligning effect when the cover portion of the packaging unit is placed on top of the bottom portion. A variety of shapes may be applied for the element, including circular shapes, saw tooth shapes, semi-circular shapes, triangular/tooth shapes, and other suitable shapes. As an even further effect of the self-aligning element, the strength of the packaging unit is further improved. This is achieved by better fixing the position of the cover part relative to the bottom part in the closed position of the packaging unit. Furthermore, the self-aligning element prevents such positioning of the cover part relative to the bottom part, in particular in the horizontal direction, so that the strength and stability of the packaging unit is also maintained in case of forces or loads acting on the packaging unit. Furthermore, the self-aligning element provides slightly more molded pulp material at a specific location of the packaging unit. Such additional material contributes to the overall strength and stability of the packaging unit. This increase in the strength of the packaging unit becomes increasingly relevant as fibrous materials derived from recycled paper have shorter fiber lengths. These shorter fibers reduce the strength of the packaging unit. Thus, providing self-aligning elements may counteract such strength loss due to a reduction in fiber length, particularly when processing recycled paper material. Tests have been carried out which show that in case a load of 30kg-40kg on the top surface of the packaging unit can be handled, a similar conventional (no-fin) packaging unit collapses.

In a presently preferred embodiment, the self-aligning element is positioned substantially in the front half of the side edge as seen in the closed position of the packaging unit.

This front half of the side edge is associated with the front half of the cover portion and the bottom portion towards the front thereof in the closed position of the packaging unit. This specific position of the self-aligning element improves the fixation of the lid portion and the bottom portion in the closed position of the packaging unit, thereby further reducing the risk of undesired or unintended opening of the packaging unit.

In a presently preferred embodiment, the self-aligning element comprises a smooth curvature.

The smooth curvature may relate to a smooth semi-circular portion or a smooth bulge, which is arranged in an upward or downward direction, as seen in the closed position of the packaging unit. This smooth shape prevents sharp edges on the side edges as seen in the back-to-front direction of the packaging unit. This has the advantage that it is easier to maintain this smooth curvature in time even in case of repeated opening and closing of the packaging unit. Sharp edges are often damaged and this may lead to a low functionality packaging unit. Preferably, the self-aligning element is provided with a wave shape. This smooth wave-shaped curvature provides a functional packaging unit, wherein the wave-shape further enhances the visual effect corresponding to the shape of the product intended to be placed in the packaging unit. Furthermore, the wave shape provides a smooth closing of the packaging unit even in the presence of disturbing forces acting on the packaging unit. Furthermore, the wave shape is minimized and even the risk of inaccurate and/or incorrect closing of the packaging unit when handling the packaging unit (e.g. when filling the packaging unit with a product) is avoided. This further reduces the risk of product loss or product damage.

In a presently preferred embodiment, the packaging unit is provided with a so-called raised hinge. Such a raised hinge provides greater stability to the packaging unit, especially in an automated packaging machine line. In an embodiment of the invention provided with such a raised hinge, the side edges of the bottom part and the side edges of the cover part are effectively inclined in a downward direction in the closed position of the packaging unit, as seen in a rear-to-front direction.

Preferably at the back side of the packaging unit, a raised hinge connects the bottom part and the lid part of the packaging unit. A hinge is provided between the bottom part and the cover part, because the raised hinge positions the hinge at a higher position from the ground surface. This enables the front surface of the cover portion to be arranged to extend below the raised hinge of an adjacent packaging unit. This reduces the space required for two or more packaging units placed adjacent to each other. This is also advantageous in case the gripper and vacuum head grip and pick up several packaging units at a time during the packaging operation. This improves the efficiency of the packaging operation. Preferably, the hinge width is reduced compared to conventional hinge widths. This contributes to overall size reduction and improved packaging operations. In addition, the combination of the raised hinge and the self-aligning element further improves the self-aligning effect, as the raised hinge enhances the closure of the self-aligning element.

In a presently preferred embodiment of the invention, the side edges of the lid portion and/or the side edges of the bottom portion comprise at least one de-nesting support portion (denesting support part), and wherein the at least one de-nesting support portion is located within 20% of the total length of the side edges in the back-to-front direction from the lid front and bottom front.

Providing a de-nesting support portion contributes to the overall strength of the packaging unit. By providing more molded pulp material, strength is improved. The denesting support portion helps to denesting the packaging units from the stack (stack). The front of the denesting section is often of paramount importance in an automated packaging machine line. By positioning the denesting support portion at a distance of about 20% of the total length of the side edges from the front surface, the denesting support portion improves the denesting operation and, in addition, contributes to the strength and stability of the packaging unit at relatively important locations near the corners of the packaging unit. Preferably, the positioning of the denesting support portion at least partially overlaps the self-aligning element. This further increases the strength and stability of the packaging unit and also better maintains the overall shape of the packaging unit.

Preferably, the denesting support portion comprises a bottom support portion and a lid support portion, which are provided on the bottom portion and the lid portion, respectively, and which engage each other in the closed position of the packaging unit to form the denesting support portion. More preferably, each side of the packaging unit is provided with two denesting support portions, one denesting support portion being positioned towards the front of the packaging unit and one denesting support portion being positioned towards the rear of the packaging unit as seen in the rear-to-front direction. The one or more denesting support portions facilitate the fixation of the cover portion, in particular in the corner portions of the packaging unit, thereby facilitating the overall support.

Preferably, in case two or more denesting support portions are provided, these portions are also preferably arranged within the above mentioned 20% distance from the front or rear of the packaging unit. More preferably, the denesting support element is provided within 15% of the total length of the side edge from the front of the lid and/or the front of the bottom.

In a presently preferred embodiment of the invention, the lid side and the bottom side comprise one or more ribs extending substantially from the top surface of the lid portion in the direction of the bottom surface, and wherein the ribs protrude from the side surfaces and provide additional support for the lid portion and the bottom portion when stacking a plurality of packaging units.

Providing ribs extending from the top surface to the bottom surface in a substantially vertical direction increases the strength of the packaging unit according to the invention. This is particularly useful in stacks of packaging units, which are typically stacked crosswise. The ribs significantly improve the stability of such stacks.

Providing self-aligning elements in the side edges of the packaging unit according to the invention makes it possible to better fix the relative positions of the cover part and the bottom part. This also allows for better alignment of the ribs of the bottom part and the ribs of the cover part within one packaging unit and between different packaging units in the stack. This better ensures the stability of such stacks during transport, for example.

Preferably, the ribs are provided with substantially straight edges to provide strength and stability and also to provide transmission of forces acting on the packaging unit (e.g. on a stack of packaging units). Alternatively, the edges extend at a relatively small angle with respect to the vertical, as seen in the back-to-front direction. This may further improve the transmission of forces under certain conditions. Furthermore, the ribs are preferably arranged at an angle to the vertical direction together with the side surfaces in the width direction or left to right direction of the packaging unit, wherein the angle is for example about 15 °.

Having the ribs protruding from the side surfaces and extending the ribs from the top surface to the bottom surface provides additional support surfaces for the top and bottom surfaces of the packaging unit. Providing an additional cover support surface increases the contact surface of the cover portion with the bottom portion of another packaging unit placed on top of the packaging unit. This provides a more stable stack of packaging units. Furthermore, any misalignment of the stacked packaging units has less impact on the stability of the entire stack. The same is true when the packaging units are stacked crosswise on top of each other. In fact, this combination of cross stacking and providing additional cover support surfaces significantly improves the stability of the stack. As a further effect, the increased stability may also increase the strength of the stack as a whole, so that the stack height may be safely increased. This may make transportation and storage more efficient. In a presently preferred embodiment, the dimensions of the additional bottom support surface substantially correspond to the dimensions of the additional lid support surface.

Preferably, the additional cover support surface of one rim has a thickness of at least 0.35cm ² Is provided. Experiments have shown that 0.35cm ² To 2.5cm ² Additional support surface area within the range provides good results and optimal stability of the stacked packaging units.

Also preferably, the rim has an average width of at least 10 mm. By increasing the average width of the edges, the strength of the packaging unit is further increased. This contributes to the overall strength of the packaging unit and thus of the stack of packaging units. Preferably, the average width is in the range of 10mm to 30 mm.

It is also preferred that the ribs protrude from the side surfaces an average distance of at least 3 mm. By having the ribs protrude a certain distance, the strength and stability of the packaging unit is improved. Preferably, the ribs protrude from the side surface an average distance in the range of 3mm to 10mm, more preferably in the range of 4mm to 8 mm.

In a presently preferred embodiment of the invention, the lock comprises a lock opening and a cam element configured for protruding from the lock opening, and wherein the cam element comprises a rib element protruding substantially from the cam element in a back-to-front direction of the packaging unit.

The additional rib elements of the locking cam element provide additional stability to the locking cam and also provide additional strength. This also improves the locking stability.

As a further effect, the cam element support of the lid portion in the closed position of the packaging unit is increased. This further contributes to the locking stability in the closed position of the packaging unit.

In a presently preferred embodiment of the invention, the lock comprises a lock opening and a cam element configured to protrude from the lock opening, and wherein the cam element comprises a front edge that extends to a side of the cam and into the cam side edge.

The cam side edges provide additional material and stiffness to the locking element. In addition, the cam side edges provide more certainty of closing the packaging unit.

In one of the presently preferred embodiments, the cam element protrudes through the opening to provide a stable lock. In an alternative embodiment, in the closed position of the packaging unit, the cam element does not protrude completely through the opening, and the cam element of the lock is located substantially behind the front plane of the packaging unit. This has the advantage that a larger display surface can be provided on the front surface of the packaging unit, to enable, for example, improved information exchange with the consumer.

Preferably, the cam element is provided in the vaneless front surface of the bottom part. This has the advantage that no fins are required. This reduces the amount of material required in the manufacturing process of the packaging unit. As a further effect, the distance required between the packaging units during the manufacturing process is reduced, whereby the total capacity of the manufacturing process can be increased. An example of such a vaneless design is shown in NL 2024536.

In another preferred embodiment of the invention, the front surface of the bottom part further comprises a front rib extending over a substantial part of the front edge of the bottom part.

Providing additional front ribs extending in a substantially horizontal/width direction of the packaging unit significantly improves the strength and stability of the packaging unit in the closed and open positions. Furthermore, such a front rib provides additional strength when the packaging unit is placed in the bundle of packaging units for storage and transport. This significantly reduces the risk of damaging the packaging units.

In a presently preferred embodiment, the front rib extends between two adjacent cam elements of the packaging unit. This further increases the rigidity and stability of the front surface of the bottom portion.

In one of the presently preferred embodiments, the packaging unit is provided with a complete front label. Such a complete front label covers a large part of the front surface of the cover part including the locking element. This significantly increases the size of the display surface on which information can be displayed to the consumer. In some presently preferred embodiments, the complete front label includes a cutout for the cam member. Such a cutout enables the cam element to protrude through the lock opening. Such a cut in the complete front label is preferably a so-called smiley face cut as disclosed in WO 2015/160248 A1.

In a presently preferred embodiment of the invention, the molded pulp material comprises a quantity of natural fibers.

Additionally or alternatively, the molded pulp material includes a quantity of biodegradable material, such as aliphatic polyester.

The use of natural fibres and/or biodegradable materials in packaging units made of moulded pulp material is described in WO 2018/067006 A1 of the same applicant. In particular the use of wheat straw and/or rape straw shows a related influence on the strength and stability of the packaging unit.

The use of natural fibres and/or biodegradable materials results in the packaging unit being essentially MOSH-free and/or MOAH-free and/or (home) compostable. These materials are preferably applied in combination with one or more of the above-mentioned features, in particular with the self-aligning element, the one or more denesting support portions and the additional side ribs and/or anterior ribs. This combination provides additional strength to the packaging unit, providing more possibilities to use alternative materials without adversely affecting the performance of the packaging unit.

In another preferred embodiment of the invention, the molded pulp material comprises an amount of microfibrillated fibers.

In one of the embodiments of the invention, the packaging unit comprises a quantity of microfibrillated cellulose (MFC) fibers. In the context of the present invention, this also relates to nanofibrillated cellulose (NFC) fibers or cellulose nanofibers or nanocellulose. MFC is preferably derived from a cellulosic feedstock of vegetable origin. Currently preferred examples of such plant sources include the use of beet pulp, sugarcane pulp and potato pulp.

The use of MFC and/or NFC enhances the fiber-fiber bond strength and further improves the reinforcing effect. Although MFC and/or NFC are preferably applied in combination with one or more biodegradable aliphatic polyesters, MFC and/or NFC may also be used as alternatives to these components. In addition, MFC and in particular NFC may even reduce the use of so-called dry strength agents in molded pulp materials.

In embodiments of the invention, the amount of microfibrillated fibers is in the range of 1wt% to 3wt% of the molded pulp material. Experiments have shown that such an amount already provides the packaging unit with increased strength and may additionally provide improved properties, for example in view of barrier properties. The barrier properties may include oxygen and/or grease and/or moisture barriers. It is believed that oxygen barrier properties are achieved by, for example, the ability of MFC and/or NFC to form a dense network including hydrogen bonds.

Another advantage of using MFC and/or NFC is improved printability, including the possibility of digital printing. Additionally, or alternatively, MFC may reduce cost by reducing weight through increasing the amount of filler. This may also enhance optical performance.

The invention also relates to a method for packaging a product, such as an egg, comprising the steps of providing a packaging unit in an embodiment of the invention and placing one or more products in the packaging unit.

This method provides the same effects and advantages as described in relation to the packaging unit.

The invention also relates to a method for manufacturing a packaging unit from molded pulp material, the method comprising the steps of:

preparing a molded pulp material; and

a packaging unit according to any embodiment of the invention is provided.

This method provides the same effects and advantages as described in relation to the packaging unit.

The method for packaging a product and/or manufacturing a packaging unit preferably comprises providing a self-aligning element presented in connection with an embodiment of the packaging unit. The self-aligning element provides additional support for relative movement between the cover portion and the bottom portion in a substantially horizontal direction or in other words in a direction or plane substantially parallel to the top surface of the cover. This effectively prevents the opening in the lid portion from moving onto the locking cam element in the bottom portion resulting in an undesired opening of the packaging unit. In addition, the self-aligning element improves storage and transport and reduces the risk of damaging the side edges of the packaging unit during transport and storage. As an even further effect of the self-aligning element, the strength of the packaging unit is further improved. This is achieved by better fixing the position of the cover part relative to the bottom part in the closed position of the packaging unit. Furthermore, the self-aligning element prevents such positioning of the cover part relative to the bottom part, in particular in the horizontal direction, so that the strength and stability of the packaging unit is also maintained in case of forces or loads acting on the packaging unit. These effects are further enhanced by the fact that the self-aligning element provides slightly more moulded pulp material at a specific location of the packaging unit. Providing self-aligning elements in the side edges of the packaging unit according to the invention makes it possible to better fix the relative positions of the cover part and the bottom part. This also allows for better alignment of the ribs of the bottom part and the ribs of the cover part within one packaging unit and between different packaging units in the stack. This better ensures the stability of such stacks during transport, for example.

Further advantages, features and details of the invention are elucidated on the basis of a preferred embodiment of the invention, reference being made to the accompanying drawings, in which:

fig. 1 shows a packaging unit for 10 eggs according to the invention in a closed position;

fig. 2 shows the packaging unit of fig. 1 in a fully open position;

fig. 3A shows a front view of the packaging unit of fig. 1-2;

fig. 3B shows a top view of the packaging unit of fig. 1-2;

fig. 3C shows a side view of the packaging unit of fig. 1-2 in a closed position;

fig. 3D shows a bottom view of the packaging unit of fig. 1-2;

fig. 4 shows a stack of packaging units according to the invention;

fig. 5 shows a bundle of packaging units according to the invention;

fig. 6 shows an alternative embodiment of a packaging unit for 12 eggs according to the present invention;

fig. 7A-7B show views of an alternative embodiment of a packaging unit for double packaging (twinpack) according to the invention;

FIG. 8 shows an alternative embodiment for 12 eggs in accordance with the present invention;

9A-9D illustrate an alternative embodiment for 10 eggs in accordance with the present invention;

FIGS. 10A-10D and 11A-11D illustrate alternative embodiments for 12 eggs and for 12 eggs in a double package, respectively, in accordance with the present invention;

FIGS. 12A-12F illustrate additional alternative embodiments for 12 eggs in accordance with the present invention;

figures 13A-13B and 14A-14B illustrate further alternative embodiments for 10 eggs and 12 eggs in double packages, respectively, according to the present invention;

15A-15B illustrate the locking member of the embodiment of FIGS. 9-12; and

fig. 16 and 17 show views of alternative embodiments of a packaging unit according to the invention.

The packaging unit 2 (fig. 1-5) comprises a wingless bottom portion 4 and a lid portion 6. The bottom portion 4 includes a front surface 8, a first side surface 10, a second side surface 12, a rear surface 14, and a bottom surface 16. The cover portion 6 includes a top surface 18, a front surface 20, a first side surface 22, a second side surface 24, and a rear surface 26. The hinge 28 connects the rear surface 14 of the bottom portion 4 and the rear surface 24 of the cover portion 6, respectively. The hinge 28 is positioned at the rear end of a side edge 50, which side edge 50 defines the contact surface of the bottom side surfaces 10, 12 with the lid side surfaces 22, 24 in the closed position of the packaging unit 2. The (raised) hinge 28 is raised by more than height E as compared to the front end of the side edge 50. In the illustrated embodiment, the transition region 19 is located between the front surface 20 and the top surface 18. This transition area 19 is optional for the packaging unit 2.

In the closed position of the packaging unit 2 (fig. 1 and 3A-3D), the front surface 8 of the bottom part 4 and the front surface 20 of the cover part 6 are closed using a locking member 30. In the embodiment shown, the lock 30 comprises a cam element 32 in the bottom part 4 and a lock opening 34 in the cover part 6. In the illustrated embodiment, the opening 34 extends from the front surface 20 into the transition region 19, and optionally an inwardly extending edge 35 is provided at the lower edge of the opening 34. The edge 35 extends from the opening 34 for 1mm to 3mm, preferably about 2mm.

A compartment 36 (fig. 2) is provided in the bottom portion 4 and is capable of containing a product P, such as an egg. Between the compartments 36 are provided a plurality of cone portions 38 extending upwardly. Optionally, the cone portion 38 is provided with an opening or aperture (not shown).

The hinge 28 comprises a hinge support portion 40, which hinge support portion 40 engages the lid 6 in the closed position of the packaging unit 2 (fig. 2 and 3D).

Furthermore, in the embodiment shown, the cam 32 is provided with a top surface 42 (fig. 3C and 3D), which top surface 42 engages with an upper edge or support surface 44 of the lock opening 34 in the closed position of the packaging unit 2 (fig. 1). A notch 46 (fig. 2) is provided above the lock opening 34.

As shown, the cam element 32 protrudes (partially) through the opening 34 (fig. 3C). Optionally, the cam element 32 does not extend beyond the cover front surface 20. Preferably, a label 48 is provided on the cover portion 6. Optionally, the opening 34 is slightly wider than the cam element 32 in order to be more "forgiving" when closing the packaging unit 2.

The side edges 50 include a lid side edge 52 and a bottom side edge 54 (fig. 2 and 3C). The hinge 28 is arranged at a first height which is higher by a height difference E (fig. 3C) compared to a second height of the front part of the bottom part 4. Thus, on average, the edge 50 slopes downward in the back-to-front direction (back to front direction) (fig. 3C). The edge 50 is provided with a self-aligning element 56 (fig. 3C), which self-aligning element 56 is provided in the front half of the side edge 50, as seen in the rear-to-front direction D. In the illustrated embodiment, the elements 56 are provided as continuous semi-circular or smooth lobes, and are preferably provided with undulations. In this illustrated embodiment, the rounded or raised portion 56 is positioned upwardly. It will be appreciated that alternatively, an upside down configuration of the elements 56 is also contemplated in accordance with the present invention. The de-nesting support element 58 (fig. 3C) comprises a lid support portion 60 and a bottom support portion 62, which lid support portion 60 and bottom support portion 62 engage each other in the closed position of the packaging unit 2. It should be appreciated that the de-nesting support elements 58 are optional in all embodiments of the invention, and that it is also contemplated that only the lid support portion 60 or the bottom support portion 62 be provided. The denesting support portion 58 is disposed proximate to the front of the edge 50, and in the illustrated embodiment, a second denesting support portion 64 having a lid portion 66 and a bottom portion 68 is disposed on the edge 50 proximate to the rear of the edge 50, as seen in the rear-to-front direction D. In this illustrated embodiment, cam 32 is positioned above hinge 28 to further improve the stability of the lock when handling packaging unit 2.

The side ribs 70 (fig. 3C) comprise a lid rib 72 and a bottom side rib 74, which lid rib 72 and bottom side rib 74 are aligned in the closed position of the packaging unit 2. Side ribs 70 extend from top surface 18 to bottom surface 16 and provide additional lid support surfaces 76 (fig. 1 and 3B) and bottom support surfaces 78 (fig. 3D). In the illustrated embodiment, the rib 70 includes a straight edge 80, the straight edge 80 being disposed at an angle α (fig. 3C) relative to the vertical portion. The sides 22, 24 of the cover portion 6 are arranged at an angle β (fig. 3A) with respect to the vertical. In the illustrated embodiment, the rib 70 is significantly separated from the medial side surface 82. At the corner portion (corner) 84 (fig. 1), a transition portion of circular shape is provided between the side surface and the front surface of the packaging unit 2. The front rib 86 extends in a substantially horizontal direction between two adjacent cam supports 88 (fig. 2). The cam member 32 includes a cam rib 90 (fig. 3D) extending in a substantially vertical direction and protruding in a rear-to-front direction D.

The molded pulp material is optionally provided with natural fibers 92 (fig. 2) and/or biodegradable materials. Alternatively, the natural fibers 92 may be allowed to remain visible on the packaging unit 2.

The stack 94 (fig. 4) of packaging units 2 in the closed position shows in the embodiment shown a cross-stack with layers 96a, 96b, 96c …. The bundle 98 (fig. 5) includes a plurality of packaging units 2 in a closed position.

Packaging unit 102 (fig. 6) includes a tabbed bottom portion 104 and a lid portion 106. The bottom portion 104 includes a front surface 108, a first side surface 110, a second side surface 112, a rear surface 114, and a bottom surface 116. The cover portion 106 includes a top surface 118, a front surface 120, a first side surface 122, a second side surface 124, and a rear surface 126. Hinge 128 connects rear surface 114 of bottom portion 104 and rear surface 124 of lid portion 106, respectively. In the illustrated embodiment, the transition region 119 extends between the front surface 120 and the top surface 118. This transition region 119 is optional for the packaging unit 102. As described with respect to other embodiments of the present invention, self-aligning element 56 is provided to packaging unit 102.

In the illustrated embodiment, the lock 130 includes a cam element 132 in the bottom portion 104 and a lock opening 134 in the cover portion 106. In the illustrated embodiment, the opening 134 is disposed in the front surface 120 of the cover portion 106 and extends toward the transition region 119 and/or into the transition region 119. In the embodiment shown, the opening 134 is provided with a support 135. The support 135 rests on the cam element 132 in the closed position of the packaging unit 102 to provide additional strength and stability. Optionally, a recess (notch) 137 is provided above the support 135 to further improve the locking function of the locking member 130. It should be appreciated that the size and location of the locking member 130 may be designed according to the particular needs of the packaging unit 102. For example, the locking member 130 may be positioned more toward the side surfaces 122, 124. The support 135 extends in the front-to-rear direction beyond a distance preferably between 1mm and 8mm, more preferably between 2mm and 6mm, or another suitable distance.

As shown with other embodiments of the invention, the cam element 132 protrudes (partially) through the opening 134. Optionally, the cam element 132 does not extend beyond the cover front surface 120. Preferably, a label is provided on the cover portion 106. Optionally, the opening 134 is slightly wider than the cam element 132 in order to be more "slack" when closing the packaging unit 2.

An alternative packaging unit 202 (fig. 7A-7B) includes a tabbed bottom portion 204 and a lid portion 206. The bottom portion 204 includes a front surface 208, a first side surface 210, a second side surface 212, a rear surface 214, and a bottom surface 216. The cover portion 206 includes a top surface 218, a front surface 220, a first side surface 222, a second side surface 224, and a rear surface 226. Raised hinge 228 connects rear surface 214 of bottom portion 204 and rear surface 224 of lid portion 206, respectively. In the illustrated embodiment, the transition region 219 extends between the front surface 220 and the top surface 218. The transition zone 219 is optional for the packaging unit 202. As described with respect to other embodiments of the present invention, self-aligning element 56 is provided to packaging unit 202. Raised hinge 228 connects bottom portion 204 and lid portion 206. In this illustrated embodiment, the notch 230 is larger than the notch 46 (fig. 1) to further enhance the locking effect in the closed position of the packaging unit 202. In addition, the recess 230 extends over substantially the entire height of the transition region 219 on the front surface 220 of the cover portion 206 (fig. 7A). In the illustrated embodiment, edge 244 is larger than edge 44 (FIG. 1).

An alternative packaging unit 302 (fig. 8) is provided with 12 compartments and with a design closely related to the design of packaging unit 202 (dual package) with 2x6 compartments.

An alternative packaging unit 312 (fig. 9A-9D) is provided with 10 compartments and is closely related to the previously illustrated embodiment. Next, only some differences will be discussed.

The recess 314 extends slightly further to a top surface 316. The denesting support portion 318 is provided only in the cover portion 320 of the packaging unit 312. In contrast to the previous embodiments shown in fig. 1-8, the side edges 322 of the front surface 324 of the cover portion 320 of the packaging unit 312 are inclined and disposed at a slightly larger angle relative to vertical.

An alternative packaging unit 332 (fig. 10A-10D) is provided with 12 compartments. An alternative packaging unit 342 (fig. 11A-11D) is also provided with 12 compartments, but is provided in a dual package configuration. Further details of the packaging units 332, 342 are similar to those of the packaging unit 312 (fig. 9A-9D).

An alternative packaging unit 352 (fig. 12A-12F) is provided with 12 compartments and includes a tabbed bottom portion 354 and a cover portion 356. Bottom portion 354 includes a front surface 358, a first side surface 360, a second side surface 362, a rear surface 364, and a bottom surface 366. The cover portion 356 includes a top surface 368, a front surface 370, a first side surface 372, a second side surface 374, and a rear surface 376. Raised hinges 378 connect rear surfaces 364, 376 of bottom portion 354 and cover portion 356, respectively. The self-aligning elements 56 are preferably wavy and are provided to the packaging unit 352 as described with respect to other embodiments of the present invention. The front surface 370 is provided at a distance D _f Upwardly extending so-called deep front (deep front). In this illustrated embodiment, in the closed position of the packaging unit, distance D _f Extending about 1cm deep towards the bottom. It will be appreciated that this significantly increases the front surface of the packaging unit and provides a larger display surface. In the presently preferred embodiment, tab 380 is configured with a so-called smiley cut 382 for the cam member of the lock.

An alternative packaging unit 384 (fig. 13A-13B) is provided with 10 compartments, and an alternative packaging unit 386 (fig. 14A-14B) is provided with 12 compartments, but in a double-package configuration. In the illustrated embodiment, packaging units 384, 386 are (optionally) provided with labels 380 having smiley cut 382. Further details of the packaging units 384, 386 are similar to those of the packaging unit 352 (fig. 12A-12F).

The lock 390 (fig. 15A-15B) is provided in the illustrated embodiment of fig. 9-14 and can be applied to other embodiments shown in fig. 1-8 if desired. Alternatively, the locking member 30 may be applied alternatively to the embodiment shown in fig. 9-14.

The lock 390 is provided with a cam 392, which cam 392 has a top surface 394, which top surface 394 engages an upper edge or support surface 396 of the lock opening 398 in the closed position of the packaging unit 2. In this embodiment, the front edge 397 of the cam 392 extends slightly further forward (and through the opening 398) in the closed position of the packaging unit than the locking member 30. In addition, front edge 397 extends to the side of cam 392 and into cam side edge 399.

As shown, the cam element 392 protrudes (partially) through the opening 398 in the closed position of the packaging unit. Optionally, the cam element 392 does not extend beyond the cover front surface 20. Preferably, the label is provided on the cover portion of the packaging unit. Optionally, the opening 398 is slightly wider than the cam element 392 in order to be more "tolerant" when closing the packaging unit.

Alternative packaging units 402, 502 (fig. 16-17) include a tabbed bottom portion 404 and a lid portion 406. Bottom portion 404 includes a front surface 408, a first side surface 410, a second side surface 412, a rear surface 414, and a bottom surface 416. The cover portion 406 includes a top surface 418, a front surface 420, a first side surface 422, a second side surface 424, and a rear surface 426. Raised hinge 428 connects rear surface 414 of bottom portion 404 and rear surface 424 of lid portion 406, respectively. In the illustrated embodiment, a transition region 419 extends between the front surface 420 and the top surface 418. This transition region 419 is optional for the packaging unit 402, 502. The self-aligning elements 56 are preferably wave-shaped and provided to the packaging units 402, 502 as described with respect to other embodiments of the present invention. Also in this embodiment, the recess 230 extends over substantially the entire height of the transition region 219 on the front surface 420 of the cover portion 406. The packaging unit 502 (fig. 10) is provided with additional shapes 504 on at least one or both of the side surfaces 422, 424. In these illustrated embodiments, edge 444 is larger than edge 44 (FIG. 1). The front surface 420 of the packaging unit 402, 502 is larger compared to the front surface 20 of the packaging unit 2 (fig. 1). In addition, the larger front surface 420 of the packaging unit 502 is provided with additional wavy corner edges 506. The edge 506 provides additional stability, for example, when handling the packaging unit 502 during filling. In addition, the edge 506 enhances the visual effect of the undulating self-aligning element 56.

In the embodiment shown, the packaging unit 2 comprises a plurality of product-receiving compartments 36, which product-receiving compartments 36 are arranged in two rows of five or two rows of six compartments 36. It should be understood that other configurations having different numbers of compartments and/or rows are also contemplated in accordance with the present invention.

When manufacturing the packaging unit 2, a mould pulp material is provided to the mould, preferably the mould pulp material comprises a plurality of additives, such as a quantity of MFC, NFC and/or AKD, ASA and/or other sizing components. In the embodiment shown, the packaging unit 2 is molded in a molding operation and then dried. The dried packaging unit 2 then packages the products P by placing one product P in the respective compartment 36 to provide a packaging unit filled with the products P and ready for storage, transport and/or display. For example, such a packaging unit 2 enables a potential purchaser to inspect the product P while the packaging unit is held on a shelf.

Tests performed with the packaging unit 2 on an automatic packaging line have shown that problems associated with undesired opening of the packaging unit are significantly reduced due to self-aligning effects. The results show that the capacity of the production line is significantly improved. In addition, the packaging unit 2 is less subject to damage during handling, shipping, storage and display due to the stabilizing action of the self-aligning elements 56.

The invention is not intended to be limited to the preferred embodiments thereof described above. The rights sought are defined by the following claims, and many modifications are conceivable within the scope of the claims. For example, the locking member 30 may be provided with locking elements of different shapes. Furthermore, a label may be attached to the packaging unit 2, e.g. the label is a full front label, optionally provided with smiley cuts. The illustrated packaging unit 2 includes ten product receiving compartments 36. It should be understood that another number of product receiving compartments 36 are also contemplated in accordance with the present invention. Although the packaging unit 2 is shown for eggs, it may also be used for other products, such as kiwi and tomato, for example.

Claims (25)

1. A packaging unit made of molded pulp material, the packaging unit comprising:

a bottom portion having a product receiving compartment for receiving a respective product, wherein the bottom portion has at least a bottom front, a bottom surface and two bottom sides;

a lid portion having at least a lid front, a lid top and two lid sides;

a hinge element for hingedly connecting the lid portion and the bottom portion; and

A locking member for locking the bottom portion and the cover portion in a closed position of the packaging unit, and

wherein the bottom side and the lid side comprise side edges having self-aligning elements.

2. The packaging unit of claim 1, wherein the self-aligning element is positioned substantially in a front half of a side edge in the closed position of the packaging unit.

3. Packaging unit according to claim 1 or 2, wherein the self-aligning element comprises a smooth curvature.

4. A packaging unit according to claim 3, wherein the self-aligning element comprises a wave shape.

5. Packaging unit according to any of the preceding claims, wherein the self-aligning element is configured for preventing or reducing relative movement between the cover part and the bottom part, thereby stabilizing the lock and/or fixing the relative position of the cover part and the bottom part, thereby strengthening the packaging unit.

6. The packaging unit of any one of the preceding claims, further comprising a raised hinge.

7. A packaging unit according to any one of the preceding claims, wherein the side edge of the lid portion and/or the side edge of the bottom portion comprises at least one de-nesting support portion, and wherein the at least one de-nesting support portion is positioned within a distance of 20% of the total length of the side edge from the lid front.

8. The packaging unit of claim 7, wherein the denesting support portion at least partially overlaps the self-aligning element.

9. A packaging unit according to any one of the preceding claims, wherein the lid side and bottom side comprise one or more ribs extending substantially from the lid top surface in the direction of the bottom surface, and wherein the ribs protrude from the side surfaces and provide additional support for the lid portion and the bottom portion when stacking a plurality of packaging units.

10. The packaging unit of claim 9, wherein the ribs extend to the bottom surface and provide the bottom surface with additional bottom support surfaces that substantially correspond to additional lid support surfaces.

11. The packaging unit of claim 10, wherein the additional lid support surface of one rim has a thickness of at least 0.35cm ² Is provided.

12. A packaging unit according to claim 9, 10 or 11, wherein the rim has an average width of at least 10 mm.

13. The packaging unit of any one of claims 9 to 12, wherein the ribs protrude from the side surface an average distance of at least 3 mm.

14. A packaging unit according to any one of the preceding claims, wherein the lock comprises a lock opening and a cam element configured to protrude from the lock opening, and wherein the cam element comprises a rib element protruding substantially from the cam element in a back-to-front direction of the packaging unit.

15. A packaging unit according to any one of the preceding claims, wherein the lock comprises a lock opening and a cam element configured to protrude from the lock opening, and wherein the cam element comprises a front edge extending to a side of the cam and into a cam side edge.

16. A packaging unit according to claim 14 or 15, wherein the cam element is provided on a vaneless front surface of the bottom part.

17. The packaging unit of any one of the preceding claims, wherein the front surface of the bottom portion further comprises a front rib extending over a majority of a front edge of the bottom portion.

18. The packaging unit of any one of the preceding claims, further comprising an integral front label.

19. The packaging unit of claim 17, wherein the complete front label comprises a cutout for the cam element.

20. A packaging unit according to any one of the preceding claims, wherein the moulded pulp material comprises a quantity of natural fibres.

21. The packaging unit of any one of the preceding claims, wherein the molded pulp material comprises an amount of microfibrillated fibers.

22. The packaging unit of claim 21, wherein the amount of microfibrillated fibers is in the range of 1wt% to 3wt% of the molded pulp material.

23. A packaging unit according to any one of the preceding claims, wherein the moulded pulp material comprises a quantity of biodegradable material.

24. A method for packaging a product, such as an egg, comprising the steps of: packaging unit according to one or more of the preceding claims is provided and one or more products are placed in the packaging unit.

25. A method of manufacturing a packaging unit from molded pulp material, the method comprising the steps of:

preparing a molded pulp material; and

a packaging unit according to any one of claims 1-23 is provided.