U.S. patent application number 11/963299 was filed with the patent office on 2009-06-25 for multiple-compartment food package.
Invention is credited to Bonita M. Hinze, Alice Tilson Koehler, Rafael Quinones.
Application Number | 20090159483 11/963299 |
Document ID | / |
Family ID | 40787327 |
Filed Date | 2009-06-25 |
United States Patent
Application |
20090159483 |
Kind Code |
A1 |
Hinze; Bonita M. ; et
al. |
June 25, 2009 |
MULTIPLE-COMPARTMENT FOOD PACKAGE
Abstract
A multiple-compartment rigid food package that allows for
individual compartments to be initially packaged together in a
connected manner, yet later be separated from each other while a
film remains intact upon the compartments to allow opening at
different times. The film and compartments each contain a weakened
portion along which the film and compartments are relatively
simultaneously separated. The back panel is used to provide a
stand-up display feature. The back panel is a single, continuous
piece, however, it can be removed or separated into at least two
pieces by tearing along an area of weakness thereon with a portion
of the back panel remaining on each compartment. The
multiple-compartment food package provides for storage of a sliced
food product, and in particular a single serving size of a sliced
food product. The rigid food package also provides for arranging
the sliced food product to have a fluffed appearance.
Inventors: |
Hinze; Bonita M.; (Sun
Prairie, WI) ; Koehler; Alice Tilson; (Madison,
WI) ; Quinones; Rafael; (Madison, WI) |
Correspondence
Address: |
FITCH EVEN TABIN & FLANNERY
120 SOUTH LASALLE STREET, SUITE 1600
CHICAGO
IL
60603-3406
US
|
Family ID: |
40787327 |
Appl. No.: |
11/963299 |
Filed: |
December 21, 2007 |
Current U.S.
Class: |
206/548 ;
206/460; 206/562 |
Current CPC
Class: |
B65D 75/525 20130101;
B65D 75/527 20130101; B65D 75/327 20130101; B65D 75/5855
20130101 |
Class at
Publication: |
206/548 ;
206/562; 206/460 |
International
Class: |
B65D 69/00 20060101
B65D069/00; B65D 1/36 20060101 B65D001/36; B65D 73/00 20060101
B65D073/00 |
Claims
1. A multiple compartment food package comprising: a rigid tray
having a pair of separate compartments with a peripheral flange
surrounding an opening of each compartment, a portion of the flange
between the compartments having a weakened portion, the
compartments having side walls extending downwardly from the
flanges to bottom walls and at least one of the compartments
containing a food product; a common air impermeable flexible film
sealed to the peripheral flanges surrounding each compartment and
forming a generally hermetic seal at least with respect to the
compartments containing food product, the film having a weakened
portion positioned between the two compartments; and a common back
panel adhered to a portion of the bottom wall of the compartments
and having a weakened area positioned between the compartments.
2. The food package of claim 1 wherein at least one of the
compartments has a generally rectangular opening.
3. The food package of claim 1 wherein each compartment contains an
individual serving size of the food product.
4. The food package of claim 1 wherein the food product is sliced
and arranged to have a fluffed appearance.
5. The food package of claim 1 wherein the back panel has an
extending edge aligned with an edge of the peripheral flange.
6. The food package of claim 1 wherein the back panel extends
outwardly from the compartments in a lower direction, such that a
lower edge of the back panel is aligned with a lower edge of the
peripheral flange such that the lower edge of the back panel and
the lower edge of the peripheral flange form a pair of edges that
are generally parallel and spaced so that the package can stand
upright on the pair of edges.
7. The food package of claim 1 wherein the area of weakness is one
of a perforated tear strip, perforation, tear tape, tear string,
and reverse cut score and the weakened portion is one of a
perforation, laser score, mechanical score, and tear tape.
8. The food package of claim 1 wherein the flexible film is
heat-sealed, glued or ultrasonically sealed to the flanges of the
trays and the flexible film is a material selected from the group
consisting of amorphous polyester, ethyl vinyl alcohol, and ethyl
vinyl acetate.
9. The food package of claim 1 wherein the back panel is a material
that is either paperboard or plastic.
10. The food package of claim 1 wherein a sliced meat product is
contained in at least one of the compartments.
11. The food package of claim 1 wherein a peggable hole is provided
on the peripheral flange of the tray or the back panel.
12. The food package of claim 1 wherein the film is unsealed to the
flange of the tray along at least one edge of the opening of each
compartment outwardly of the adjacent seal between the flange of
the tray and the film to provide for free flaps of the film that
can be grasped to open the compartments.
13. A multiple compartment package for a food product comprising: A
rigid tray having a pair of compartments each having a generally
rectangular opening surrounded by a common peripheral flange, a
bottom wall opposite the flange, and sidewalls extending from the
flange to the bottom wall with a weakened area between the
compartments, and at least one of the compartments containing a
food product; a common air impermeable flexible film affixed to the
flange surrounding the opening of each compartment to seal the
compartments, the film having a weakened portion positioned between
the two compartments; and a common back panel adhered to a portion
of the bottom wall of each compartment, the back panel having an
area of weakness positioned between the two compartments.
14. The food package of claim 13 wherein the back panel has an edge
substantially aligned with an edge of the peripheral flange such
that the edges can support the package upright.
15. The food package of claim 13 wherein each compartment contains
an individual serving size of a sliced food product and is arranged
to have a fluffed appearance.
16. A method of separating adjacent compartments of a food package,
the method comprising: separating a common back panel attached to a
bottom of each compartment, a pair of parts each attached to the
bottom of one of the compartments; and substantially simultaneously
separating a common flexible film sealed to a flange surrounding an
opening of each compartment and separating the flange between the
compartments along generally aligned weakened portions while
maintaining the seals surrounding the opening of each
compartment.
17. A method of forming a multiple compartment food package
containing a food product, the method comprising: forming a series
of connected base trays from a web of rigid film, the series of
connected base trays having a series of recesses therein connected
by flanges about openings of the recesses; filling at least some of
the recesses of the series of the connected base trays with the
food product; overlaying a web of flexible film onto the flanges of
the connected base trays to cover the food product contained within
the recesses; applying a gas flush to the food product inside the
recesses and sealing the flexible film to the flanges of the
connected base trays about the periphery of each opening;
separating the series of connected base trays into packages having
at least two adjacent recesses; substantially simultaneously
forming lines of weakness in the flexible film and the flanges
between adjacent recesses in the package; and attaching a back
panel to an exterior bottom surface of each recess of the package,
the back panel having an area of weakness positioned between the
adjacent recesses of the tray.
Description
FIELD
[0001] A multiple-compartment food package having a rigid base and
a flexible film lid, and in particular, a multiple-compartment food
package with an attached back panel card.
BACKGROUND
[0002] Food packages are known to comprise multiple compartments
within for storage of food. The multiple compartment food packages
can comprise an assortment of food items contained in the recessed
compartments or a single variety of food product and can be covered
by a single continuous sheet of film, or alternatively a rigid lid.
Once the sheet of film or lid is removed, all of the multiple
compartments are simultaneously exposed, such that all of the food
items in the different compartments can be consumed in one sitting.
One such food package comprised of a single tray with multiple food
compartments is disclosed in U.S. Pat. Nos. 5,375,701 and
5,657,873, where the single tray has multiple compartments with a
common flexible film placed across each of the compartments to seal
the food within the package until it is opened. Once the film is
removed from the tray in order to provide access to the food
products within, the film is no longer resealable, thus preventing
any remaining food from being resealed in the compartments.
SUMMARY
[0003] A multiple-compartment, rigid food package is provided that
allows for multiple individual serving sizes of a sliced food
product to be packaged and sold together in a connected manner, yet
allows the individual compartments to be separated from each other
and opened independently of each other. For example, each multiple
compartment can store a sliced food product having a fluffed
appearance and covered with a common film having a perforation
therein or other weakened portion between the individual
compartments. The multiple compartments are connected together at
an upper surface, along adjacent peripheral flanges of the
compartments, and can be separated along a perforation or other
line of weakness in order to separate the compartments from each
other.
[0004] The multiple compartment food package has a back panel that
is attached to the bottom of each compartment. The back panel is
configured to provide either a stand-up display feature and/or a
hole in the top of the panel to use with peggable displays. The
back panel can be separated into at least two pieces along a line
or area of weakness positioned between the individual compartments,
thus providing for a portion of the back panel to remain on each
compartment when the compartments are separated from each other. In
addition, the back panel provides increased rigidity to the
package.
[0005] The common flexible film is placed over the top opening of
each of the compartments to cover and seal the compartments until
the food products therein are ready to be consumed. The flexible
film is a single continuous sheet of film that overlays all of the
multiple compartments of the food package. Between adjacent food
compartments the film contains a perforation or other line of
weakness which allows for the film to be torn along the perforation
in order to separate the multiple compartments, allowing for the
film on one compartment to be opened without removing the film from
another adjacent compartment that was previously attached to that
compartment. This allows for the consumer to open up only one of
the multiple compartments and to save the rest of the compartments,
still containing sealed food products, for later consumption. In
one aspect, the weakened line of the film is aligned with a
weakened line between the two compartments, and may be made
together during manufacturing to ensure alignment. When the
flexible film is being sealed to the compartments of the food
package, a small flap of film or unsealed portion can be created
which provides a grasping point to initiate removal of the film and
unsealing of the underlying compartment. The flap of film can be
provided about substantially the entire periphery of the package so
that when the compartments are separated, each one can still have
at least one edge, or portion thereof, with an unsealed flap of
film available for grasping the film to initiate its removal.
[0006] The multiple compartment food package can be separated into
its individual multiple compartments and opened for consumption
separately, and at different times. To separate the multiple
compartment food package, the back panel is first separated into at
least two parts along a line of weakness, with a portion of the
back panel remaining affixed to each of the compartments. Then the
flexible film and upper surface of the compartments are separated
along their perforations into at least two compartments, with a
portion of the flexible film remaining sealed to its respective
compartment. However, the reverse of these steps could also be
performed. When a food item is to be consumed, the user simply
removes the flexible film from a single compartment, while
permitting the remaining compartments to remain sealed.
[0007] A method of manufacture of the multiple compartment package
is also provided where the package can be made in a process line. A
web of rigid film can be provided and advanced in a longitudinal
direction. Pockets, or recesses, can be formed therein to resemble
the base trays of the package. These recesses are then filled with
a sliced food product, preferably sliced meat, and then overlaid
with a common sheet of flexible film. The recesses are then gas
flushed and the film is sealed to the outer flanges of the base
tray or web. Weakened areas are then together formed in the rigid
film and the flexible film, and are advanced in a longitudinal
direction along the process line to receive the back panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a front perspective view of a multi-compartment
food package having a flexible film cover and a back panel;
[0009] FIG. 2 is a back perspective view of the multi-compartment
food package of FIG. 1;
[0010] FIG. 3 is a front elevation view of the multi-compartment
food package of FIG. 1;
[0011] FIG. 4 is a back elevation view of the multi-compartment
food package of FIG. 1;
[0012] FIG. 5 is a view showing the line of weakness being removed
from the back panel of the multi-compartment food package of FIG.
1;
[0013] FIG. 6 is a view showing the compartments being separated
along both a perforation on the flexible film cover and between the
compartments of the multi-compartment food package of FIG. 1;
[0014] FIG. 7 is a top view of the separated compartments of the
multi-compartment food package of FIG. 1;
[0015] FIG. 8 is a view showing one of the separated compartments
being opened by removing the flexible film cover; and
[0016] FIG. 9 is a process line schematic of the manufacture of the
multi-compartment food package of FIG. 1.
DETAILED DESCRIPTION OF THE DRAWINGS
[0017] A multiple-compartment, rigid food package providing for
consumption of the food product stored therein at separate times
and including upright display of the food package and, in
particular, a common flexible film covering all of the compartments
of the food package that can be separated along a weakened portion
prior to opening and a back panel that can be separated into at
least two parts along a line or area of weakness are disclosed
herein and illustrated in FIGS. 1-9. The back panel extends along
the back walls of the compartments and is attached to each
compartment. The back panel can function as a support to stand the
food package in an upright position for display purposes in
combination with an edge of the package, as well as provide
increased rigidity to the package. The back panel can be divided
such that one portion of the back panel remains attached on the
bottom of one compartment and a second portion remains attached on
the bottom of another compartment. Alternatively or in addition,
the back panel can contain an aperture to permit peggable display
of the package. The flexible film comprises a single continuous
sheet of film that overlays a top of the compartments and further
contains a perforation or other line of weakness between adjacent
compartments aligned with the area of weakness between the
compartments. To separate the compartments, the flexible film,
adjacent compartments, and back panel are each separated along
their respective lines of weakness to allow the adjacent
compartments to be separated from each other and used
individually.
[0018] The food package 10 has a base tray 20 with two generally
rectangular rigid or semi-rigid, connected compartments 14 and 16,
as illustrated in FIG. 1. However, more than two compartments can
be included. Each of the two compartments 14 and 16 can contain a
sliced food product, such as a fluffed meat product. The
compartments 14 and 16 are generally rectangular, having side walls
extending downwardly from peripheral flanges 12 surrounding an
opening of each compartment 14 and 16 to bottom walls 42, including
a common periphery flange 22 between the compartments 14 and 16.
Alternatively, the base tray may contain unconnected compartments
that are held together by their common features, such as by the
film and/or back panel. As used herein and throughout this
application, the term "rigid" can refer to semi-rigid, rigid,
plastic, flexible or any other similar embodiments, and is used
herein to indicate that structures made of these films have the
ability to generally at least partially retain their respective
shapes during normal handling.
[0019] The flexible film 18 can comprise a single, continuous sheet
of film that overlays the top portion of both compartments 14 and
16 and can also be rigid, semi-rigid or flexible. The single,
continuous sheet of film 18 assists in maintaining the two
compartments 14 and 16 connected to each other. The flexible film
18 can be affixed to each of the compartments 14 and 16 at the
peripheral flange 12, thus forming a relatively air impermeable,
hermetic seal with respect to the compartments 14 and 16 containing
the sliced food product. The common flexible film 18 can comprise a
transparent or semi-transparent film 18 such that the food products
contained within the compartments 14 and 16 can be at least
partially visible. Furthermore, the flexible film 18 can contain
printing or labeling. For example, a design can be printed on an
upper portion of the package 10 (adjacent a peripheral flange 12)
such that the design is presented as an opaque area on the flexible
film 18 itself, leaving transparent areas therein for viewing
interiors of the compartments 14 and 16 therethrough.
[0020] The flexible film 18 and base tray 20 both further contain a
weakened portion such as a laser score, mechanical score, tear tape
or, preferably, perforations 24 and 26, that can be positioned
between adjacent compartments 14 and 16 along the common periphery
flange 22. Alternatively, where the compartments 14 and 16 of the
tray are not connected to each other, then the weakened portion can
be along the flexible film only. The perforations 24 and 26 can
span the entire length of the package 10, from one side end to
another opposite side end, or it can span a shorter length as long
as the perforations 24 and 26 allow separation of the adjacent
compartments 14 and 16 (and overlying film 18) from each other.
Where there are only two compartments, the perforations 24 and 26
may be centrally located between the compartments 14 and 16 at the
common periphery flange 22. Both the film and the base material are
separately perforated (i.e., each contains its own separate
weakened portion) and each tears along its own weakened portion to
separate. When the film 18 and base tray 20 are torn along their
perforations 24 and 26 and are separated, the film 18 can be
divided into at least two portions 18a and 18b and the base tray 20
can likewise be divided into at least two separated units with each
film portion remaining intact until a force is applied to remove
the film 18a and 18b to uncover the openings of the compartments 14
and 16.
[0021] A portion of the film 18 on the peripheral flange 12 can
remain unsealed, such that it creates a flap 38 of film that can be
easily grasped and pulled to remove the film 18 and open the
compartment. This flap 38 of film can be located around the entire
periphery of the package 10, or substantially the entire periphery,
and is created by sealing bars, or other sealing tools, that seal
around the package 10 periphery but slightly inwards from the
outermost edge of the flange 12. Thus, when the package 10 is
separated into its two compartments 14 and 16, each compartment has
a flap 38 for opening the compartment. For example, the uppermost
compartment 14 has a longer flange 12 such that it is easy to grasp
and remove the flexible film 18 therefrom. The second compartment
16 does not have this extended flange. However, the second
compartment 16 contains a portion of the film 18 that is unsealed
and likewise has the flap 38 of film that can be grasped and pulled
to remove the film 18 therefrom. Alternatively, the film 18 can
have a portion that extends outwardly from the peripheral flange 12
and past an edge of the peripheral flange 12 to provide a gripping
surface for the removal of the film 18. Still alternatively, the
film 18 can include tabs at the corners of the package 10 to
further aid in removal of the film 18. The film 18 can be sealed to
the compartments 14 and 16 by any suitable methods, such as by
using glue, adhesive, ultrasonically sealing or heat-sealing to
seal the film 18 to the peripheral flanges 12.
[0022] Turning to FIG. 2, a back perspective view is shown of the
food package 10 having a back panel 28 affixed to each compartment
14 and 16. The back panel 28 can be attached to a portion of the
bottom wall 42 of each compartment 14 and 16, as shown in FIG. 2.
The back panel 28 may also be a single, common panel that spans the
bottom walls of both compartments 14 and 16. The back panel 28 can
extend outwardly from the compartments 14 and 16 in at least one
direction so that its edge is parallel and generally aligned with
the outer periphery of one of the sides of the peripheral flanges
12 such that it is located immediately beneath it. The package 10
can then be placed in an upright position by standing it up on the
edge of the back panel 28 and the parallel peripheral edge 12 along
the edge of the lowermost compartment 16. As used herein and
throughout this application, the term "parallel" is used in a
general sense, and is not used in a precise, geometric manner. The
back panel 28 can be attached to the bottom walls 42 by any
suitable means, such as by hot melt adhesive.
[0023] When the back panel 28 is attached to the bottom 42 of the
compartments 14 and 16, it is preferably attached in generally the
same plane so that the back panel 28 is relatively flat or level
across the bottom of the compartments 14 and 16 so that it can
provide adequate support when stood upright. This may require the
bottom walls 42 of the compartments 14 and 16 to all be aligned in
about the same plane, which can be achieved by all of the
compartments 14 and 16 having a portion of each compartment
generally at the same depth. Alternatively, the bottom wall 42 may
include a first portion having a first depth and a second portion
having a second depth, where the second depth is greater than the
first depth and the back panel is adhered to the second
portion.
[0024] The back panel 28 also operates to further connect the
compartments 14 and 16 together and provide support, keeping the
compartments 14 and 16 attached as one single package 10. The back
panel 28 also contains a line or area of weakness 30, which can be
removed to separate the back panel 28 into at least two parts 28a
and 28b, where each part 28a and 28b of the back panel remains
attached to its respective compartments 14 and 16. The back panel
28 may not be as easy to remove or to separate along its area of
weakness 30 as is the film 18 along its weakened portion 24. The
back panel 28 can provide a sturdier support to aid in keeping the
compartments 14 and 16 of the tray 20 together. The area of
weakness 30 functions to separate the package 10 into its
individual compartments 14 and 16 upon removal of the area of
weakness 30. The area of weakness 30 can be centrally located such
that it may be generally equidistant between the two compartments
14 and 16. The area of weakness 30 may comprise a perforated tear
strip, perforation, tear tape, tear string, reverse cut score or
the like. The area of weakness 30 may also include a tab 36 or
other gripping end that makes grasping and removing the area of
weakness 30 easier. The back panel 28 may also contain printing or
labeling thereon. Alternatively, the back panel 28 may not contain
a line or area of weakness 30 but instead can be torn off or
removed by hand, thus removing substantially the entire back panel
28 from the bottom walls of the compartments 14 and 16 to allow
separation of the compartments 14 and 16.
[0025] When the back panel 28 is used to display the package 10 and
to aid in standing the package 10 upright along a bottom edge, the
back panel 28 can have a lower edge 32 that extends beyond the
edges of the side wall of at least one of the compartments 14 or
16, or of the lowermost positioned compartment 16, as shown in FIG.
2. The lower edge 32 of the back panel 28 can be parallel to a
lower edge 34 of the peripheral flange 12 of the lower-positioned
base compartment 16 such that the lower edge 32 of the back panel
28 and the lower edge 34 of the peripheral flange 12 form a pair of
edges that are generally within a line in the same plane upon which
the package 10 can be stood upright. When in this upright position,
the package 10 can then be balanced to remain upright on its own
from the combined support from the lower edge 34 of its bottom-most
peripheral flange 12 and the lower edge 32 of the back panel 28.
The back panel 28 is preferably rectangular in shape; however, any
number of shapes are possible as long as the back panel shape
provides for a lower edge 32 to stand on.
[0026] Alternatively and/or in addition to the stand-up feature, a
peggable hole can be provided on a peg member, where the peg member
may be the back panel 28 containing a hole in an uppermost portion
of the back panel 28 for hanging overhead on a hook in a display
case. When the back panel 28 is used to hang the package from an
overhead hook or the like, the back panel 28 can have an upper edge
that extends beyond an upper edge of the peripheral flange 12 of
the upper positioned compartment 14, such that the upper edge of
the back panel 28 extends past the upper edge of the peripheral
flange 12 and is parallel to it. A hole can then be placed in the
upper portion of the back panel 28 such that the hole is located in
a plane that is above the package 10 such that when placed on a
hook or the like, the hook will not interfere with the compartments
14 and 16 of the package 10.
[0027] In an alternate aspect, a peggable hole can be provided on a
peg member that can be attached to one or all of the compartments
where the peg member may be a separate tape or other attachment
that already contains a hole and can be affixed to the top portion
of either the package 10 or the back panel 28, thus the back panel
28 itself would not contain a hole through the panel. The tape or
attachment can be affixed to either a front side or a back side of
the package 10 or back panel 28, where the front side is the part
of the package where the film 18 is attached. In addition to the
hole feature, whether on the back panel 28 itself or attached as a
separate attachment, the back panel 28 can also still contain an
area of weakness 30 positioned between the compartments 14 and
16.
[0028] In yet another alternative, the package 10 can contain a
peggable aperture or hole 40 through one of its peripheral flanges
12 in order to hang it from a display rack in a vertical
orientation. The peggable hole 40 can be along any side edge of the
package 10, and is preferably placed on a peripheral flange portion
that is longer than the other flanges of the package 10, such that
the hole 40 is placed in a portion of the peripheral flange 12 that
extends about 0.50 inches beyond the perimeter of the package 10,
for example. Similarly, the flexible film 18 of the package can
also extend slightly longer in one direction to compliment the
extended peripheral flange 12. In that case, the flexible film 18
would also have a hole aligned with the hole 40 in the base tray
peripheral flange 12.
[0029] The rigid compartments 14 and 16 may be formed from any
suitable packaging materials, such as amorphous polyester,
polyethyl vinyl alcohol and/or ethyl vinyl acetate. The rigid
compartments 14 and 16, which can be formed from a single sheet of
material, may contain a protective multilayer laminate portion,
having an inner and outer layer that serves as a moisture barrier
and sealant layer and a middle layer that serves as an oxygen
barrier layer, or any number of such layers in between. The rigid
compartments 14 and 16 preferably comprise a multiple layer,
co-extruded film made up of amorphous polyester ("APET"), ethyl
vinyl alcohol ("EVOH") and ethyl vinyl acetate ("EVA") layers and
having a combined thickness of approximately 16 mils. The multiple
layers can be adhered to each other with a sealant that allows for
delamination between certain layers when the package is later
opened. For example, after the flexible film 18 is sealed to the
package and later opened, the flexible film 18 may not necessarily
delaminate at the contact point between the flexible film 18 and
the rigid film used for the base tray 20, rather, the point of
delamination may occur between one of the multiple layers of the
rigid film for the base tray 20. However, to the naked eye the
point of delamination appears to have occurred at the contact point
between the lid film and the base tray film. A representative
multiple layer rigid film can be provided by Curwood, Inc.,
Oshkosh, Wis.
[0030] The rigid compartments 14 and 16, however, can also be
formed of various other materials, such as polyvinyl chloride,
polypropylene, polystyrene, nylon, and the like. If formed of a
relatively stiff material such as polystyrene, the rigid
compartments 14 and 16 can tend to be relatively stiff and of such
a nature that the compartments 14 and 16, and especially the lower
corners thereof, could be damaged if dented or the like in
handling. Using certain other materials such as high density
polyethylene can provide a somewhat softer and more durable package
10 such that the lower corners may not be as readily damaged.
[0031] The rigid construction of the base tray 20 allows for
storing food products therein without undue concerns for the food
product getting crushed, such as during shipping and handling.
Moreover, where the food product is a sliced food product it can be
arranged to have a fluffed appearance. The base tray 20 can
comprise a transparent or semi-transparent material such that the
food products contained within the compartments 14 and 16 can be at
least partially visible.
[0032] The flexible film 18 may also comprise a co-extruded
multilayer film comprising APET-EVOH-EVA that is similar in
construction to the rigid film used for the base tray 20. Other
types of multi-layer films can also be used having an inner, outer
and a middle layer. The outer layer of the film can be formed of a
number of different film materials, such as polyester, nylon or
polyethylene. The middle layer can comprise an oxygen barrier layer
such as ethylene vinyl alcohol (EVOH) or polyvinylidene dichloride
(PVDC). The inner layer could comprise a moisture barrier and
heat-sealable material such as low density polyethylene. The
flexible film may optionally contain a printed image thereon and
can have a thickness of 2 mils.
[0033] The back panel 28 of the package 10 can be constructed of a
relatively stiff material, such as paperboard or a relatively thick
plastic material such as high density polyethylene when used as a
stand-up feature and for providing further support to keep the
compartments together.
[0034] The individual compartments 14 and 16 may have a length of
about 4 to about 9 inches, preferably about 5.25 inches, and a
width of about 1.5 to about 4 inches, preferably about 2.75 inches.
A height or depth of the tray can be at least about 0.50 inches,
with the compartment 14 and 16 depths preferably between
approximately 0.75 inches and 2 inches. The package 10 comprising
two compartments can have a similar length and depth as the
individual compartments, however, the package can have a different
width of about 3 to about 8 inches, preferably about 6 inches,
since it is equal to the width of two compartments, or however many
are packaged together, and an optional peripheral flange extension
for a peggable hole. The openings of the compartments 14 and 16 may
be circular, rectangular, square or any other shape. Not all of the
compartments 14 and 16 need to be shaped the same in a single
package.
[0035] The food package 10 may include many types of food products.
For example, proteinaceous foods, such as meat, fish, poultry,
cheese, peanut butter, and the like, or farinaceous foods, such as
bread, crackers, and the like. Still other foods that may be
included in the compartments 14 or 16 may be condiments, desserts,
confectioneries, fruits, and the like. Preferably, the food product
will be a sliced food product, such as a sliced deli meat product
comprising ham, turkey, roast beef, and the like, for example. A
typical package 10 may include two compartments 14 and 16 having
the same size and containing the same sliced food product, such as
a sliced deli meat. The slices of meat contained therein are
typically a single serving size containing multiple slices, such as
between one to ten slices. Additionally, the sliced food product
can be arranged to have a fluffed appearance.
[0036] In order to separate the compartments 14 and 16 and to open
at least one of the compartments 14 and 16 for consumption of the
food products therein, the line or area of weakness 30 in the back
panel 28, as shown in FIG. 5, can first be broken. If there is a
tab 36, then the tab 36 can be grasped and pulled across the back
panel 28 to aid in removing the line of weakness 30. Upon
separation of the line of weakness 30, the back panel 28 is in at
least two parts 28a and 28b, with one part 28a remaining connected
to one compartment 14 and the other part 28b remaining connected to
the other compartment 16, and the compartments 14 and 16 are no
longer connected to each other along the back plane of the package
10. Alternatively, if the back panel 28 does not contain an area of
weakness 30 then substantially the entire back panel 28 can be
removed to detach the compartments 14 and 16.
[0037] After the back panel 28 has been separated into at least two
parts 28a and 28b, then the front plane of the package 10 can be
separated along the perforations 24 and 26 of the film 18 and the
base trays, as shown in FIG. 6. A consumer can grasp the two
opposing sides of the package 10, by grasping each compartment 14
and 16, and gently applying a force to the film 18 and base tray 20
such that each tears along its perforations 24 and 26 in order to
separate into at least two separated compartments with their
respective film portions 18a and 18b remaining intact until opened.
Thus after removing the line of weakness 30 and tearing along the
perforations 24 and 26 of the film 18 and base tray 20, the package
10 is divided into its individual compartments 14 and 16, as shown
in FIG. 7, thus providing for separate compartments 14 and 16 that
can be opened at different times and the food therein can be
consumed at different times without having to expose all of the
compartments 14 and 16 upon opening. FIG. 8 shows one of the
compartments being opened separately.
[0038] A variety of methods for manufacturing the package 10
described herein can be utilized. For example, the
multiple-compartment package 10 can be made using the apparatus and
process 200 diagrammed in FIG. 9. A web supply roll 202 provides
rigid film to a heating and forming station 204, which forms a
series of pockets or recesses 206 in the film 202 that make up the
base trays of the package 10. The web material 202 is typically
advanced in a longitudinal process direction, as indicated by arrow
A. The film 202 can comprise a multiple layer, co-extruded film
made up of APET-EVOH-EVA layers and have a combined thickness of
approximately 16 mils. As the film 202 passes through the heating
and forming station 204, it is heated and formed into the base
trays of the package 10, such as by suitable thermoforming or heat
molding techniques, and advanced along a process line 205 towards
the next station. The film 202 can contain any number of rows of
base trays or recesses 206, however, preferably the film 202 will
contain four rows of recesses 206 along the web 202. As the film
202 is advanced in a machine direction, the film can be held in
place by clips or other similar fasteners, rather than being
advanced along a conveyor system. However, the process can be
modified to be advanced along a conveyor system if desired.
[0039] Next, the web 202 is advanced to a meat filling station 208,
or any other type of food station that inserts the desired food
product. At the meat filling station 208, a meat slicer cuts the
desired meat into slices and arranges the slice(s) into the
recesses 206. Where a fluffed appearance of the slices is desired,
a rod or finger-like tool can be used to arrange the meat in such a
fashion prior to filling the recesses 206 such that it folds the
meat over upon itself and appears fluffed, rather than being
arranged flat on its surface or folded over in half.
[0040] Once the meat, or other desired sliced food product, is
placed in the recesses 206 of the web 202, then the flexible film
18 or lid is added via a web supply roll 209. The flexible film is
overlaid over the top of the web 202 as it is conveyed down the
process line in the longitudinal direction. The flexible film
comprises a common sheet of film that is placed over the top of the
web 202 such that it covers the opening of the recesses 206
therein. After the flexible film is in place over the recesses, a
gas flush 210 is applied such that the air is drawn out of the
recesses and a nitrogen flush or nitrogen/carbon dioxide mixture is
added and the flexible film is then sealed, relatively
simultaneously afterwards, over the top of the web of film 202
containing the filled recesses 206.
[0041] Once the film has been sealed over the recesses 206, the web
of film is separated 212 into double compartment rows within the
web by cutting the web in the cross-web direction, or in the
direction perpendicular to the machine direction, as indicated by
arrow B. The film is cut such that only two adjacent recesses 206
or base trays remain attached, thus making up the double
compartment packages. At the same time as the cross-cut is being
formed, the perforations, or lines of weakness, are also formed in
the package in the lid and base tray. Additionally, if a peggable
hole is going to be added to the package along the flange of the
package, then that too is formed at the same time as the
perforations.
[0042] The double compartment package is still attached in the
cross-web direction as a series of four rows. At the next station
213 a longitudinal cut is made. The longitudinal cut is made in the
machine direction, as indicated by arrow A, and separates the
attached rows of recesses into four single and separate rows. After
the longitudinal cuts are made, double compartment packages emerge
from the process line and drop onto a single lane conveyor belt to
be advanced to the next station.
[0043] The double compartment packages are then advanced along one
of typically four conveyor lines that advance the package to
receive the application of the back panel 214. One conveyor line
may advance, while the other three remain stationary in order to
efficiently move along the process line on multiple lanes.
Furthermore, the four conveyor lines may converge into one lane
prior to application of the back panel. The conveyor line that is
advancing contains one row of the separated double compartment
packages and the back panel is then applied to the bottom surface
of the base trays using standard equipment. Typically, the bottom
surface of each compartment will receive an application of an
adhesive, such as a hot melt adhesive, and the back panel card can
then be applied thereto and compressed into place, however, the
back panel card may alternatively contain the adhesive on the card
only or both may contain the adhesive. Once the back panels are
applied, then the completed packages are packaged in cases 216 and
shipped to the final destination.
[0044] From the foregoing, it will be appreciated a
multiple-compartment food package is provided, and methods of
manufacture therefor, that allow for packaging the multiple
compartments together initially and later provides for separating
the compartments without unsealing the food compartments. However,
the disclosure is not limited to the aspects and embodiments
described hereinabove, or to any particular embodiments. Various
modifications to the multiple-compartment food package can result
in substantially the same package and methods of manufacture.
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