Sept. 21, 1965 R. F. REIFERs ET AL 3,207,409 MODED PULP EGG CARTON Filed Sept. 4, 1962 5 Sheets-Sheet 37/

INVENTORS ?9/3/ Aichard AE A’effers Henry A. Lord BY KAel- (Otto c MOLDED PULP EGG CARTON Filed Sept. 4, 1962 5. Sheets-Sheet 2

ShhAAhhAAJJ HLLLLLhAAALAAAAhJA L Hh

INVENTORS Aichard AE A’e/fers Henry A. Lord BY - KA ReSr. - - GUD,2 Foc- ATTONEy SS Sept. 21, 1965 R. F. REIFERS ETAL 3,207409 MOLDED PULP EGG CARTON Filed Sept. 4, 1962 5 Sheets-Sheet 3

A/6.6

INVENTORS Alchard AE feifers Henry A. Lord BY KARL GUD. FL-Ocksts ATTORNEY Sept. 21, 1965 R. F. REIFERs ETAL 3,207409 MODED PULP EGG CARTON Filed Sept. 4, 1962 5 Sheets-Sheet 4

A/G 10

A/G, ?/

A/6/2

Rigid-, - Flexible Area - Rigid 62 86" 68 86' 62'

A/6 /3

INVENTORS AFPichard A feifers Henry A. Lord P° KARA (). Flock

A/G f4 252 226

W.W ,

INVENTORS Aichard A5 /eifers Henry A. Lord BY KAR- Uu). Locks ????y 3,207,409 United States Patent Office Patented Sept. 21, 1965 2 vide a novel substantially universal molded pulp egg 3,207,409 carton in which egg movement and rattle are substan MOLEDED PULP EGG CARTON tially reduced, to accommodate for varying dimensions Richard F. Reifers, New Canaan, Conn., and Henry A. of the eggs and reduce accidental breakage to a minimum. Lord, Palmer, Mass, assignors to Diamond interna A further object of the present invention is to provide tional Corporation, a corporation of Delaware an egg carton which includes features which permit ready Filedi Sept. 4, 1962, Ser. No. 221,028 denesting or separation of a stack of egg cartons, one 10 Ciaims. (Cf. 229-2.5) from the other. The present invention relates generally to molded pulp A still further object of the present invention is to pro articles, and more particularly to an improved molded O vide a molded pulp egg carton in which both large and pulp egg carton in which selected portions of the egg Small dimensioned eggs will be adequately supported, and cells are provided with increased strength and improved the eggs will be supported in a relatively soft support cushioning characteristics. Surface on support structure to retain them in a rel Eggs are widely marketed throughout the World in atively protected and fixed position within an egg cell cartons that hold a dozen eggs each, and among the most 15 and both relatively large and small sized eggs can be widely known type of egg carton, is one that is produced readily accommodated in the same carton. from molded pulp. Molded pulp egg cartons are pro Still another object of the invention is to provide a duced on pulp molding machinery in a conventional molded pulp egg carton which includes a cell structure manner, wherein the carton is deposited by Suction im having relatively rigid and reinforced outer walls to pro posed within a die of desired configuration and a slurry 20 tect against external shock, and a relatively soft and re of pulp is deposited on the exterior of the die. There silient inner support surface for readily absorbing shock after, in order to enhance the appearance of the carton transmitted to the eggs from the outer wall. as well as to substantially soften the material from which And yet another object of the present invention is to the carton is produced, the article is pressed between utilize a novel reforming method for molded pulp egg cell mating dies. 25 Support structure whereby the nature of the egg support In these known egg cartons, the eggs are held in egg Surface, due to the fiber character of the material used cells, separated from each other by saddle portions be to produce the carton, is such that certain fiber portions tween adjacent cells and verticals posts having four cells are Substantially softened and reoriented to a degree to formed thereabout. The eggs are generally in contact afford in a sense mechanical movement between integral with the walls of the cells and thus shocks to the ex 30 and reoriented fiber. terior of the carton result in force being transmitted to And a still further object of the present invention is the eggs through the walls of the carton, accordingly to provide, in a novel egg cell structure for molded pulp resulting in the small amount of egg breakage that pres carton portions, substantially tangential contact with ently exists. eggs in the cell so that there is a minimum of sticking of Additionally, in known molded egg cartons, there is the eggs in a cell due to “leakers' or broken eggs whereby some egg movement or egg rattle, and this rattling of eggs may be readily removed from the cells. the eggs within the carton as they are shipped or the And yet another object of the present invention is to carton is handled, has in part contributed to egg break provide a novel cell structure in molded pulp egg car age. Further, the so-called rattling of the eggs has re tons of a capacity different from the conventional one sulted in a deleterious effect on the quality of the eggs. 40 dozen egg capacity. Further, in prior art egg cartons, it has been the general Still another object of the present invention is to pro practice of packaging eggs of a given size or quality to vide a novel carton of the character involved which in gether in one carton, and in order to provide the best pos cludes a novel lid end wall support and ventilation struc sible marketing of eggs, consistent with necessary econ ture which affords the necessary strength, rigidity and omies, it has been the general practice to provide differ 45 load transmittal characteristics for cartons of the char ent sizes of cartons for Some of the different grades of acter involved. eggs. Despite the care that has been taken in sorting the Other objects and the nature and advantages of the in eggs, unless the selection is carried to a degree far beyond stant invention will be apparent from the following de that which is economically feasible, a dozen eggs of a Scription taken in conjunction with the accompanying particular grade, as far as marketing standards are con 50 drawings, wherein: cerned, will nevertheless vary, one from another, over a FIG. 1 is a top plan view of a molded pulp egg carton, certain range of exterior dimensions as well as weight. incorporating the novel features of the invention; Thus, as a result of the variations of individual egg grades FIG. 2 is a front elevation of the carton of FIG. 1, and weights, it has been found that those eggs which de on a reduced Scale, showing the carton in a closed condi part from the standard of a particular grade, will not be 55 tion; securely and properly retained in an egg cell. FIG. 3 is a vertical section taken substantially on the Although molded pulp egg cartons may be produced plane of line 3-3 of FIG. 2; to accommodate all sizes of eggs, however, to store and FIG. 4 is a vertical section taken substantially on the tool up to produce the range of sizes of egg cartons nec plane of line 4-4 of FIG. 1; essary to accommodate all the single variations is neither 60 FIG. 5 is a fragmentary vertical section taken sub practical nor economical. Additionally, the shipping car stantially on the plane of line 5-5 of FIG. 1; tons in which egg cartons are shipped and stored gener FIG. 6 is a vertical section similar to FIG. 5, showing ally have uniform exterior dimensions, and therefore the appearance of a separator post after initial disposition there has been a constant attempt to maintain exterior of a pulp slurry on a suction mold die, and prior to press dimensions of the egg cartons relatively uniform. Fur 65 ing of the same; ther, there has been a constant research to develop a sub FIG. 7 is a vertical section similar to FIGS. 5 and 6, stantially universal carton which will accommodate and showing the appearance of a separator post cushioning protect substantially all ranges of sizes of eggs without area during initial pressing: materially changing exterior dimensions of the carton, FIG. 8 is a vertical section similar to FIGS. 5-7 show and it is toward this end which the novel carton and 70 ing the appearance of the cushioning area of a vertical method of the present invention is directed. Separator post after reforming or secondary pressing The primary object of the present invention is to pro thereof; 3,2O7,409 3 4. FIG. 9 is a vertical section similar to FIGS. 5-8, show carton; however, the egg supporting structure in the end ing the residual position of the vertical separator post most cells functions in substantially the same manner as cushioning areas; that of the innermost cells. Each of the cells 34 com FIG. 10 is an enlarged fragmentary horizontal section prises a transverse bottom 48 preferably including a taken substantially on the plane of line 10–19 of FIG. cushioning button 50. The cells, when viewing the in 6, showing a cross section through one vertical post cush terior thereof, as seen in FIG. 1, are formed with up ioning area after original molding or disposition of the wardly and outwardly integrally connected adjacent cell pulp slurry on a suction mold forming die; and illustrat forming sections, or segments 52 and 54, which converge ing diagrammatically the random or normal orientation upwardly and terminate at the upper surface of the saddle of the article fibers; O 38. Adjacent segments 56 and 58 converge upwardly and FIG. 11 is an enlarged horizontal section taken sub terminate at the longitudinally extending Saddles 36. stantially on the plane of lines -i of FIG. 7, showing Segments 60 extend outwardly and terminate at the hinge the initial forming step which generally is accompanied line 4 and constitute a portion of the forward wall of by considerable pressure and heat applied between mating the egg receiving section of the carton, and segments 62 pressing dies, and illustrating the manner in which the extend upwardly and outwardly and from a portion of fibers at the cushioning are reoriented, the inner surface the rear wall of the egg receiving Section. fibers being subject to greater tension than those in the The segments 52, 54, 56 and 62 are generally not en outer surface of the cushioning area; gaged by an egg disposed in the cells unless than eggs are FIG. 12 is an enlarged horizontal section taken sub particularly large or of a “golf-ball” shape, for example. stantially on the plane of line 12-12 of FIG. 8, showing Each of the cells affords a substantial four-point Support the manner in which the cushioning area is reformed be for the eggs disposed therein. This four-point Suspension tween mating dies to subject the outer surface fibers to of the eggs is afforded by a pair of similar cell forming greater tension than those on the inner surface as men segments 64 and 66 which have a lower portion having tioned with respect to FIG. 11; a convex cross section, when viewing the interior of the FIG. 13 is an enlarged horizontal section taken sub 25 cells, this convex cross section merging into vertically stantially on the plane of line 13-3 of FIG. 9, illustrat extending and elliptical or tear-shaped pressed areas 68 ing the manner in which the cushioning area tends to and 70, respectively. If preferred, the elliptically shaped assume a substantially planar condition due to the sections 68 and 70 may have vertically extending therein "memory” effect caused by the step of FIG. 11, shown by inwardly pressed rib portions 72 and 74 respectively, which phantom lines, the cushioning area comprising "Super 30 soft' fibers on both the inner and outer surfaces of the in effect reduce the surface exposure to the eggs in the cushioning area; cells to prevent sticking of eggs in the case of a “leaker, FIG. 14 is a perspective view of another embodiment for example. of the novel carton in an open condition, incorporating The segments 62, 64 and 66 provide a relatively rigid the novel cells and including a modified lid end wall in wall in the cells, however, the pressed areas 68 and 70 conjunction with a slightly modified support post top wall; are relatively “soft” and together with the ribs 72 pro F.G. 15 is an end view of the carton of FG. 14 when vide a minimum of egg contact. The conveX Surface may closed, looking from left to right at FIG. 14; and have an arc which is shallower than that found in most FIG. 16 is a fragmentary vertical section taken sub eggs, and thus minimum egg contact is insured. This stantially on the plane of line 6-16 of FIG. 15. relatively rigid outer wall construction for the cells affords Referring to the drawings in detail, a molded pulp 40 protection of the eggs due to lateral shock occurring egg carton is indicated generally at 0 and comprises a during handling, packing and shipping. lower bottom or egg receiving section 12, to which is The frusto-pyramidal separator posts 40 include Sub hingedly connected at 14 a lock flap i6. Hingedly con stantially planar post forming segments 76 and 78 in nected opposite the lock flap 16 as indicated at 18 is a the respective cells 34, and four adjacent cells including substantially planar lid or cover member 20. 45 opposed pairs of segments 76 and 78, as clearly Seen in The cover member 29 includes a substantially planar FIG. 1, which together with the top portion 42 form one top 22 integral with an outwardly angled or diverging of the frusto-pyramidal separator posts. It will be noted peripheral side wall 24 which terminates in a peripheral thay the opposed pairs of post forming segments 76 and lower bead 26. The front or forward wall 28 of the pe 78 converge into the substantially rectangular or square ripheral wall 24 has extending therethrough longitudin 50 upper end portion 42 of the separator post. The cell ally spaced apertures or slots 30 for receiving there segments 62 extend in planar relation down to the cell through locking buttons 32 projecting forwardly from the bottoms and are disposed at a greater angle with respect lock flap 16, the rear appearance of these lock buttons to the vertical than the adjacent convex segments 64 and being shown in FIG. 1. 66. Stated in another way, the segments 64 and 66 are The lower or egg receiving section 2 of the carton 55 more vertically disposed than the segments 62. The includes a plurality of substantially similar, egg receiving pressed areas 68 and 70 are formed above the base of the cells indicated generally at 34, each of the cells being !!!! and extend upwardly and outwardly at a still greater separated one from the other by means of longitudinally angle. and transversely extending saddle portions 36 and 38, re The cushioning areas or "bubble indents' 30 are formed spectively. Intersecting pairs of the saddle portions 36, 60 above the base of the cells and are arcuate along their 38 substantially define edge portions of frusto-pyramidal length, first curving inwardly a greater degree than the separator posts indicated generally at 40 which terminate shallow return curve as seen in FIG. 7. The shallow in a substantially square top portion 42, the corners of return curve aids to control egg rattle in the upper zone which are disposed in alignment with the saddle portions of the egg cells. 36 and 38. The upper portions 42 of the separator posts 65 The adjacent cell walls 76 and 78 are set off from 40, as seen in FIG. 3, will abuttingly engage the inner each other at approximately 45 degrees with respect to a surface of the planar top 22 of the cover member 20 for vertical plane passing through the saddle 36therebetween, absorbing force on the cover member and transmitting it and the flutes or areas 68 and 70 are at approximately 32 through the post to the bottom portions of the cells with degrees with respect to this vertical plane. out injury to the eggs contained therein. 70 This arrangement provides maximum base footing for The egg receiving section 22 includes a peripheral the carton when closed to transmit vertical loads on the marginal edge portion 44, portions of which engage the closed carton. Further, good nesting is obtained with peripheral bead 26 of the cover member when the carton this arrangement. All of the egg bearing surfaces 64, is closed in the manner shown in FIG. 2. The posts are 66, 76 and 78 of a cell extend upwardly and outwardly eliminated at portions 46 at the opposite ends of the 75 from the cell base at Substantially 12% degrees at a lesser 8,207,409 5 6 angle than adjacent non-egg bearing segments. The cush or thickened to substantially rigidify the post for the ioning areas 68 and 70 extend at an angle of Substantially purpose of transmitting vertical force on the carton lid. 21 degrees, and the egg cushioning areas 80 on the up The ribs 88 of the separator post side walls will have posts comprise a compound arc along their length for Substantially tangential contact with eggs supported in controlling egg rattle as mentioned above. the cells, and lateral blows to the carton will be readily ad Each of the separator post segments 76, 78 has formed Sorbed by the super softened cushioning areas 86' when therein vertically extending and substantially elliptically the separator post walls are disposed in the planar rela shaped egg contact or cushioning areas, the major axis tionship as indicated at 82, in FIG. 13, or medium or of which extends above and below the upper edge margin large size eggs will be accommodated in the cells. How 44 of the egg receiving section 12. The egg contact areas O ever, in the event a packer decides to pack extra large or include therein a vertically extending and substantially jumbo size eggs in the cell, this is readily permitted since thin strip of natural random formation fiber extending the cell walls which have been supersoftened, and the substantially the length thereof, and surrounded by a cushioning areas 82 may be displaced inwardly to the po relatively thicker section of reoriented fiber bordered by sition shown by the dotted lines in FIG. 13. still thicker sections of reoriented fiber reinforcing the Referring to FIGS. 14-16, a further embodiment corners of the separator posts. The structure will be of an egg carton is indicated generally at 210, this carton described in detail with respect to FIGS. 6-13. including, as indicated by general reference characters, Considering FIG. 6, a typical separator post is indi a lower bottom or egg receiving section 212 hingedly con cated at 40', this constituting substantially the configura nected at 214 to a lock flap 216. Hingedly connected to the bottom section 212, opposite the lock flap 216 as in tion of the posts when they are initially deposited on a 20 dicated at 218 is a substantially planar lid or cover mem suction mold. Further, considering one of the wall por ber 220. tions 82, also see FIG. 10, there is formed in these wall The bottom section 212 includes a plurality of cells 234 portions by means of a suitably conformed blanking formed by vertically extending posts 242; it being noted element om the suction die, an elongated, relatively thin in this embodiment that ten egg cells are joined in the strip 84 of natural random formation fiber visible when 25 bottom section. The nature of the cells 234 and posts 42 looking into the posts; see FIG. 6. is substantially identical in structure and function with After the initially molded carton or preform is removed the similar parts of the previously described embodiment from the suction die screen, it is pressed between a pair and thus further description of the similar portions ap of cooperating male and female dies into the condition pears to be unnecessary. shown in FIG. 7. The separator post indicated at 40', 30 When the posts 242 as well as previously described FIG. 7, and the wall 82 thereof is subjected to consider posts 42 are initially formed, they may have a trans able pressures and/or heat which reorients the fibers verse aperture 243 therein which will have an annular rib into substantially parallel planes, this resulting in a soften 245 thereabout; see FIG. 16, within the post, after the ing of the separator post. The pressing dies are suitably posts are reformed as previously described. formed to provide cushioning areas 86 extending around 35 The bottom section 212 includes peripheral, marginal the fiber strips 84. Still further the pressing dies will flange portions 244 which extend into the hinges 214 and form on the outer surface of the normally oriented fibers 218. The lock flap 216 includes forwardly projecting elongated ribs 88 which will provide substantially tan lock buttons 232 which will cooperate with apertures 230 ???! contact with the outer surface of eggs supported in in the forward wall 228 of the lid 220. 3. CCII. 40 The forming step illustrated in FIGS. 7 and 11, is for The lid 220 includes a substantially planar top 222 the purpose of not only softening the cushioning area which will abuttingly engage the upper surface of the 86 but also imposing in the separator post Wall 82 an posts 242, and includes marginal flange portions 226 indented portion to normally accommodate the largest which will seat on the marginal flange portions 244 of Size egg of a particular range that will be packed in the 45 the bottom section 212. cartons. The excessive curvature results in the fibers of The lid also includes diverging end walls 246 and the inner Surface of the wall 82 as indicated at 90, being 248 including upwardly extending notched-out portions Subject to tension or in a sense “pulled apart.' 250 and 252, respectively, which are bordered by out Considering FIG. 8, the separator post is indicated at wardly projecting U-shaped flange portions 254 and 256, 42. and the cushioning area fiber 86' is reversely oriented 50 respectively. These notched-out portions, as clearly seen in the direction opposite that shown in FIG. 11, see FIG. in FIG. 15, provide a through passage within the closed 12. The reverse pressing of reorientation that occurs due cartons to facilitate air movement for ventilation and re to Suitably conformed dies to obtain the construction frigeration i.e. maintain uniform temperatures at storage shown in FIG. 8, results in an outward bowing of the and distributing facilities. The flanges 254 and 256 re cushioning area now indicated at 86", and the cushioning inforce the openings 250 and 252 for maintaining struc area fiber indicated at 90 is subject to a compression tural strength during vertical loading and shocks to the which tends to cause the fiber in this inner surface area closed cartons. The apertures 250, 252 afford a saving to move together or slide with respect to adjacent fiber, in the amount of pulp used in carton production, and and the fiber at the outer surface of the cushioning area afford the consumer means to examine the carton con as indicated at 90' is now subject to tension similar to 60 tents. that described with respect to the portion at 90. The Thus there has been provided a substantially universal reverse reorientation results in the cushioning area assum separator post construction which will accommodate an ing a substantially planar condition as indicated at 82’ unusually large range of egg sizes. Not only does this in FIGS. 9 and 13, the separator post walls 82 assuming eliminate the necessity for producing a plurality of differ this condition due to a substantial "memory” effect due to ent ranges of sizes of egg cartons, but it also eliminates the configuration initially produced in the steps shown in the excessive stock a packer must normally carry in his FIG. 7 and FIG. 11. The cushioning area 86' of the egg packing room, and further the eggs are protected and Separator post walls will have been “super softened' cushioned against breakage and damage during handling. wherein the fibers on the outer and inner surface will be The "memory” position of the separator post walls facili in effect in interdigitated relationship to permit ready in tates denesting. ward or outward movement. The planar condition of the Briefly in review, the segments 62, 64, 66 of the cells post walls facilitates denesting. . 34 provide relatively rigid stable outer wall construction, Additionally, during the multiple pressing steps men and the cushioning areas of the separator post walls pro tioned above, the corners of the separator post will receive vide an unexpected versatility in a single carton due to the the excessive material therein and become relatively rigid 75 utilization of the "memory after-forming' phenomena