US3128932A - Molded egg carton - Google Patents

Molded egg carton Download PDF

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Publication number
US3128932A
US3128932A US18623A US1862360A US3128932A US 3128932 A US3128932 A US 3128932A US 18623 A US18623 A US 18623A US 1862360 A US1862360 A US 1862360A US 3128932 A US3128932 A US 3128932A
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US
United States
Prior art keywords
pulp
areas
screen
die
thickness
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US18623A
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English (en)
Inventor
Richard F Reifers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Diamond National Corp
Original Assignee
Diamond National Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Diamond National Corp filed Critical Diamond National Corp
Priority to US18623A priority Critical patent/US3128932A/en
Priority to GB5506/61A priority patent/GB954305A/en
Priority to DK71061AA priority patent/DK100409C/da
Priority to SE2554/61A priority patent/SE324498B/xx
Priority to BE601762A priority patent/BE601762A/fr
Priority to CH373561A priority patent/CH394785A/de
Priority to FI610599A priority patent/FI43667C/fi
Priority to AT261761A priority patent/AT253908B/de
Priority to DE19611411252 priority patent/DE1411252A1/de
Priority to DE19611436925D priority patent/DE1436925B1/de
Priority to US155523A priority patent/US3185615A/en
Application granted granted Critical
Publication of US3128932A publication Critical patent/US3128932A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/30—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
    • B65D85/32—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for eggs
    • B65D85/324—Containers with compartments made of pressed material
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J7/00—Manufacture of hollow articles from fibre suspensions or papier-mâché by deposition of fibres in or on a wire-net mould

Definitions

  • the present invention relates to pulp molding and more particularly to a new construction of pulp molding die, a new method of pulp molding and the resulting product.
  • Another object of the present invention is to provide a method of molding using standard pulp, molding time and vacuum to produce an article of lesser weight than previously obtained, with the lesser thickness being restricted to given areas of the article.
  • a still further object of the present invention is to provide a method of molding pulp articles so that they have a reduced nesting interval.
  • Another object of the present invention is to provide a method of molding a pulp article having portions thereof of a lesser thickness than other portions thereof.
  • a still further object of the present invention is to provide a novel molding die for pulp articles which permits molding articles having portions thereof of a lesser thickness than other portions thereof.
  • FIGURE 1 is a cross sectional view of an example of a pulp product made in accordance with the present invention.
  • FIGURE 2 is a top plan View of a die screen in accordance with the present invention before it has been formed into its three dimensional shape;
  • FIGURE 3 is an enlarged cross sectional view of the screen taken along the line 33 of FIGURE 2;
  • FIGURE 4 is a partial cross sectional view showing the screen and molding apparatus.
  • the present invention solves this problem by utilizing a molding screen in which relatively large areas thereof are blocked out in a plurality of discrete small areas in a repeated geometric pattern.
  • a wire screen 20 is shown in which an area B is not blocked out and a large area A, is blocked out at a plurality of small, discrete areas 2.2 which are identical in configuration.
  • the blocked out areas are small circles arranged in horizontal and vertical rows.
  • the shapes of the blocked out areas need not be identical, and may be of various shapes. Also, the arrangement of the areas need not be in horizontal and vertical rows. The only important and critical limitations are in the total area blocked out in the area A, and the diameter of each of the small discrete areas blocked out.
  • the method of blocking out of the screen die can be accomplished in a number of ways.
  • the impregnation or blocking out of the screen is so conducted that the surface characteristics of the screen are not affected as shown in FIGURE 3. This is done by impregnating less than the thickness of the screen. Good results have been obtained by using polyethylene to block out the small screen areas.
  • An ironing technique may be employed for embedding the polyethylene into the screen.
  • the use of a stencil having the desired cut out areas may be used.
  • plastic or paint-like material can be sprayed onto the screen for blocking out the desired areas.
  • the use of a mask in conjunction with a hot spray of a metal, such as lead, against the die could be utilized.
  • a further method is the use of electroplating onto the screen in controlled areas to build up the thickness of deposit sufficiently to reduce or completely block out these areas.
  • the screen is formed into the three dimensional finished shape.
  • the molding process is conducted in the usual manner.
  • the die acts as a filter medium so as to separate the water from the pulp fibers which are in suspension in the pulp.
  • the amount of open area in the Wire screen generally far exceeds the amount of open area necessary to successfully mold an article.
  • One of the reasons for having the openings as large as they are and in such a high percentage is to prevent the dies from becoming clogged in continued use.
  • the usual drainage as in the unblocked portion B of the die in a direct vertical direction thru the die and pulp is changed.
  • the drainage In the blocked out section A of the die, the drainage translates itself from vertical drainage to horizontal and angular drainage and thus increases the distance of travel thru the new filter medium formed.
  • the amount of pulp deposited is less in section A of the die than in the unblocked section B of the die where the vertical drainage takes place and a thicker mat is formed.
  • the effective thickness of the resulting article in the portions corresponding to the blocked out areas of the die is uniformly less than in the portions corresponding to the unblocked out areas of the die.
  • a filter of varying density is produced thereby causing a slower rate of build up of material in a given unit area as compared with another untreated area.
  • an egg crate as shown in FIG- URE 1 was molded on a wire screen die as shown in FIGURE 4 wherein the port-ion of the die corresponding to the cover 30 of the egg carton was untreated, and the portion of the die corresponding to the bottom of the egg carton 32 was treated as illustrated with dots of polyethylene embedded therein, each dot having a diameter of W and 25% of that area of the die being blocked out.
  • an egg carton was obtained in a production run which had an overall weight reduction of over from that obtained under the same conditions using a standard untreated die.
  • the molding apparatus of FIGURE 4 includes a former member 40 provided with a plurality of apertures 42 passing therethru. The edge of the former is provided with a flange. 44 which is bolted to the apparatus. The molding die 44 of wire screen shaped to correspond to the shape of the former rests thereon and is also bolted to the apparatus. The pulp 46 is shown forming on the die. The portion of the die which forms the bottom of the egg carton has been partially blocked out by the dots of polyethylene 48. As shown, the pulp forming over the partially blocked out area of the die is thinner than the pulp forming over the remainder of the die.
  • the finished article shown in FIGURE 1 shows the difference in :wall thickness of the two portions of the egg carton.
  • This method is particularly well suited for an egg carton construction since the cell areas therein have always been overly strong as compared to the cover portion of the carton.
  • the blocking out has been described with an impregnation of the screen of a thickness less than that of the screen, it is contemplated that for some purposes the blocking out can be either flush with or higher than the thickness of the screen. Certain decorative or esthctic effects can be obtained in this manner.
  • the block out technique utilized must not seriously affect the screen contouring properties necessary to make a three dimensional die. It is therefore important that the block out technique used be flexible to stretching in the screen forming technique.
  • the use of a rubber latex solution for this purpose to obtain maximum flexibility is contemplated.
  • the block out medium must be capable of withstanding harsh chemicals, steam and other cleaning procedures normally used on the screens in production. It must be able to withstand the acid action of the molded pulp along with the abrasive action experienced by the die in actual production.
  • the present technique has great magnitude of importance to production economy. Broadly it permits the reduction of the thickness of portions of molded pulp articles where less strength and greater flexibility is required, and also, it permits the reduction of the thickness of portions of an article to be nested to reduce the nesting interval.
  • An egg carton molded of pulp of single ply construction comprising a cover portion and a bottom portion having cells therein adapted to hold the eggs, said bottom portion containing the egg cells having a uniformly lesser effective thickness of pulp and Weight per square inch than said cover section.
  • a molded pulp article of single ply construction having portions thereof of an irregular configuration which inherently gives greater strength to said portions than other portions thereof, said portions being formed of pulp of a uniformly lesser effective thickness and weight per square inch than the remaining portions of the article.
  • An egg carton molded of pulp of single ply construction comprising a cover portion and a bottom portion having cells therein adapted to hold eggs, said cover portion and bottom portion being integral, said bottom portion containing the egg cells having a uniformly lesser weight per square inch than said cover portion, said bottom portion having discrete areas therein in a repeated geometric pattern of less than major dimension to each discrete area which are of lesser thickness than the remainder of said bottom portion and which are each completely surrounded by thicker pulp areas.
  • a molded pulp article of single ply construction comprising certain portions thereof of lesser weight. of pulp per square inch and portions of greater weight of pulp per square inch, the portions of lesser Weight per square inch being of irregular shape and having a plurality of small discrete thinner pulp areas therein in a repeated geometric pattern, said areas not exceeding major dimension to each area, each said area being surrounded by thicker pulp areas whereby the weight per square inch of said portions of lesser weight is uniformly reduced as compared to said portions of greater weight per square inch.
  • An egg carton molded of pulp of single ply construction comprising a cover portion and a bottom portion having oells therein adapted to hold eggs, said cover portion and said bottom portion being integral, said egg cells each having a uniformly lesser weight per square inch than the remainder of said carton, said cells having discrete areas therein in a repeated geometric pattern of less than major dimension to each area which are of lesser thickness than the remainder of said cell and which are each completely surrounded by thicker pulp areas.
  • a molded pulp article comprising a ply therein, said ply having a portion thereof of an irregular configuration which inherently gives greater strength to said portion than other portions thereof, said portion being formed of pulp of a uniformly lesser effective thickness and Weight per square inch than the remaining portions of the article.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Paper (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
US18623A 1960-03-30 1960-03-30 Molded egg carton Expired - Lifetime US3128932A (en)

Priority Applications (11)

Application Number Priority Date Filing Date Title
US18623A US3128932A (en) 1960-03-30 1960-03-30 Molded egg carton
GB5506/61A GB954305A (en) 1960-03-30 1961-02-14 Improvements in or relating to the molding of pulp articles
DK71061AA DK100409C (da) 1960-03-30 1961-02-20 Raster af trådvæv til anvendelse ved sugestøbning af en af fibrøs pulpmasse bestående genstand.
SE2554/61A SE324498B (de) 1960-03-30 1961-03-10
BE601762A BE601762A (fr) 1960-03-30 1961-03-24 Procédé et dispositif de moulage d'objets en pâte à papier
CH373561A CH394785A (de) 1960-03-30 1961-03-28 Verfahren zur Herstellung eines geformten Gegenstandes aus fasriger Pulpe, Form zur Ausführung des Verfahrens und nach dem Verfahren hergestellter Gegenstand
FI610599A FI43667C (fi) 1960-03-30 1961-03-29 Lankaviiramuotti
AT261761A AT253908B (de) 1960-03-30 1961-03-30 Verfahren und Gesenk zur Herstellung von Gegenständen, wie Eikartons u. dgl. mit verschiedener Wandstärke
DE19611411252 DE1411252A1 (de) 1960-03-30 1961-03-30 Verfahren zur Herstellung eines Faserstoffkoerpers
DE19611436925D DE1436925B1 (de) 1960-03-30 1961-03-30 Verfahren zum Herstellen eines einschichtigen,sauggeformten Faserstoffbehaelters und nach diesem Verfahren hergestellter Faserstoffbehaelter
US155523A US3185615A (en) 1960-03-30 1961-10-30 Method and mold for controlled stock formation in a pulp molding operation

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US18623A US3128932A (en) 1960-03-30 1960-03-30 Molded egg carton

Publications (1)

Publication Number Publication Date
US3128932A true US3128932A (en) 1964-04-14

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ID=21788894

Family Applications (1)

Application Number Title Priority Date Filing Date
US18623A Expired - Lifetime US3128932A (en) 1960-03-30 1960-03-30 Molded egg carton

Country Status (3)

Country Link
US (1) US3128932A (de)
AT (1) AT253908B (de)
DK (1) DK100409C (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4081123A (en) * 1974-04-29 1978-03-28 Diamond International Corporation Dual basis weight multi-walled egg carton end cells
US4162935A (en) * 1975-10-02 1979-07-31 Idra Ag Papier-mache coffin and method of making it
US4448344A (en) * 1982-09-01 1984-05-15 Diamond International Corporation Egg cell construction
US6276531B1 (en) 2000-03-01 2001-08-21 Pactiv Corporation Molded fiber nestable egg tray packaging system
US7678307B1 (en) 2004-04-14 2010-03-16 Materials Innovation Technologies, Llc Vortex control in slurry molding applications
JP2010189830A (ja) * 2010-03-29 2010-09-02 Oishi Sangyo Kk 球状果実の包装用トレーの製造法

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1850584A (en) * 1927-07-21 1932-03-22 Holed Tite Packing Corp Carton for fragile articles
US2009874A (en) * 1934-05-25 1935-07-30 Thomas P Cauley Egg carton
US2423756A (en) * 1943-12-17 1947-07-08 Merle P Chaplin Molded fibre article
US2515113A (en) * 1943-12-17 1950-07-11 Chaplin Corp Method of producing molded fiber articles
US2560847A (en) * 1947-06-03 1951-07-17 Chaplin Corp Molded fiber article
US2738914A (en) * 1950-10-31 1956-03-20 Keyes Fibre Co Fruit and vegetable container
US2739750A (en) * 1952-01-29 1956-03-27 Diamond Match Co Molded pulp egg carton
US2829568A (en) * 1957-04-05 1958-04-08 Chaplin Corp Pulp forming die
US2843304A (en) * 1952-11-20 1958-07-15 Diamond Gardner Corp Molded pulp carton lock
US2927635A (en) * 1958-03-13 1960-03-08 Diamond National Corp Die for pulp molding
US2974847A (en) * 1957-10-24 1961-03-14 Diamond National Corp Packages or cartons for eggs and other fragile articles
US3040948A (en) * 1959-01-27 1962-06-26 Diamond National Corp Molded pulp article

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1850584A (en) * 1927-07-21 1932-03-22 Holed Tite Packing Corp Carton for fragile articles
US2009874A (en) * 1934-05-25 1935-07-30 Thomas P Cauley Egg carton
US2423756A (en) * 1943-12-17 1947-07-08 Merle P Chaplin Molded fibre article
US2515113A (en) * 1943-12-17 1950-07-11 Chaplin Corp Method of producing molded fiber articles
US2560847A (en) * 1947-06-03 1951-07-17 Chaplin Corp Molded fiber article
US2738914A (en) * 1950-10-31 1956-03-20 Keyes Fibre Co Fruit and vegetable container
US2739750A (en) * 1952-01-29 1956-03-27 Diamond Match Co Molded pulp egg carton
US2843304A (en) * 1952-11-20 1958-07-15 Diamond Gardner Corp Molded pulp carton lock
US2829568A (en) * 1957-04-05 1958-04-08 Chaplin Corp Pulp forming die
US2974847A (en) * 1957-10-24 1961-03-14 Diamond National Corp Packages or cartons for eggs and other fragile articles
US2927635A (en) * 1958-03-13 1960-03-08 Diamond National Corp Die for pulp molding
US3040948A (en) * 1959-01-27 1962-06-26 Diamond National Corp Molded pulp article

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4081123A (en) * 1974-04-29 1978-03-28 Diamond International Corporation Dual basis weight multi-walled egg carton end cells
US4162935A (en) * 1975-10-02 1979-07-31 Idra Ag Papier-mache coffin and method of making it
US4448344A (en) * 1982-09-01 1984-05-15 Diamond International Corporation Egg cell construction
US6276531B1 (en) 2000-03-01 2001-08-21 Pactiv Corporation Molded fiber nestable egg tray packaging system
US7678307B1 (en) 2004-04-14 2010-03-16 Materials Innovation Technologies, Llc Vortex control in slurry molding applications
US20100124650A1 (en) * 2004-04-14 2010-05-20 Ervin Gieger Vortex control in slurry molding applications
JP2010189830A (ja) * 2010-03-29 2010-09-02 Oishi Sangyo Kk 球状果実の包装用トレーの製造法

Also Published As

Publication number Publication date
AT253908B (de) 1967-04-25
DK100409C (da) 1964-11-23

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