US20180029743A1

US20180029743A1 - Egg packaging

Info

Publication number: US20180029743A1
Application number: US15/224,220
Authority: US
Inventors: Michelle D'Arpino; Prateek Khanna; Abhijeet Dudi
Original assignee: Google LLC
Current assignee: Google LLC
Priority date: 2016-07-29
Filing date: 2016-07-29
Publication date: 2018-02-01

Abstract

A cruciform sheet including a rectangular central section bounded by two sections on each side substantially coextensive with the central section, and dimensioned to wrap around an egg carton. The sheet is bound at top and bottom by flaps, from which tabs extend. The flaps can be folded to cover a carton end, with the tabs inserted between the carton top and the folded side sections.

Description

TECHNICAL FIELD

The present disclosure relates to packaging. Example embodiments related to a cover for improved packaging of cartoned eggs, and to a kit including the cover and an egg carton insert.

BACKGROUND

An egg carton is a package designed for carrying and transporting whole eggs. Referring to FIG. 1, a typical carton 100 used at retail stores is illustrated. The carton 100 may include a bottom 110 comprising an array of dimples 112 connected to each other. The array of dimples 112 may be connected to a bottom rim 114 around the perimeter of the array. Each dimple 112 may be shaped to support the bottom of a single egg. One or more of the regions between any group of four dimples may be formed as a cone 116 that may extend above the plane of the bottom rim 114 to a height not substantially greater than the top of an egg expected to be carried in the carton 100. The cones 116 may inhibit, but do not prevent, an egg in the carton from contacting eggs in adjoining dimples 102.
The egg carton may include a top 120. The top 120 may be flexibly connected along a top back edge 128 to a bottom back edge 118 in a manner allowing the top 120 to be closed over the bottom 110. When the carton is closed, a top rim 124 may be substantially in contact with one or more portions of the bottom rim 114. Each cone 116 may extend no higher than an inside upper surface of the top 122.
The egg carton may include a flap 130 flexibly connected to a bottom front edge 119 for releasably securing the top 120 in place when the carton 100 is closed. The flap outer surface 136 may abut a top inside front surface 126 when the carton 100 is closed. The flap 130 may include detents 132 sized and shaped to mate with holes 129 formed in the top 120 to releasably secure the top 120 in place when the carton 100 is closed.
This egg carton 100 structure may protect eggs against stresses exerted during some forms of transportation and storage by absorbing shock. An egg carton 100 may be made of various materials, including foamed plastics such as polystyrene foam, clear plastic, or may be manufactured from recycled paper or molded pulp.
While a typical egg carton 100 is illustrated in FIG. 1, other variations are known. For example, the flap 130 may comprise three detents 132 for engaging three holes 120 in the top 120; or the middle cone 116 may be replaced with a divider that extents across both columns of the array of dimples 112; or some portion of one or more cones 116 may extend through the top 120. A typical egg carton 100 can accommodate one dozen eggs—though egg cartons 100 for other amounts, such as four, six, eight, ten, eighteen (for example, comprising three columns of six eggs), are known.
Online grocers may allow consumers to order groceries and other products typically found in grocery stores, online. Either the grocer, or a third party, then may deliver the ordered goods to consumers. Often, a variety of mixed good, for example, eggs, bread, milk, and potato chips, are packaged in the same bag or box.

SUMMARY

In certain example embodiments described herein, a cover for cartoned eggs is disclosed. In such embodiments, the cover is a cruciform sheet of material having stiffness of at least corrugated cardboard. The cover includes a rectangular central section. The central section is dimensioned along each of the central section right edge and the central section left edge to the length of an egg carton, and along each of the central section top edge and the central section bottom edge to the width of the egg carton.
The cover includes a rectangular first right section abutting, and coextensive with, the central section right edge along the first right section left edge. The first right section is dimensioned along each of a first right section top edge and first right section bottom edge to the overall height of the egg carton plus the thickness of the sheet.
A rectangular second right section abuts, and is coextensive with, the first right section right edge along the second right section left edge. The second right section is dimensioned along each of a second right section top edge and second right section bottom edge to the overall width of the egg carton plus the thickness of the sheet.
The cover includes a rectangular first left section that is abutting, and coextensive with, the central section left edge along the first left section right edge. The first left section is dimensioned along each of a first left section top edge and first left section bottom edge to the overall height of the egg carton plus the thickness of the sheet.
A rectangular second left section abuts, and is coextensive with, the first left section left edge along the second left section right edge. The second left section is dimensioned along each of a second left section top edge and second left section bottom edge to the overall width of the egg carton.
The cover includes a rectangular top flap abutting, and coextensive with, the central section top edge along the top flap bottom edge. The top flap is dimensioned along each of the top flap left edge and the top flap right edge to the overall height of the egg carton.
A top tab abuts the top flap along the top edge of the top flap. The top tab is dimensioned along a top tab bottom edge and a top tab top edge less than the width of the egg carton by at least the thickness of the sheet.
The cover includes a rectangular bottom flap abutting, and coextensive with, the central section bottom edge along the bottom flap top edge. The bottom flap is dimensioned along each of the bottom flap left edge and the bottom flap right edge to the overall height of the egg carton.
A bottom tab abuts the bottom flap along the bottom edge of the bottom flap. The bottom tab is dimensioned along a bottom tab bottom edge and a bottom tab top edge less than the width of the egg carton by at least the thickness of the sheet.
These and other aspects, objects, features, and advantages of the example embodiments will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of illustrated example embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a typical egg carton.

FIG. 2 illustrates an egg carton cover, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 3 is a block flow diagram depicting a method to package eggs using an egg carton cover, in accordance with example embodiments of the technology disclosed herein.

FIG. 4A-FIG. 4F, in conjunction with FIG. 3, illustrate methods for packaging eggs using an egg carton cover, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 5 illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 6 illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 7 illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 8 is a block flow diagram depicting a method to package eggs, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 9 is a block flow diagram depicting a method to package eggs, in accordance with certain example embodiments of the technology disclosed herein.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

Turning now to the remaining drawings, in which like numerals indicate like (but not necessarily identical) elements throughout the figures, example embodiments are described in detail.

Overview

Delivering eggs purchased from an online retailer in cartons can result very high egg breakage rates, especially if the online retailer uses a common carrier for delivery. Egg breakage rates can increase if the egg carton is delivered in the same overall container, for example a cardboard box, along with heavy products or products packaged in hard-sided containers. A typical egg carton is not designed to withstand the forces likely to be encountered by the eggs being handled like books, clothing, and other goods delivered by common carriers. Even specialty carriers, accustomed to transporting fragile items, can see unacceptable breakage rates. Private testing has shown breakage rates as high as 44% for 6-count and 12-count egg cartons shipped for overnight delivery in outer boxes with other grocery products.
Embodiments of the technology disclosed herein include devices, systems, and methods for supplementing a typical egg carton with a cover that can reduce the rate of egg breakage during transport. Some embodiments combine a cover and an insert in a kit to package cartoned eggs. Some embodiments disclosed herein have demonstrated breakage rates of less than 3%.

Example Embodiments

Referring to FIG. 2, and continuing to refer to prior figures for context, a first embodiment of an egg carton cover 200 is illustrated, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton cover 200 is a cruciform sheet of material having stiffness of at least corrugated cardboard. As a continuing example, consider a cover 200 for the conventional one dozen-egg carton 100 of FIG. 1. The example cover 200 is 19½ inches wide by 11½ inches tall across most of its width, with a first and a second 4⅝ inch wide by 2⅞ inch high section extending above and below, respectively, therefrom. The cover 200 is ⅛ inch thick. All measurements herein are approximate. Variations, such as to accommodate the thickness of the sheet and maintain a substantially rectangular overall shape of the cover when applied to an egg carton, are contemplated.
The cover 200 includes a rectangular central section 210 dimensioned along each of the central section right edge 212 and the central section left edge 214 to the length of an egg carton. The central section 210 is dimensioned along each of the central section top edge 216 and the central section bottom edge 218 to the width of the egg carton. In the continuing example, the central section 210 of the cover 200 is 11¾ inches along each of the central section right edge 212 and the central section left edge 214, and is 4½ inches along the central section top edge 218 and the central section bottom edge 218.
The cover includes a rectangular first right section 222 that abuts, and is coextensive with, the central section right edge 212 along the first right section left edge 223. The first right section 222 is dimensioned along each of a first right section top edge 224 and first right section bottom edge 225 to the overall height of the egg carton plus the thickness of the sheet. In the continuing example, the first right section top edge 224 and first right section bottom edge 225 are 3 inches across.
A rectangular second right section 226 abuts, and is coextensive with, the first right section right edge along the second right section left edge 227. The second right section 226 is dimensioned along each of a second right section top edge 228 and second right section bottom edge 229 to the overall width of the egg carton plus the thickness of the sheet. In the continuing example the second right section top edge 228 and second right section bottom edge 229 are 4½ inches across.
The cover includes a rectangular first left section 232 that abuts, and is coextensive with, the central section left edge 214 along the first left section right edge 233. The first left section 232 is dimensioned along each of a first left section top edge 234 and first left section bottom edge 235 to the overall height of the egg carton. In the continuing example, the first left section top edge 234 and the first left section bottom edge 235 are 2⅞ inches across.
A rectangular second left section 236 abuts, and is coextensive with, the first left section left edge along the second left section right edge 237. The second left section 236 is dimensioned along each of a second left section top edge 238 and second left section bottom edge 239 to the overall width of the egg carton. In the continuing example, the second left section top edge 238 and second left section bottom edge 239 are 4⅜ inches across.
The cover includes a rectangular top flap 242 abutting, and coextensive with, the central section top edge 216 along the top flap bottom edge 243. The top flap 242 is dimensioned along each of the top flap left edge 244 and the top flap right edge 245 to the overall height of the egg carton. In the continuing example, the top flap left edge 244 and the top flap right edge 245 are 2⅞ inches, while the distance between the edges is 4⅝ inches ( 2/8 inches more—twice the thickness of the sheet—than the second left section top edge and second left second bottom edge).
The cover includes a top tab 246 abutting the top flap 242 along the top edge of the top flap 247. The top tab 246 is dimensioned along a top tab bottom edge 248 and a top tab top edge 249 less than the width of the egg carton by at least the thickness of the sheet. In the continuing example, top tab bottom edge 248 and a top tab top edge 249 are 4⅜ inches across (twice the thickness of the sheet less than the width of the top flap 242).
A rectangular bottom flap 252 abuts, and is coextensive with, the central section bottom edge 218 along the bottom flap top edge 253. The bottom flap 252 is dimensioned along each of the bottom flap left edge 254 and the bottom flap right edge 255 to the overall height of the egg carton 100. In the continuing example, the bottom flap left edge 254 and the bottom flap right edge 255 are 2⅞ inches, while the distance between the edges is 4⅝ inches ( 2/8 inches more that the second left section top edge and second left second bottom edge).
The cover includes a bottom tab 256 abutting the bottom flap 252 along the bottom edge of the bottom flap 257; the bottom tab is 256 is dimensioned along a bottom tab bottom edge 258 and a bottom tab top edge 259 less than the width of the egg carton by at least the thickness of the sheet. In the continuing example, bottom tab bottom edge 248 and a bottom tab top edge 249 are 4⅜ inches across (twice the thickness of the sheet less than the width of the bottom flap 252).
In some embodiments, each central section edge (212, 214, 216, and 218), the second right section left edge 227, the second left section right edge 237, the top flap top edge 247, and bottom flap bottom edge 257 are creased toward the front face of the sheet. In some of those embodiments, the top flap bottom edge 243 and bottom flap top edge 253 are perforated.
In some embodiments of the cover 200, the second left section top edge 238 defines therein an upper tab 272 slotted inward from the second left section top edge 238, and the second right section top edge 228 forms therein an upper cutout 274 corresponding to the upper tab 272. Also, the second left section bottom edge 239 defines therein a lower tab 282 slotted inward from the second left section bottom edge 239, and the second right section bottom edge 229 forms therein a lower cutout 284 corresponding to the lower tab 282. In the continuing example, each of the upper tab 272 and lower tab 282 is trapezoidal with the trapezoid base at the respective edge. Tab shapes other then trapezoidal can be used, for example, portions of square, rectangular, and other regular and irregular polygons (such as an arrowhead), along with portions of curved shapes can be used. The upper tab 272 is adapted to be bent through the upper cutout 274 to secure the second right section 226 over the second left section 236 when the cover 200 is assembled around an egg carton 100.
In various embodiments, each of the top tab 282 and the bottom tab 272 are one of rounded and chamfered. In some embodiments, the cover material is one of corrugated fiberboard, corrugated cardboard, and plastic.
Referring to FIG. 3 and FIG. 4A-FIG. 4F, and continuing to refer to prior figures for context, a method for packaging eggs using an egg carton cover 200 is illustrated, in accordance with example embodiments of the technology disclosed herein. In such methods, a cover, as described above, is provided—Block 305. In the continuing example, the cover 200 is provided.
An egg carton is placed on the cover with the egg carton bottom aligned with the central panel—Block 310. FIG. 4A illustrates an egg carton 100 placed on cover 200, in accordance with certain example embodiments disclosed herein.
The first left section of the cover is folded to contact the side of the egg carton nearest the central panel left edge, and the second left section is folded to be substantially parallel to the top of the egg carton—Block 320. FIG. 4B illustrates the first left section 232 of cover 200 folded to contact the side of the egg carton 100 nearest the central panel left edge 214. The second left section 236 is folded to be substantially parallel to the top of the egg carton 100.
The first right section of the cover is folded to contact the side of the egg carton nearest the central panel right edge, and the second left section is folded to contact the top of the second left section, aligning the lower tab with the lower cutout, and aligning the upper tab with the upper cutout—Block 325. FIG. 4C illustrates the first right section 222 of cover 200 folded to contact the side of the egg carton 100 nearest the central panel right edge 212. The second right section 226 is folded to be substantially parallel to the top of the egg carton 100, with the lower tab 282 aligned with the lower cutout 284, and the upper tab 272 aligned with the upper cutout 274.
The bottom flap of the cover is folded to be substantially parallel to the side of the egg carton nearest the central panel bottom edge, while the bottom tab is inserted between the folded second left section and the egg carton—Block 330. FIG. 4D illustrates the bottom flap 252 of cover 200 folded to be substantially parallel to the side of the egg carton 100 (not shown) nearest the central panel bottom edge 218, while the bottom tab 256 (not shown) is inserted between the folded second left section 236 (not shown) and the egg carton 100 (not shown).
The top flap of the cover is folded to be substantially parallel to the side of the egg carton nearest the central panel top edge, while the top tab is inserted between the folded second left section and the egg carton—Block 335. FIG. 4E illustrates the top flap 242 (not shown) of cover 200 folded to be substantially parallel to the side of the egg carton 100 (not shown) nearest the central panel top edge 216, while the top tab 246 (not shown) is inserted between the folded second left section 236 (not shown) and the egg carton 100 (not shown).
The lower tab of the cover is bent through the lower cutout aligned therewith, and the upper tab is bent through the upper cutout—Block 340. FIG. 4F illustrates the lower tab 282 of cover 200 bent through the lower cutout 284 aligned therewith, and the upper tab 272 bent through the upper cutout 274.
The various steps in the method, along with other methods disclosed herein, can be performed in an automated fashion. Variations in order and minor variations in the steps of the methods described herein are contemplated to be included in the methods. For example, while Block 320 and Block 325 should be performed in that order, the egg carton 100 can be inserted into an open end of the rectangular space formed after Block 320 and 325 have been completed. As another example, Block 330 and Block 335 can be performed immediately after Block 305.
In some variations, the cover 200 can include an adhesive applied to one or more surfaces, such as a release tape seal, a gum seal activated by moistening, a self-adhering latex adhesive applied to the back surface of the second right section and the second left section. In some variations, tape can be applied to secure one surface to another, for example, taping across the back side of the second right section to the back side of the first left section when the process described with reference to FIG. 3 and FIG. 4 is performed.
The cover 200 can be used in combination with an egg carton insert to form a kit for packaging cartoned eggs. The process described above with reference to FIG. 3 and FIG. 4 can be performed before the process described below with reference to FIG. 8 (with respect to the device described in FIG. 5 or similar device), FIG. 9 (with respect to the device described in FIG. 6 or similar device), or an analogous process with respect to the device describe in reference to FIG. 7 or similar device.
Referring to FIG. 5, and continuing to refer to prior figures for context, a first embodiment of an egg carton insert 500 is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton insert 500 is a six row 502 a-502 f by two column 504 a-504 b array of domes 510. While 6×2 is the most common egg carton 100 configuration, the egg carton insert 500 can be sized to any commonly used N row×M column egg carton 100.
Each dome 510 in FIG. 5 is shaped and sized to enclose a top portion of an egg. In some embodiments, the dome is shaped and sized to enclose less that the portion of an egg above its largest substantially round cross section. Other dome forms, including a truncated dome with a solid top, a truncated dome with an open top, and a pyramidal dome, can be used. In the example embodiment of FIG. 5, each dome 510 includes a substantially cruciform feature 540 that can facilitate orienting each egg top portion in its corresponding dome 510. Egg carton inserts 500 can be made from other materials, such as foamed plastics, rubber, clear plastic, and felt.
Each dome 510 can be connected to each neighboring dome in the array. In the example embodiment of FIG. 5 representing a pulp insert, each dome 510 is connected to each neighboring dome 510 at the dome edge, including by a small bridge 520. In other embodiments, each dome 510 can be connected to neighboring domes 510 without the use of a bridge 520.
The array of domes 510 forms an opening 530 between each group of four adjacent domes 510. Each opening 530 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 530 can provide lateral stability to the combined egg carton 100 and egg carton insert 500. The loose, but laterally restrained, coupling between the egg carton insert 500 and the egg carton 100 can contribute to the protection of the eggs contained in the egg carton 100. The egg carton insert 500 is arranged such that each dome 510 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 500 can be placed.
The overall dimensions of the egg carton insert 500 are such that the egg carton 100 can be closed when the egg carton insert 500 is placed over one egg occupying each dimple 116 of the egg carton 100.
In some embodiments, at least one dome 510 defines therein a cutout 512 along a portion of the at least one dome at a long side of the array. The cutout 512 is oriented substantially parallel to the long side of the array. The cutout 512 can be in the shape of an arch, a rectangle, or other shape for providing clearance for egg carton 100 features that would otherwise impede closing the egg carton 100 over the egg carton insert 500 when the egg carton 100 dimples 112 are holding eggs.
Referring to FIG. 6, and continuing to refer to prior figures for context, a second embodiment of an egg carton insert 600 is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton insert 600 is a substantially flat 6×2 array of rings 610 defining holes therein. While 6×2 is the most common egg carton 100 configuration, the egg carton insert 600 can be sized to any commonly used N row×M column egg carton 100. The length of the egg carton insert 600 is less than the interior length of an egg carton 100. The width of the egg carton insert 600 is less than the interior width of an egg carton 100. The thickness of the egg carton insert 600 is less than one half the height of an egg to be carried in the egg carton 100. The overall dimensions of the egg carton insert 600 are such that the egg carton 100 can be closed when the egg carton insert 600 is placed over one egg occupying each dimple 166 of the egg carton 100.
Each ring 610 in FIG. 6 defines therein a hole 620 shaped and sized to fit over a top portion of an egg placed in an egg carton 100. In some embodiments, each ring 610 defines a hole 620 therein that is shaped and sized to encircle the egg above its largest substantially round cross section, leaving a portion of the egg projecting through the ring 610. While the outer portion of the ring 610 illustrated in FIG. 6 is substantially circular, other ring forms, including various regular polygons and truncated polygons, can be used. The hole 620 formed by each ring 610 is aligned with a corresponding dimple 116 of the egg carton 100.
Each ring 610 is connected to each neighboring ring 610 in the array. In the example embodiment of FIG. 6 representing a pulp insert, each ring 610 is connected to each neighboring ring 610 at the ring edge. Egg carton inserts 600 can be made from other materials, such as foamed plastics, rubber, clear plastic, and felt.
The array of rings 610 forms an opening 630 between each group of four adjacent rings 610. Each opening 630 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 630 can provide lateral stability to the combined egg carton 100 and egg carton insert 200. The loose, but laterally restrained, coupling between the egg carton insert 600 and the egg carton 100 can contribute to the protection of the eggs from damage. The egg carton insert 600 is arranged such that each ring 610 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 600 can be placed.
Referring to FIG. 7, and continuing to refer to prior figures for context, a third embodiment of an egg carton insert 700 is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. In the egg carton insert 700 of FIG. 7, each odd-numbered ring position of the egg carton insert illustrated in FIG. 6 in the second column 720 each is vacant, and each even-numbered ring position of the egg carton insert illustrated in FIG. 6 in the first column 710 is vacant.
Referring to FIG. 8, a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein, is shown. In such methods an N row by M column egg carton containing a plurality of eggs is provided—Block 810. For example, a 6×2 conventional egg carton 100 as shown in FIG. 1, with one egg in each carton dimple 116, is provided.
An N row by M column egg carton insert in the form of an array of interconnected domes is provided—Block 820. For example, the egg carton insert 200 in the form of a 6×2 array of domes 210 of FIG. 2 is provided. Each dome 210 is sized to enclose a top portion of an egg. Each dome 210 is connected to each neighboring dome 210 in the array 200. The array of domes 210 forming an opening 230 between each group of four adjacent domes 210. The array is arranged such that each dome 210 corresponds to a dimple 116 of the egg carton 100. The overall dimensions of the egg carton insert 200 are such that the egg carton 100 can be closed when the egg carton insert 200 is placed over one egg occupying each dimple 116 of the egg carton.
The array is placed over the eggs such that each dome 210 aligns with a dimple 116—Block 830. The egg carton, containing the eggs and the egg carton insert 200, is closed—Block 840.
Referring to FIG. 9, a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein, is shown. In such methods an N row by M column egg carton containing a plurality of eggs is provided—Block 910. For example, a 6×2 conventional egg carton 100 as shown in FIG. 1, with one egg in each carton dimple 116, is provided.
An egg carton insert in the form of a substantially flat elongated rectangle of material is provided—Block 920. For example, the egg carton insert 300 having a length less than the interior length of the egg carton 100, a width less than the interior width of the egg carton 100, and a thickness less than one half the height of an egg in the egg carton 100 is provided. The material defines therein an N row by M column array of through holes of common diameter. The hole diameter less then the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton.
The material is placed over the eggs such that each hole aligns with a dimple 116—Block 930. The egg carton, containing the eggs and the egg carton insert 300, is closed—Block 940.
The example systems, methods, and acts described in the embodiments presented previously are illustrative, and, in alternative embodiments, certain acts can be performed in a different order, in parallel with one another, omitted entirely, and/or combined between different example embodiments, and/or certain additional acts can be performed, without departing from the scope and spirit of various embodiments. Accordingly, such alternative embodiments are included in the technology described herein.
Although specific embodiments have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects described above are not intended as required or essential elements unless explicitly stated otherwise. Modifications of, and equivalent components or acts corresponding to, the disclosed aspects of the example embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of the present disclosure, without departing from the spirit and scope of embodiments defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures.

Claims

What is claimed is:

1. A cover to package cartoned eggs, comprising:

a cruciform sheet of material having stiffness of at least corrugated cardboard, comprising:

a rectangular central section dimensioned along each of the central section right edge and the central section left edge to the length of an egg carton, and along each of the central section top edge and the central section bottom edge to the width of the egg carton;

a rectangular first right section abutting, and coextensive with, the central section right edge along the first right section left edge; the first right section dimensioned along each of a first right section top edge and first right section bottom edge to the at overall height of the egg carton plus the thickness of the sheet;

a rectangular second right section abutting, and coextensive with, the first right section right edge along the second right section left edge; the second right section dimensioned along each of a second right section top edge and second right section bottom edge to the overall width of the egg carton plus the thickness of the sheet;

a rectangular first left section abutting, and coextensive with, the central section left edge along the first left section right edge; the first left section dimensioned along each of a first left section top edge and first left section bottom edge to the overall height of the egg carton;

a rectangular second left section abutting, and coextensive with, the first left section left edge along the second left section right edge; the second left section dimensioned along each of a second left section top edge and second left section bottom edge to the overall width of the egg carton;

a rectangular top flap abutting, and coextensive with, the central section top edge along the top flap bottom edge; the top flap dimensioned along each of the top flap left edge and the top flap right edge to the overall height of the egg carton;

a top tab abutting the top flap along the top edge of the top flap; the top tab dimensioned along a top tab bottom edge and a top tab top edge less than the width of the egg carton by at least the thickness of the sheet;

a rectangular bottom flap abutting, and coextensive with, the central section bottom edge along the bottom flap top edge; the bottom flap dimensioned along each of the bottom flap left edge and the bottom flap right edge to the overall height of the egg carton; and

a bottom tab abutting the bottom flap along the bottom edge of the bottom flap; the bottom tab dimensioned along a bottom tab bottom edge and a bottom tab top edge less than the width of the egg carton by at least the thickness of the sheet.

2. The cover of claim 1, wherein each central section edge, the first right section left edge, first right section right edge, top flap top edge, and bottom flap bottom edge are creased toward the front face of the sheet.

3. The cover of claim 2, wherein the top flap bottom edge and bottom flap top edge are perforated.

4. The cover of claim 1, wherein the second left section top edge comprises an upper tab slotted inward from the second left section top edge, and the second right section top edge forms therein a cutout corresponding to the upper tab; and second left section bottom edge comprises a lower tab slotted inward from the second left section bottom edge, and the second right section bottom edge forms therein a cutout corresponding to the lower tab.

5. The cover of claim 4, wherein each of the upper tab and lower tab is trapezoidal with the trapezoid base at the respective edge.

6. The cover of claim 1, wherein each of the lower tab and the upper tab are one of rounded and chamfered.

7. The cover of claim 1, wherein the cover material is one of corrugated fiberboard and corrugated cardboard.

8. The cover of claim 1, wherein the cover material is a plastic.

9. A method for packaging eggs, comprising:

providing a cover of claim 1;

placing an egg carton on the sheet with the egg carton bottom aligned with the central panel;

folding the first left section to contact the side of the egg carton nearest the central panel left edge and the second left section to be substantially parallel to the top of the egg carton;

folding the first right section to contact the side of the egg carton nearest the central panel right edge and the second left section to contact the top of the second left section; and

folding the bottom flap to be substantially parallel to the side of the egg carton nearest the central panel bottom edge;

folding the bottom tab to be substantially parallel to and contacting the top of the egg carton;

folding the top flap to be substantially parallel to the side of the egg carton nearest the central panel top edge; and

folding the top tab to be substantially parallel to and contacting the top of the egg carton.

10. The method of claim 9:

wherein:

the second left section top edge comprises an upper tab slotted inward from the second left section top edge,

the second right section top edge comprises an upper cutout corresponding to the upper tab,

the second left section bottom edge comprises a lower tab slotted inward from the second left section bottom edge, and

the second right section bottom edge comprises a lower cutout corresponding to the lower tab; and

the method further comprises:

after folding the first left section to contact the side of the egg carton nearest the central panel left edge and the second left section to be substantially parallel to the top of the egg carton, and after folding the first right section to contact the side of the egg carton nearest the central panel right edge and the second left section to contact the top of the second left section,

bending the upper tab through the upper cutout; and

bending the lower tab through the lower cutout.

11. The method of claim 10, further comprising:

providing an egg carton insert, comprising:

an N row by M column array of interconnected domes:

each dome sized to enclose a top portion of an egg;

each dome connected to each neighboring dome in the array;

the array of domes forming an opening between each group of four adjacent domes; and

the array arranged such that each dome corresponds to a dimple of an egg carton into which the insert can be placed;

wherein the overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton; and

providing an egg carton insert in the form of an array of interconnected domes sized corresponding to the array of dimples of the egg carton:

each dome sized to enclose a top portion of an egg,

each dome connected to each neighboring dome in the array,

the array of domes forming an opening between each group of four adjacent domes, and

the array arranged such that each dome corresponds to a dimple of the egg carton;

wherein the overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton;

placing the array over the eggs such that each dome aligns with a dimple; and

closing the egg carton.

12. The method of claim 11, wherein at least one dome defines therein a cutout along a portion of the at least one dome at a long side of the array.

13. The method of claim 11, wherein the insert material is molded pulp.

14. The method of claim 11, wherein

N is at least two and M is at least two;

in each even-numbered column, each odd-numbered dome position is vacant; and

in each odd-numbered column, each even-numbered dome position is vacant.