U.S. patent application number 13/551218 was filed with the patent office on 2012-11-08 for container having a rim or other feature encapsulated by or formed from injection-molded material.
This patent application is currently assigned to Graphic Packaging International, Inc.. Invention is credited to Peter W. Blaas, Kevin J. Hjort, Terrence P. Lafferty, Scott W. Middleton, Brian R. O'Hagan, Mark R. Sinclair, Patrick J. Smith, Patrick H. Wnek.
Application Number | 20120279895 13/551218 |
Document ID | / |
Family ID | 44911050 |
Filed Date | 2012-11-08 |
United States Patent
Application |
20120279895 |
Kind Code |
A1 |
Middleton; Scott W. ; et
al. |
November 8, 2012 |
CONTAINER HAVING A RIM OR OTHER FEATURE ENCAPSULATED BY OR FORMED
FROM INJECTION-MOLDED MATERIAL
Abstract
A tray having at least one sidewall having a top edge, an
interior surface, an exterior surface, and a bottom surface
adjacent to the sidewall. The bottom surface and the interior
surface combine to form a product receiving space of the tray. The
tray has an injection-molded feature having an anchor portion and a
flange portion. The anchor portion is adjacent the interior surface
of the at least one sidewall, and the flange portion extends from
the anchor portion and is adjacent the top edge of the at least one
sidewall.
Inventors: |
Middleton; Scott W.;
(Oshkosh, WI) ; Sinclair; Mark R.; (Arvada,
CO) ; O'Hagan; Brian R.; (Appleton, WI) ;
Wnek; Patrick H.; (Sherwood, WI) ; Lafferty; Terrence
P.; (Winneconne, WI) ; Blaas; Peter W.;
(Marion, WI) ; Hjort; Kevin J.; (Clintonville,
WI) ; Smith; Patrick J.; (Iola, WI) |
Assignee: |
Graphic Packaging International,
Inc.
|
Family ID: |
44911050 |
Appl. No.: |
13/551218 |
Filed: |
July 17, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12950215 |
Nov 19, 2010 |
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13551218 |
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11578357 |
Apr 17, 2007 |
7862318 |
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PCT/US2003/032164 |
Oct 8, 2003 |
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12950215 |
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PCT/US03/08491 |
Mar 17, 2003 |
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11578357 |
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60500519 |
Sep 4, 2003 |
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60488209 |
Jul 15, 2003 |
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60417192 |
Oct 8, 2002 |
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60417192 |
Oct 8, 2002 |
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60364560 |
Mar 15, 2002 |
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Current U.S.
Class: |
206/557 |
Current CPC
Class: |
B29C 45/14508 20130101;
B65D 5/209 20130101; B65D 77/2016 20130101; B29C 2045/14918
20130101; B65D 2581/3498 20130101; B29L 2031/712 20130101; B65D
5/445 20130101; B65D 43/169 20130101; B65D 77/208 20130101; B31B
50/592 20180501; B29C 45/14336 20130101; B29C 2045/0027 20130101;
B65D 43/162 20130101; B65D 77/245 20130101; B29C 45/1671 20130101;
B65D 81/3453 20130101; B65D 77/2032 20130101; B65D 1/48 20130101;
B65D 2581/344 20130101; B29C 45/14467 20130101; B29C 45/14065
20130101; B65D 77/2088 20130101 |
Class at
Publication: |
206/557 |
International
Class: |
B65D 1/34 20060101
B65D001/34; B65D 51/00 20060101 B65D051/00; B65D 43/00 20060101
B65D043/00 |
Claims
1. A tray comprising: at least one sidewall having a top edge, an
interior surface, and an exterior surface; a bottom surface
adjacent to the sidewall, the bottom surface and the interior
surface combining to form a product receiving space of the tray;
and an injection-molded feature having an anchor portion and a
flange portion, the anchor portion being adjacent the interior
surface of the at least one sidewall, and the flange portion
extending from the anchor portion and being adjacent the top edge
of the at least one sidewall.
2. The tray of claim 1 wherein the flange portion has a sealing
surface for contact with a lid to seal the product receiving space
of the tray.
3. The tray of claim 1 wherein the anchor portion is in contact
with an upper portion of the at least one sidewall that is adjacent
to the top edge of the sidewall.
4. The tray of claim 1 wherein the flange portion is in contact
with the top edge of the at least one sidewall.
5. The tray of claim 1 wherein the flange portion extends laterally
outward from the anchor portion beyond the top edge of the at least
one sidewall.
6. The tray of claim 1 wherein the at least one sidewall comprises
a lower portion extending upward from the bottom surface, an offset
portion foldably connected to the lower portion, and an upper
portion extending upward from the offset portion to the top surface
of the at least one side panel.
7. The tray of claim 6 wherein the exterior surface of the lower
portion is substantially coplanar with the exterior surface of the
upper portion.
8. The tray of claim 6 wherein the exterior surface of the lower
portion is spaced apart from the exterior surface of the upper
portion.
9. The tray of claim 8 wherein the exterior surface of the lower
portion is in a parallel planar relationship with the exterior
surface of the upper portion and the offset portion is oblique
relative to exterior surface of the lower portion and the exterior
surface of the upper portion.
10. The tray of claim 6 wherein the offset portion is in contact
with the anchor portion of the injection-molded structure.
11. The tray of claim 1 in combination with a lid, the lid being in
sealing contact with the flange portion of the injection-molded
structure to seal the tray.
12. The tray of claim 11, wherein the lid comprises a peelable film
that is sealingly attached to the flange portion.
13. The tray of claim 12 wherein the lid is heat sealed to the
flange portion.
14. The tray of claim 12 wherein the lid is adhesively attached to
the flange portion.
15. The tray of claim 12 wherein the lid is ultrasonically sealed
to the flange portion.
16. The tray of claim 1 wherein the at least one sidewall comprises
paperboard and the injection-molded feature comprises resin.
17. The tray of claim 1 wherein the anchor portion has a greater
cross-sectional area than the flange portion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/950,215, filed Nov. 19, 2010, which is a continuation
of U.S. patent application Ser. No. 11/578,357, filed Apr. 17,
2007, which application is the national stage of International
Application No. PCT/US2003/32164, filed Oct. 8, 2003, which claims
the benefit of U.S. Provisional Application No. 60/500,519, filed
Sep. 4, 2003, U.S. Provisional Application No. 60/488,209, filed
Jul. 15, 2003, U.S. Provisional Application No. 60/417,192, filed
Oct. 8, 2002, and International Application No. PCT/US2003/08491,
filed Mar. 17, 2003, which claims the benefit of U.S. Provisional
Application No. 60/417,192, filed Oct. 8, 2002, and U.S.
Provisional Application No. 60/364,560, filed Mar. 15, 2002.
INCORPORATION BY REFERENCE
[0002] U.S. patent application Ser. No. 12/950,215, filed Nov. 19,
2010, U.S. patent application Ser. No. 11/578,357, filed Apr. 17,
2007, International Application No. PCT/US2003/32164, filed Oct. 8,
2003, U.S. Provisional Application No. 60/500,519, filed Sep. 4,
2003, U.S. Provisional Application No. 60/488,209, filed Jul. 15,
2003, International Application No. PCT/US2003/08491, filed Mar.
17, 2003, U.S. Provisional Application No. 60/417,192, filed Oct.
8, 2002, and U.S. Provisional Application No. 60/364,560, filed
Mar. 15, 2002, are hereby incorporated by reference for all
purposes as if presented herein in their entirety.
FIELD OF THE INVENTION
[0003] This invention relates generally to a container, and more
specifically to a container having a flange, rim, handle, rib,
bottom surface, sidewall, or other feature that is encapsulated by
or formed from injection-molded material.
BACKGROUND OF THE INVENTION
[0004] For many years, perishable goods such as foodstuffs have
been stored in sealed trays or containers. Press-formed paperboard
trays are typically formed by pressure forming a single sheet or
blank of material, which may comprise multiple layers that have
been laminated together, into a predetermined shape, or by folding
and adhering the sheet or blank into the desired tray shape. Once
assembled, the tray may be filled and closed.
[0005] Typically, gaps in the tray surface created during the
pressure forming or folding of the tray present avenues for gas and
moisture to enter the tray that has been sealed by known means (for
example, a lid film). For example, many modern trays are pressure
formed in a mold that creates pleated or crimped corners, walls,
rims, or flange areas as a byproduct of forcing the tray into a
desired shape. As a further example, trays formed by folding a
blank generally have overlapping partial walls that are imperfectly
adhered to one another, leaving irregularities between the walls
where no adhesive is present.
[0006] Many times, trays are sealed with a separate lid, plastic
film, or other top designed to minimize airflow or vapor flow into
the tray interior. Few such barriers, however, form a perfectly
hermetic seal. The aforementioned gaps and irregularities prevent
the tray and top from uniformly mating, because the top is
insufficiently flexible to fill in such minute spaces in the rim or
flange areas of the tray. Thus, even though a partially effective
seal may be created, the tray contents are nonetheless exposed to
some amount of external air and moisture seeping through these
gaps. This in turn accelerates the spoiling of the tray's
contents.
[0007] Further, many trays or containers are relatively flimsy.
Oftentimes a tray may buckle under a comparatively light weight due
to inherent weaknesses in the paperboard material and processes
used to form the tray. That is, the tray sidewalls do not provide
sufficient support to prevent the tray from bending, folding, or
torquing when a load is placed on the tray. Such trays may also
become substantially weaker if they are exposed to high moisture
environments, such as those present in a refrigerator, microwave
over, or freezer.
[0008] A tray may also be difficult to carry, due to its size and
awkwardness. Especially large trays, whether circular or
rectangular, easily shift masses placed thereon when the tray is
carried from beneath. This in turn changes the balance of the tray
and may cause the tray to be dropped. Similarly, many large trays
are too flimsy to be carried by the edges, or lack a good gripping
area along the edges.
[0009] Many cooking trays may be loaded with different types of
food and heated in an oven, microwave, or other suitable appliance.
As these foods heat, they may run together, creating an
unappetizing appearance and taste. Further, a cooking tray may
unevenly distribute heat across its interior surface, causing food
in different portions of the tray to heat unevenly. Finally, many
cooking trays are not reusable or washable, because the tray
material cannot withstand immersion in water or detergent.
[0010] Accordingly, there is a need in the art for an improved
tray.
BRIEF SUMMARY OF THE INVENTION
[0011] In one form, the invention is generally a container having a
rim feature, such as an encapsulated portion of the tray body,
formed from injection-molded material. The container may be
hermetically salable. Typically, the injection-molded material is
some form of plastic, although other materials such as rubber may
be used. Different embodiments may have different injection-molded
features, such as an encapsulated rim, handle, tray interior,
sidewall, divider, and so forth. Further, depending on the nature
of the rim feature and intended tray use, the injection-molded
material may vary.
[0012] In one form, the invention generally comprises a tray having
a fully- or partially-encapsulated rim. It should be understood
throughout this document that a reference to an "encapsulated rim"
embraces both fully- and partially-encapsulated rims, unless
specifically stated otherwise. Further, the terms "encapsulated
rim" and "encapsulated flange" may be used interchangeably. The
tray may be of varying shapes and sizes, but typically has at least
one sidewall with a top edge and a bottom surface adjacent or
connected to the sidewall. The sidewall may be circular or several
sidewalls may exist. For example, a rectangular tray would have
four sidewalls.
[0013] The tray may have a flange extending outwardly from the
sidewall or sidewalls. The flange generally extends parallel to the
bottom surface of the tray, but may instead extend at other angles.
Typically, the flange and sidewall contain irregularities created
during creation of the tray. For example, the flange and sidewall
might be pleated or crimped as a result of press-forming the
tray.
[0014] Generally, the encapsulated rim is made of the flange and an
encapsulating material. The encapsulating material supports, and at
least partially surrounds, the flange and may be substantially
uniformly thick. The encapsulating material is generally made of a
plastic such as polyolefin, nylon, polyethylene terepthalate,
polycarbonate, or other engineering thermoplastic resins, but may
also be made from other materials. This encapsulating material
covers a portion of the flange and may extend a distance from the
flange's outer edge. The exterior of the encapsulating material is
substantially smooth, even those portions filling or overlying
irregularities in the flange. Further, the encapsulated rim
presents a hermetic barrier to gases and moisture, and may be
sealed with a film or other material to completely insulate the
tray interior. In one form, the tray does not include a paperboard
flange. Rather, the encapsulating material encapsulates the upper
edge of the sidewall or sidewalls, forming a flange in the
process.
[0015] Depending on the type of tray, the encapsulated rim may also
provide structural support. By controlling the geometry of the
encapsulated rim, it is possible to strengthen and stabilize the
tray even if the injection-molded material comprising the
encapsulated rim has a lower modulus than the paperboard itself.
This provides a benefit to any and all trays not requiring a
hermetic seal, such as common paper plates or pressed trays.
[0016] Further, the injection-molded or encapsulated features may
include handles to simplify carrying the tray, interior ribs or
dividers to keep foodstuffs separate during cooking, or even a
complete internal and external coating of the tray in order to
permit washing, drying, and reuse of the tray. In addition, an
embodiment may have a hinged handle made of injection-molded
material capable of folding inwardly for microwave cooking and
outwardly for carrying.
[0017] An injection-molding tool or apparatus may injection-mold
resin onto a tray to form the encapsulated rim or other
encapsulated feature. The tool may be capable of both press-forming
the tray from a tray blank and injection-molding resin onto the
tray in a single operation, without requiring the adjustment,
repositioning of, or moving of the tray between press-forming and
injection-molding.
[0018] In one embodiment, the disclosure is generally directed to a
tray having at least one sidewall having a top edge, an interior
surface, an exterior surface, and a bottom surface adjacent to the
sidewall. The bottom surface and the interior surface combine to
form a product receiving space of the tray. The tray has an
injection-molded feature having an anchor portion and a flange
portion. The anchor portion is adjacent the interior surface of the
at least one sidewall, and the flange portion extends from the
anchor portion and is adjacent the top edge of the at least one
sidewall.
[0019] That the present invention fulfills the above-described
needs and presents additional advantages will be apparent to one of
ordinary skill in the art upon reading the description and claims
set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is an isometric view of a rectangular tray having
crimped or folded corners and an outwardly extending flange.
[0021] FIG. 2 is an isometric view of the rectangular tray of FIG.
1, but having an encapsulated rim in accordance with an embodiment
of the present invention.
[0022] FIG. 3 is a top-down view of a tray blank that, when
assembled, forms the tray of FIG. 1.
[0023] FIG. 4 is an isometric view of a circular tray having a
crimped or folded side wall and an outwardly extending flange.
[0024] FIG. 5 is an isometric view of the circular tray of FIG. 4,
but having an encapsulated rim in accordance with an embodiment of
the present invention.
[0025] FIG. 6 is a top-down view of the rectangular tray of FIG.
1.
[0026] FIG. 7 is an enlarged, fragmentary cross-sectional view
along line 7-7 of FIG. 6.
[0027] FIG. 8 is a fragmentary, cross-sectional view of a partially
encapsulated tray flange, wherein the outward edge of the flange is
encapsulated and the injection-molded material is flush with the
upper surface of the flange, including a first embodiment of a
sealing lid.
[0028] FIG. 9 is a fragmentary, cross-sectional view of another
embodiment of a partially encapsulated tray flange, but wherein the
injection-molded material extends further past the outer edge of
the paperboard flange than it does in FIG. 8.
[0029] FIG. 10 is a fragmentary, cross-sectional view of the
partially encapsulated tray flange of FIG. 8, including a lid
sealing ring.
[0030] FIG. 11 is a fragmentary, cross-sectional view of a tray
sidewall and a horizontal flange, wherein the flange and tray
sidewall are partially-encapsulated, and the injection-molded resin
does not extend beyond the outer edge or onto the upper surface of
the flange.
[0031] FIG. 12 is a perspective view of the bottom of a tray having
an encapsulated rim, showing the injection-molded resin extending a
first distance along the tray sidewalls.
[0032] FIG. 13 is a perspective view of the bottom of a tray having
an encapsulated rim, showing the injection-molded resin extending a
second distance along the tray sidewalls.
[0033] FIG. 14 is a fragmentary, cross-sectional view of another
embodiment of a partially encapsulated tray flange.
[0034] FIG. 15 is a fragmentary, cross-sectional view of a
partially encapsulated tray flange similar to the embodiment of
FIG. 14, but wherein the injection-molded material is extended to
form a gripping surface.
[0035] FIG. 16 is a fragmentary, cross-sectional view of another
embodiment of a partially encapsulated tray flange.
[0036] FIG. 17 is a fragmentary, cross-sectional view of the
partially encapsulated tray flange similar to the embodiment of
FIG. 16, but wherein the injection-molded material is extended to
form a gripping surface.
[0037] FIG. 18 is a fragmentary, cross-sectional view of another
embodiment of a partially encapsulated tray flange.
[0038] FIG. 19 is a fragmentary, cross-sectional view of a
partially encapsulated tray flange, wherein the injection-molded
material provides a surface for sealing a lid, film, or cover to
the tray.
[0039] FIG. 20 is a fragmentary, cross-sectional view of another
embodiment of a partially encapsulated tray flange, wherein the
injection-molded material provides a surface for sealing a lid,
film, or cover to the tray.
[0040] FIG. 21 is a fragmentary, cross-sectional view of yet
another embodiment of a partially encapsulated tray flange, wherein
the injection-molded material provides a surface for sealing a lid,
film, or cover to the tray.
[0041] FIG. 22 is a fragmentary view of a corner of a notched
web-corner tray blank.
[0042] FIG. 23 is a fragmentary, cross-sectional view of a
web-corner tray assembled from the blank of FIG. 22 and having an
injection-molded, polymer flange, the cross-sectional view taken
through the notch.
[0043] FIG. 24 is a top-down view of a web-corner tray blank,
similar to the blank shown in FIG. 22 but lacking notches.
[0044] FIG. 25 is an isometric view of the web-corner tray blank of
FIG. 24 in an assembled state.
[0045] FIG. 26 is an isometric view of a tray having an
encapsulated rim and a cross-sectional view of a folded lid
designed to mate with the rim.
[0046] FIG. 27 is a top-down view of the lid of FIG. 26 in an
unfolded state.
[0047] FIG. 28 is a top view of a lid similar to the lid depicted
in FIG. 27, but having material removed from each corner and a
single semicontinuous score line.
[0048] FIG. 29 is a cross-sectional side view of the tray and lid
of FIG. 26 in a mated position.
[0049] FIG. 30 is an expanded view of the corner of the tray shown
in FIG. 29.
[0050] FIG. 31 is a cross-sectional view of a tray having an
encapsulated rim including a recess cavity.
[0051] FIG. 32 is a cross-sectional view of the tray of FIG. 31,
showing a lid resting in the recess cavity.
[0052] FIG. 33 is a top view of a five-panel blank folded into a
tray shape prior to injection of material.
[0053] FIG. 34 is a side view of the folded five-panel blank of
FIG. 33.
[0054] FIG. 35 is a front view of the folded five-panel blank of
FIGS. 33 and 34.
[0055] FIG. 36 is an enlarged, fragmentary view of a corner of the
five-panel blank of FIGS. 33-35 folded into a tray shape and
showing a gap between adjacent walls of the tray.
[0056] FIG. 37 is a top-down view of a five-panel tray similar to
the tray of FIGS. 33-36, but also having an injection-molded
rim.
[0057] FIG. 38 is an isometric view of a five-panel tray similar to
the tray of FIG. 37, but also having injection-molded corner
beads.
[0058] FIG. 39 is an end view of the five-panel tray of FIG.
38.
[0059] FIG. 40 is a side view of the five-panel tray of FIGS. 38
and 39.
[0060] FIG. 41 is a cross-sectional view taken along line 41-41 of
FIG. 40.
[0061] FIG. 42 is an enlarged, fragmentary view in partial
cross-section of the circled portion of FIG. 41 of the flange and
sidewall of the tray shown in FIGS. 38-41.
[0062] FIG. 43 is a fragmentary cross-sectional view of a corner of
a tray made according to one embodiment of the present invention,
wherein the injection-molded resin bead remains on the inside of
the package and forms a smooth, curved surface with the exterior of
the sidewalls.
[0063] FIG. 44 depicts a fragmentary cross-sectional view of a tray
corner having an alternative bead configuration to that depicted in
FIG. 43, wherein the injection-molded resin extends past the
exterior surface of the sidewalls.
[0064] FIG. 45 depicts a fragmentary cross-sectional view of a tray
corner having an alternative bead configurations to that depicted
in FIGS. 43 and 44, wherein the injection-molded resin does not
extend past the exterior surface of the sidewalls.
[0065] FIG. 46 is a top-down view of a five-panel tray blank.
[0066] FIG. 47 is an isometric view of the tray blank of FIG. 46 in
an assembled state.
[0067] FIG. 48 is a top-down view of one tray blank suitable for
use in an injection-molding apparatus.
[0068] FIG. 49 is a top-down view of a second tray blank suitable
for use in an injection-molding apparatus.
[0069] FIG. 50 is an isometric view of the tray blank of FIG. 49 in
an assembled state.
[0070] FIG. 51 is a top-down view of a third tray blank suitable
for use in an injection-molding apparatus.
[0071] FIG. 52 is a perspective view of the tray blank of FIG. 51
in an assembled state.
[0072] FIG. 53 is a top-down view of a fourth tray blank suitable
for use in an injection-molding apparatus.
[0073] FIG. 54 is a perspective view of the tray blank of FIG. 53
in an assembled state.
[0074] FIG. 55 is a top-down view of a fifth tray blank suitable
for use in an injection-molding apparatus.
[0075] FIG. 56 is a perspective view of the tray blank of FIG. 55
in an assembled state.
[0076] FIG. 57 is a top-down view of a sixth tray blank suitable
for use in an injection-molding apparatus.
[0077] FIG. 58 is a perspective view of the tray blank of FIG. 57
in an assembled state.
[0078] FIG. 59 is a view of an alternative embodiment of the
present invention, which is a three-piece package consisting of a
bottom panel member, a sidewall member, and a lid member, including
an injection-molded seam and extending bottom lip.
[0079] FIG. 60 is a cross-sectional view taken along the
injection-molded seam of the embodiment shown in FIG. 59.
[0080] FIG. 61 is a view of an embodiment of the present invention
similar to that shown in FIG. 59, but lacking the extending bottom
lip.
[0081] FIG. 62 is a cross-sectional view of the embodiment shown in
FIG. 61, taken along the injection-molded seam.
[0082] FIG. 63 depicts a retortable embodiment of the present
invention, which is a three-piece package consisting of a bottom
panel member, a sidewall member, and a top panel member.
[0083] FIG. 64 is a top-down view of a tray having encapsulated
interior ribs or dividers and a coated interior.
[0084] FIG. 65 is a top-down view of a tray having an encapsulated
rim and susceptor layer.
[0085] FIG. 66 is an isometric view of a circular tray having an
encapsulated rim that includes handles.
[0086] FIG. 67 is an isometric view of a rectangular tray having an
encapsulated rim that includes handles.
[0087] FIGS. 68 and 69 are isometric views of a circular tray
having an encapsulated rim that includes a folding handle.
[0088] FIG. 70 is an end view of a container according to the
present invention having a trivet feature.
[0089] FIG. 71 is an expanded view of the bottom right corner of
FIG. 70, more clearly showing an injection-molded trivet
feature.
[0090] FIG. 72 depicts a stand-up feature that can be accomplished
according to the present invention.
[0091] FIG. 73 is an isometric view of a tray having a hinged,
snap-fit lid.
[0092] FIG. 74 is a cross-sectional, schematic view of an open
injection mold tool according to a first embodiment with a tray
positioned for insertion therein.
[0093] FIG. 75 is a cross-sectional view of the injection mold tool
and tray of FIG. 74, when the injection mold tool is closed.
[0094] FIG. 76 is a cross-sectional view of the closed injection
mold tool of FIG. 75, with pressurized runner lines injecting
molten encapsulating material into the injection mold tool.
[0095] FIG. 77 is an enlarged, fragmentary cross-sectional view of
the closed injection mold tool of FIG. 75.
[0096] FIG. 78 is an enlarged, fragmentary cross-sectional view of
a first alternate embodiment of a closed injection mold tool.
[0097] FIG. 79 is an enlarged, fragmentary cross-sectional view of
the operational injection mold tool of FIG. 76.
[0098] FIG. 80 is an enlarged, fragmentary cross-sectional view
along line 80-80 of FIG. 79.
[0099] FIG. 81 is a further enlarged, fragmentary cross-sectional
view along line 80-80 of FIG. 79.
[0100] FIG. 82 is a cross-sectional view of a closed injection mold
tool according to a second alternate embodiment and containing a
tray.
[0101] FIG. 83 is an isometric view of the bottom surface of a tray
having a partially-encapsulated rim.
[0102] FIG. 84 is a bottom-up view of the tray of FIG. 83.
[0103] FIG. 85 is a bottom-up view of a tray having a
fully-encapsulated rim.
[0104] FIG. 86 is a view of a first embodiment of an injection
cavity, looking towards a cavity half of an injection-molded
tool.
[0105] FIG. 87 is a cross-sectional view of the injection cavity of
FIG. 86, taken along line 87-87 of FIG. 86.
[0106] FIG. 88 is a cross-sectional view of a tray having an
encapsulated rim formed in the injection cavity of FIG. 86.
[0107] FIG. 89 is a view of a second embodiment of an injection
cavity, looking towards a cavity half of an injection-molded
tool.
[0108] FIG. 90 is a cross-sectional view of the injection cavity of
FIG. 89, taken along line 90-90 of FIG. 89.
[0109] FIG. 91 is a cross-sectional view of a tray having an
encapsulated rim formed in the injection cavity of FIG. 90.
[0110] FIG. 92 is a view of the injection cavity of FIG. 86,
showing resin flowing through the cavity.
[0111] FIG. 93 is a first cross-sectional view of a third
embodiment of an injection-molding tool.
[0112] FIG. 94 is a second cross-sectional view of the
injection-molding tool of FIG. 93, showing the tool in a partially
closed position.
[0113] FIG. 95 is a third cross-sectional view of the
injection-molding tool of FIG. 93, showing the tool in a fully
closed position.
[0114] FIG. 96 is a fourth cross-sectional view of the
injection-molding tool of FIG. 93, showing the tool in a fully open
position, and also showing a cross-section of a tray press-formed
by the operation of the tool.
[0115] FIG. 97 depicts an embodiment wherein the paperboard is
extrusion laminated, or polymer coated, and wherein the
injection-molded resin forming the corner bead is directed to the
laminated or coated paperboard.
[0116] FIG. 98 depicts an embodiment of the present invention
similar to the embodiment depicted in FIG. 43, but wherein the mold
cavity has been modified to ensure that the injection-molded resin
remains inward of the outer surface of the panels comprising the
tray.
[0117] FIG. 99 is a top-down view of a tray having outwardly
deflected precurved sidewalls and an outwardly deflected precurved
rim.
[0118] FIG. 100 is a bottom-up view of a first embodiment of a tray
having a cored encapsulated rim.
[0119] FIG. 101 is a bottom-up view of a second embodiment of a
tray having a cored encapsulated rim.
[0120] FIG. 102 is a cross-sectional view of a tray having an
encapsulated rim comprising an arcuate head portion, a flange
portion, and an anchor portion.
[0121] FIG. 103 is a cross-sectional view of a package comprising
the tray of FIG. 102 and a frictionally and adhesively affixed
lid.
[0122] FIG. 104 is a fragmentary, cross-sectional view of one end
of the lid depicted in FIG. 103.
[0123] FIG. 105 is a fragmentary, cross-sectional view of a portion
of the tray depicted in FIGS. 102 and 103.
[0124] FIG. 106 is an enlarged, fragmentary, cross-sectional view
depicting the lid of FIGS. 103 and 104 frictionally and adhesively
bonded to a first alternative embodiment of the encapsulated rim
depicted in FIGS. 102,103, and 105.
[0125] FIG. 107 is an enlarged, fragmentary, cross-sectional view
depicting the lid of FIGS. 103 and 104 frictionally and adhesively
bonded to a second alternative embodiment of the encapsulated rim
depicted in FIGS. 102,103, and 105.
[0126] FIG. 108 is an enlarged, fragmentary, cross-sectional view
depicting the lid of FIGS. 103 and 104 frictionally and adhesively
bonded to a third alternative embodiment of the encapsulated rim
depicted in FIGS. 102,103, and 105.
[0127] FIGS. 109-113 depict the assembly and operation of a package
having asymmetrically-injected encapsulated rims, including a
crimpable encapsulated rim and a friction-fit encapsulated rim.
[0128] FIGS. 114 and 115 depict crimping of the crimpable
encapsulated rim depicted in FIGS. 109-113.
[0129] FIGS. 116 and 117 depict crimping of an alternative
embodiment of a crimpable encapsulated rim.
[0130] FIG. 118 is an isometric view looking downwardly into a tray
having encapsulated rims like those discussed in connection with
FIGS. 102-117, wherein a first opening feature recess is formed in
the corners of the tray.
[0131] FIG. 119 depicts a package wherein a lid having rounded
corners is affixed to the tray of FIG. 118.
[0132] FIG. 120 is an enlarged, cross-sectional view through a
first corner of the package depicted in FIG. 119, showing a corner
hinge feature.
[0133] FIG. 121 is an enlarged, cross-sectional view through a
second corner of the package depicted in FIG. 119, showing the
opening feature recess.
[0134] FIG. 122 depicts a package similar to that depicted in FIG.
119, but having an edge score permitting the lid to hinge adjacent
to one of its longer edges.
[0135] FIG. 123 is an enlarged, fragmentary, cross-sectional view
through a corner of the package depicted in FIG. 122 and showing
the opening feature recess.
[0136] FIG. 124 is similar to FIG. 118, but depicts a tray having
an alternative opening feature recess formed in the corners of the
tray.
[0137] FIG. 125 is similar to FIG. 119, but depicts a dispensing
feature through the center area of the lid.
[0138] FIG. 126 is an enlarged, fragmentary, cross-sectional view
through an indicated portion of the encapsulated rim.
[0139] FIG. 127 is similar to FIG. 125, but depicts a package
wherein the encapsulated rim extends around the entire perimeter of
the lid.
[0140] FIG. 128 is an enlarged, fragmentary, cross-sectional view
through a portion of the encapsulated rim in an upper end of the
tray sidewall.
[0141] FIGS. 129-131 are top down views depicting, in general, flow
front progression during a center-point, resin-injection
process.
[0142] FIGS. 132-139 are similar to FIGS. 129-131, but depict in
greater detail resin flow front progression during center-point,
resin injection designed to minimize flashing while encapsulating
portions of a lidded tray.
[0143] FIG. 140 is an isometric view of a lidded tray having
encapsulated portions formed from a center-point, resin-injection
process.
[0144] FIGS. 141-146 are enlarged, fragmentary views showing corner
flow details of the flow stages also depicted in FIGS. 134-136.
[0145] FIG. 147 is a plan view of a blank for a press-formed
tray.
[0146] FIG. 148 is a press-formed tray having an encapsulated,
injected-resin rim and formed from the blank depicted in FIG.
147.
[0147] FIG. 149 is a five-panel, folded formed blank that may be
used to form a tray.
[0148] FIG. 150 is a tray having features formed from injected
resin using a center-point, resin-injection process similar to the
process previously described in connection with FIGS. 129-146.
[0149] FIG. 151 is a press-formed, folded blank that may be used to
make a tray according to the present invention.
[0150] FIG. 152 is an isometric view of a tray having
injected-resin features and formed from the blank depicted in FIG.
151 using the center-point, resin-injection process previously
described in connection with FIG. 150.
[0151] FIG. 153 is an eight-panel, rounded-corner blank.
[0152] FIG. 154 is a tray formed from the blank of FIG. 153 using a
center-point, resin-injection process.
[0153] FIG. 155 is a web-corner blank.
[0154] FIG. 156 is a tray formed from the web-corner blank of FIG.
155 using a center-point, resin-injection process.
[0155] FIG. 157 is an eight-panel, straight-corner blank.
[0156] FIG. 158 is a tray formed from the blank depicted in FIG.
157 using a center-point, resin-injection process.
[0157] FIG. 159 is a cross-sectional view of a tray according to
another embodiment of the present invention and having an
encapsulated rim with a flange portion and an anchor portion.
[0158] FIG. 160 is a schematic, cross-sectional view of a typical
prior art forming tool with a core and a cavity.
[0159] FIG. 161 is a schematic, cross-sectional view of a forming
tool incorporating single-stage cavity articulation at the tray
bottom and lower sidewall.
[0160] FIG. 162 is a schematic, cross-sectional view of a forming
tool incorporating multi-stage cavity articulation.
[0161] FIG. 163 is a schematic, cross-sectional view of a forming
tool incorporating single-stage cavity articulation at the bottom
of the tray only.
[0162] FIG. 164 is a view looking directly at the bottom of a
press-formed tray with a partially-encapsulated rim according to
one embodiment of the present invention.
[0163] FIG. 165 is a side view of the tray depicted in FIG.
164.
[0164] FIG. 166 is an end view of the tray depicted in FIGS. 164
and 165.
[0165] FIG. 167 is a cross-sectional view taken along line 167-167
of FIG. 164.
[0166] FIG. 168 is an enlarged, fragmentary, cross-sectional view
of portion 168 in FIG. 167.
[0167] FIG. 169 is a view looking directly at the bottom of a
press-formed tray with a partially-encapsulated rim according to
another embodiment of the present invention.
[0168] FIG. 170 is a side view of the tray depicted in FIG.
169.
[0169] FIG. 171 is an end view of the tray depicted in FIGS. 169
and 170.
[0170] FIG. 172 is a cross-sectional view taken along line 172-172
of FIG. 169.
[0171] FIG. 173 is an enlarged, fragmentary, cross-sectional view
of portion 173 in FIG. 172.
[0172] FIG. 174 is an isometric view of a folded-style,
injection-molded polymer paperboard composite package manufactured
using a co-extrusion injection-molded process for improved gas
barrier properties.
[0173] FIG. 175 is an enlarged, fragmentary cross-sectional view of
a portion of FIG. 174.
[0174] FIG. 176 is a top plan view of a package like that shown in
FIG. 174, but also including supporting ribs on the inside of the
package as an injection-molded stiffening feature.
[0175] FIG. 177 is a side view of the package depicted in FIG. 176,
demonstrating that the supporting ribs shown in FIG. 176 are not
visible from outside the package.
[0176] FIGS. 178-182 depict examples of cylindrical containers that
can be made with the same technology used to make the packages
depicted in FIGS. 174-177.
[0177] FIG. 183 is an open, prior art compartmented tray, having
first and second secondary packages in first and second
compartments, respectively.
[0178] FIGS. 184 and 185 depict an example of a compartmented tray
according to the present invention, wherein different compartments
of the same tray have different characteristics.
[0179] FIG. 186 depicts an example of a one-piece package made in
accordance with an embodiment of the present invention, wherein a
lid is connected to a tray by a pair of short living hinges.
[0180] FIG. 187 depicts an example of a two-piece package made in
accordance with an embodiment of the present invention, wherein a
lid having a pair of windows and a living hinge is about to be
mechanically adhered to a mounting surface comprising part of a
formed tray.
[0181] FIG. 188 depicts an example of a two-piece package made in
accordance with an embodiment of the present invention, wherein a
snap-fit lid with a living hinge dispensing feature is about to be
snapped to a formed tray.
[0182] FIG. 189 depicts an example of a two-piece package made in
accordance with an embodiment of the present invention, wherein a
snap-fit lid with a mechanically-hinge dispensing feature is about
to be snapped to a formed tray.
[0183] FIG. 190 depicts an example of a one-piece package made in
accordance with an embodiment of the present invention, wherein a
lid is connected to a tray by a living hinge, and where a
dispensing feature lid is connected to the tray by a second living
hinge.
[0184] FIG. 191 is a plan view looking at the inside surface of a
lid that incorporates a two-piece, break-out serving utensil.
[0185] FIG. 192 is a plan view of the outer surface of the lid
depicted in FIG. 191, depicting a sealing film fixed over the
break-out serving utensil.
[0186] FIG. 193 depicts a tray and lid combination according to the
present invention, incorporating an easy-opening feature comprising
an extended tab on both the lid and tray.
[0187] FIG. 194 depicts an enlarged view of circled region 194 of
FIG. 193.
[0188] FIG. 195 depicts a tray and lid sealing and locking
mechanism, including an easy-open, raised sealing ridge on the tray
flange, wherein the paperboard has been encapsulated.
[0189] FIG. 196 depicts an injection-molded/paperboard composite
tray having warped or wavy sidewalls.
[0190] FIG. 197 depicts an injection-molded/paperboard composite
tray constructed from the material depicted in FIGS. 97 and 86.
[0191] FIG. 198 depicts a fragmentary, cross-sectional view of an
embodiment wherein the paperboard is extrusion laminated, or
polymer coated, and wherein the injection-molded resin forming the
flange is directed to the laminated or coated paperboard.
[0192] FIG. 199 is a plan view looking downwardly on a tray that
incorporates a venting feature into the flange.
[0193] FIG. 200 is a fragmentary, cross-sectional view of the
portion of the flange that incorporates the venting feature
depicted in FIG. 199.
[0194] FIG. 201 depicts an embodiment of an injection-molded
sealing and locking mechanism, wherein the edge of the paperboard
comprising the lid has been encapsulated.
[0195] FIG. 202 depicts an embodiment of an injection-molded
sealing and locking mechanism, wherein the edge of the paperboard
comprising the lid and the edge of the paperboard comprising the
tray have not been encapsulated.
[0196] FIG. 203 depicts an alternative embodiment of the
injection-molded sealing and locking mechanism depicted in FIG.
202.
[0197] FIGS. 204-208 depict different views of a twelve count,
folded paperboard tray that has a flange extending outwardly from
each sidewall and a first portion of a sealing-and-locking
mechanism, similar to the one depicted in the lower portion of FIG.
202, molded on the upper surface of the flange around the perimeter
of the tray.
[0198] FIGS. 209-213 depict different views of a twenty-four count,
folded paperboard tray that has a flange extending outwardly from
each sidewall and a first portion of a sealing-and-locking
mechanism, similar to the one depicted in the lower portion of FIG.
202, molded on the upper surface of the flange around the perimeter
of the tray.
[0199] FIGS. 214-216 depict a top view, an end view, and a side
view, respectively, of three twenty-four count trays, similar to
those depicted in FIGS. 209-213, stacked together.
[0200] FIGS. 217-221 depict several views of a lid for use on trays
like those depicted in FIGS. 204-216, and these five figures show a
second portion of a sealing-and-locking mechanism, similar to the
one depicted in the upper portion of FIG. 202, molded on the lower
surface of the lid around the perimeter of the lid, and these five
figures also show a pull tab feature.
[0201] FIGS. 222-228 depict several views of the lid depicted in
FIGS. 217-221 attached to the twelve count, folded paperboard tray
of FIGS. 204-208, wherein the first portion and the second portion
of the sealing-and-locking mechanism are engaged.
[0202] FIGS. 229-235 depict several views of the lid depicted in
FIGS. 217-221 attached to the twenty-four count, folded paperboard
tray of FIGS. 209-216, wherein the first portion and the second
portion of the sealing-and-locking mechanism are engaged.
DETAILED DESCRIPTION OF THE INVENTION
Overview
[0203] Injection-molded resin can have higher flexural and tensile
moduli than paperboard and is resistant to moisture. Capitalizing
on these properties, the present invention may comprise paperboard
press-formed or folded-style trays or plates, and other paperboard
containers, including cylindrical containers or cups, that are
enhanced by having high-modulus plastic polymer added (e.g., by
injection molding) in one or more selected areas (e.g., around the
rim to create a "rim feature") to provide a number of advantages,
including the following, among others:
[0204] i) increased stiffness and rigidity (for example,
high-strength paper plates, serving trays, and other containers
that resist collapsing under loads may be created by molding a
plastic rim onto an existing flange or onto the unflanged upper
perimeter of the tray. This plastic rim helps prevent a tray
containing a large food load from flexing upwardly when the tray is
lifted);
[0205] ii) the ability to obtain a hermetic-quality heat seal of
lid film/stock onto the plastic rim or bead for good shelf-life
during the distribution cycle;
[0206] iii) the ability to incorporate a rim feature that will
accept a snap-fit plastic lid; and
[0207] iv) the ability to incorporate other useful features like
fixed and foldable handles, internal ribs, and lids.
[0208] The trays of the present invention may be used, among other
purposes, for conventional or microwave preparation or storage of
food. They may also be washed and reused.
Press-Formed Tray with Formed Rim
In General
[0209] One embodiment of the present invention comprises a
press-formed, paperboard tray or other container having at least
one sidewall; a bottom wall; and a flange, lip, or rim extending
from the sidewall. Alternate embodiments may use different methods
to manufacture the basic tray, some of which may be suitable only
for certain tray materials. Injection-molded resin can have a
higher modulus than the paperboard used in the press-formed tray.
Thus, combining such resins with paperboard can dramatically
increase the stiffness and rigidity of the resulting paperboard
tray. For example, molding a plastic rim onto the existing flange
increases tray stiffness and rigidity.
[0210] In the embodiment shown in FIG. 1, the tray 100 is
rectangular in shape, having a first and second major sidewall
102,104 and a first and second minor sidewall 106,108. In this
embodiment, each sidewall is joined to another by a corner 110 that
is generally crimped, pleated, or folded as shown in FIG. 1.
Alternate embodiments of the tray 112 may be circular, as shown in
FIG. 4, or may have a different number of sidewalls 114, such as a
pentagonal tray.
[0211] The tray 100 may be made from paperboard or a paperboard
substitute, such as a bleached, unbleached, or recycled cellulose
pulp molded fiber matrix. Alternate embodiments may include
additional or different materials to form the tray 100, such as
metal, foil, plastic, and so forth. The tray body and flange are
formed from a single piece of material. Within the context of this
document, the phrase a "single piece of material" includes a single
piece of material that comprises a single layer or multiple layers
of the same material or multiple layers of different materials.
These multi-layered materials could include, for example, layers of
two or more paper and/or paperboard substrates completely bonded
together and/or partially bonded together, such as a corrugated
board material, with or without any other layer or layers of any
other materials such as metal, foil, plastic, and so forth. Thus,
laminates formed from two or more differing types of material are
nonetheless encompassed by the phrase a "single piece of
material."
[0212] As mentioned, the tray 100 has a flange 116 protruding
outwardly from the sidewalls 114 to mate with a lid or sealing
film. Generally, when the material is formed into the flange, no
portion of the flange extends into the interior of the tray.
Rather, the flange 116 protrudes outwardly from the tray sidewalls
as shown in, for example, FIGS. 1 and 4. Alternate embodiments may
have the flange extending at a different angle from the sidewalls,
such as at a forty-five degree angle to or flush with the
sidewalls.
[0213] In the rectangular tray 100 depicted in FIG. 1, the flange
comprises "corner flanges" 118 and "sidewall flanges" 120. The term
"corner flange" 118 refers to those portions of the flange that
extend radially outwardly from each corner 110 of the tray 100,
while the term "sidewall flange" 120 refers to the portions of the
flange 116 extending outwardly from each tray sidewall 102,104,
106,108. It should be understood that these terms merely refer to
different portions of what is generally a unitary flange. It should
be further understood that the press-formed flange 116 and tray 100
are typically formed from a continuous piece of material, although
alternate embodiments may shape the flange 116 and tray 100 from
different pieces of material, which are in turn joined
together.
[0214] FIGS. 1, 4, 6, and 7 show folds, pleats, and creases 122
inherent in a press-formed tray that make it difficult to achieve a
hermetic seal around, for example, the flange 116. Layers of
material often overlap at each corner, resulting in the corners 110
having a greater cross-sectional thickness than the sidewalls 102,
104, 106, 108. The same is true for the corner flanges 118 when
compared to the sidewall flanges 120 the corners 110 of the tray,
100 and thus the corner flanges 118, are crimped or pleated as a
byproduct of being press-formed, whereas the sidewalls 102, 104,
106, 108, and sidewall flanges 120 are smooth. The crimping or
folding of material to form a corner flange typically results in
irregular or nonplanar upper and lower flange surfaces in each
corner. FIG. 6 is a top-down view of the rectangular tray 100
initially depicted in FIG. 1. FIG. 7 is an enlarged, fragmentary
cross-sectional view of the pleated flange 116, taken along line
6-6 of FIG. 6. The irregularities or pleats created within the
pleated flange 116 are easily seen. Although FIG. 7 depicts the
tray pleats 122 as roughly equally wide, in reality the pleats 122
may be of varying widths, depths, and so forth. Each tray is unique
in its irregularities.
[0215] When a lid is placed atop the tray 100, or a film is sealed
thereto, the film or lid lies smoothly across the top of the
pleated corner flanges 118. Ordinarily, the overlapping material,
irregularities, and discontinuous surface present a path for
airborne contaminants, moisture, vapor, odors, and so forth to
enter the interior of the tray (e.g., beneath the film or lid, and
through the corner pleats) and affect any contents stored therein.
Because the irregularities 122 are relatively small with respect to
the overall surface area of the flange corners 118 or sidewalls
120, films or covers mated directly to the flange 116 typically do
not completely seal the irregularities. Accordingly, tray flanges
lacking an encapsulated rim often present partial gas or vapor
paths even when bonded to an overlying film. To eliminate these
problems, the flange may be fully or partially encapsulated with
plastic.
[0216] The embodiment 100 may have only an encapsulated rim, or may
have additional injection-molded features such as handles, hinges,
coatings, ribs, and so forth. Encapsulated rims are further
described next, and the additional features are described in more
detail below.
[0217] The terms "plastic rim" and "encapsulated rim" are used
interchangeably and may in fact refer to encapsulated rims made of
a material other than plastic. Any injection-molded material
capable of forming a rim encapsulating all or a portion of the tray
flange 116 and providing a hermetic barrier is usable with the
present invention. For example, an alternate embodiment of the
invention may form a hermetic seal from rubbers, such as neoprene
or butyl, rather than plastic.
Fully-Encapsulated Rim
[0218] In one embodiment, as shown in FIGS. 2 and 5, the flange 116
is fully encapsulated to a substantially uniform thickness and
width, to form an "encapsulated flange" 124 with the possible
exception of the outer tip 126 of the encapsulated flange. The
plastic overlays the top and bottom 130 of the flange 124, and
extends outwardly slightly past the flange's outer edge 132. The
plastic used to form this encapsulated flange 124 is typically
vapor-, gas-, and moisture-proof in order to provide a hermetic
seal between the tray and the encapsulated rim 124 or flange 116
itself. This encapsulated rim 124 may maintain a substantially
uniform thickness from the root 134 to the tip 136 of the flange
116 despite any step changes or discontinuities in the thickness of
the flange 116 itself, such as those produced at the corner flanges
118. Alternate embodiments may vary the width or thickness of the
encapsulated rim 124, as necessary, and may employ an encapsulated
rim of non-uniform thickness or width. FIG. 3 is a top-down view of
a tray blank 101 that, when assembled, forms the tray of FIG.
1.
[0219] The encapsulated rim 124 generally bonds well with a thin
film, paper, fiberboard, or a composite material overlaying the
tray. Such overlays will be collectively referred to as a "film."
The encapsulated rim 124 and the film overlay also create a
hermetically-sealable tray, thus preventing gas or vapor from
entering or escaping the tray until the film is removed. An
alternate embodiment may use a reclosable lid in place of the film
overlay. Such lids are discussed further below. The reclosable lid
provides a moisture-proof seal when fitted atop the encapsulated
rim and may be made from a variety of suitable materials such as
rubber, plastic, or fiberboard.
[0220] FIG. 2 is an isometric view of a rectangular tray 100 having
a fully-encapsulated flange 124 as a "rim feature." Generally, the
term "rim feature" as used herein refers to any feature formed on
or adjacent to the rim of a container or tray by either fully- or
partially-encapsulating a portion of the tray with injection-molded
material. For example, the fully-encapsulated flange 124 just
described is a "rim feature" as that term is used herein. The
aforementioned pleated corner flanges 118, along with the rest of
the flange, is encapsulated in plastic, resin, or other material
substantially impermeable to air and moisture. The plastic rim 124,
also referred to as an encapsulated rim 124, completely encloses
the top, bottom, and outside edge of the flange 116 (see, e.g.,
FIG. 79). The plastic rim 124 also provides a smooth surface of
uniform thickness to maximize contact, and thus sealing, between
the aforementioned lid or film and the rim.
[0221] A typical fully-encapsulated rim 124 in the present
embodiment is approximately one-eighth of an inch thick and extends
approximately three-eighths of an inch beyond the outer edge 132 of
the flange 116. This thickness adequately coats the flange 116 on
both its top 128 and bottom 130, thus creating the potential for
the aforementioned hermetic seal, and the rim's width ensures a
stable surface with sufficient area to which a covering film may be
bonded to effect the hermetic seal. The dimension of a
fully-encapsulated rim may vary in alternative embodiments.
[0222] Many different tray shapes may accept an encapsulated rim.
For example, FIG. 4 displays a shallow circular tray 112, such as a
pizza baking tray. Unlike the rectangular tray 100 displayed in
FIG. 1, the entire single sidewall 114 and flange 116 of the
circular tray 112 are pleated. Even in such instances, an
encapsulated rim evenly surrounding the entirety of the pleated
flange may be provided. A sample circular tray 112 with a
fully-encapsulated rim 124 is shown in FIG. 5.
[0223] The encapsulated rim 124 may additionally serve to
strengthen the tray. The injection-molded material used to
encapsulate the tray rim may be molded into geometries capable of
stabilizing and stiffening the paperboard tray, regardless of the
stiffness modulus of the injection-molded material itself.
Accordingly, the ring of injection-molded material minimizes the
tray's ability to flex, twist, or compress. The strength and
rigidity of a tray having an encapsulated rim prevents flexing not
only in a rotational direction, but also upwardly or outwardly when
a tray bearing a significant food load is lifted. Accordingly, the
encapsulated rim also minimizes the chances of food slipping off a
tray.
[0224] The encapsulated rim 124 pictured in FIG. 5 not only
provides a hermetic barrier when mated with a covering, but also
reinforces the circular tray 112 itself. Trays constructed from
paperboard and many other materials bend easily, especially when
the surface area of the tray is large with respect to the sidewall
depth. In such cases, a tray may bend or fold under a comparatively
light load. By adding an encapsulated rim of substantially rigid
plastic, the tray's tendency to buckle, twist, or torque is
reduced. A substantially rigid encapsulated rim is especially
useful where a tray's diameter is eight to ten inches or greater,
insofar as trays of such size bend or fold very easily.
Partially-Encapsulated Rim and Stiffening Feature
[0225] The polymer for the encapsulation is expensive and the
amount used increases the cycle time required to form useful trays
100. Thus, reducing the amount of polymer by encapsulating only a
portion of the flange 116 reduces the manufacturing costs and time.
The stiffness and rigidity of paperboard trays can be dramatically
increased in a cost-effective manner by encapsulating only a
portion of the flange.
[0226] FIGS. 8,9, 10, and 11 are cross-sectional views of tray
sidewalls 137 having a horizontal flange with an encapsulated
bottom. In the embodiments of FIGS. 8 and 9, the outward edge 142
of the flange 138 is also encapsulated and the injected material
144 is flush with the upper surface 146 of the flange 138. In FIG.
9, the injection-molded material 144 extends further past the outer
edge of the paperboard flange 138 than it does in FIG. 8.
[0227] The entire upper surface of the flange 138 is unencapsulated
and can bond directly with the lidding material. The intermolecular
mixing between the lidding material and the material on the upper
exterior surface 146 of the flange 138 contributes to achieving a
hermetic seal. For example, the inner surface of the tray 100 and
the outer surface of the flange may be made from a SARAN-coated
polyester. SARAN is one example of a polyvinyl dichloride. By using
a lidding material that is also a SARAN-coated polyester, a good
hermetic seal is possible through the intermolecular mixing of the
lining material and the lidding material.
[0228] Alternatively, if the lidding material and the material on
the upper exterior surface 146 of the flange 138 are not matched to
provide intermolecular mixing, by projecting the injection-molded
material 144 a small distance beyond the outer edge 142 of the tray
flange 138 but flush with the tray top 148 (as shown in FIGS. 8 and
9), a surface capable of providing a hermetic seal with a lid is
provided outwardly of the upper exterior surface 146 of the flange
138.
[0229] Also, as previously mentioned and as shown in FIGS. 8,9, and
10, additional material may be injected at the intersection of the
bottom surface 140 of the flange 138 with the outer wall 152 of the
tray to create a bump or stair step 150 that enhances de-nesting
operations by providing a space between flanges 138 of multiple
stacked or nested trays, thus simplifying de-nesting of trays.
Typically, a de-nester includes a screw that shuffles and
separates. The bump 150 is also advantageous with pick-and-place
operations, and may impart additional stiffness and/or strength to
the sidewalls 137. The depth that this additional material or bump
150 extends along the sidewall may vary.
[0230] The geometry of the injection-molded material covering the
bottom 140 of the tray flange provides enhanced strength and
rigidity for the tray 100. The injection-molded material 144 may
extend at least partially down the tray's outer sidewall 152,
stiffening the sidewalls 137 and body of the tray. Examples of such
extension are shown in FIGS. 8, 9, and 10. This ring or layer of
injection-molded material 144 reduces outward bowing of the
sidewalls 136 when a tray containing a heavy food load is lifted
and additionally may prevent inward compression when the tray is
subjected to crushing or deforming forces.
[0231] Currently, press-formed trays have flange surfaces that are
rough and will not form a hermetic seal with conventional lidding
films. When forming the embodiments of FIGS. 8, 9, 10, and 6,
however, such pleats (not shown) practically disappear from the
pressure and heat generated within an injection mold tool used to
manufacture an injection-molded feature. Hot resin 144 comes into
the mold under high pressure. By injecting resin only on the bottom
140 or backside of the rim during the injection-molding process,
exposed paperboard pleats on the upper surface 146 of the flange
are pressed upwardly against a surface of the metal mold by the
hot, high-pressure resin injectant, which compresses or "irons" the
pleats on the upper surface of the flange. This creates an improved
seal surface that helps ensure a hermetic seal is obtained across
the now-flattened pleats.
[0232] During the injection-molding process, the paperboard forming
the tray is plasticized to the point that it flows and closes up
any surface gaps, thereby reducing the severity of irregularities
on the upper flange surface. This is one example of mechanical
crosslinking, described later.
[0233] In addition to creating an encapsulated rim 158 having good
sealing properties, as shown in FIGS. 9 and 11, an embodiment may
be provided with a lid 154 capable of snapping onto or otherwise
fitting onto or around an encapsulated rim, as shown in
cross-section in FIG. 8. Here, the lid may include a cavity or
recess 156 running along a downturn or lip 160 extending downwardly
from the lid edge 162 sized to accept the outer edge 164 of the
encapsulated rim 158. The lid 154 may be pressed down onto the tray
until the encapsulated rim 158 seats in the cavity.
[0234] In yet another embodiment, the lip 160 may be omitted from
the lid 154. Instead, a sealing ring 166 may be provided as a
separate element, as shown in FIG. 10. Here, the sealing ring 166
includes two cavities running along its interior sidewall-one
cavity 168 sized to accept the outer edge 170 of the lid 172, and
one cavity 174 sized to accept the outer edge 164 of the
encapsulated rim 158. The sealing ring 166 may be placed around
either the tray rim 158 or lid 172 initially. The other element
(seal or lid) may then be mated to the sealing ring 166 by pressing
the element until it seats within the ring, or pressing down on the
ring 166 until the element seats in the proper cavity.
[0235] The embodiment shown in FIG. 10 includes a film layer 176
bonded to the lower surface 178 of the lid 172. Alternate
embodiments may include a Rim layer bonded to the upper surface of
the tray 100. Generally, all trays, lids, blanks, and other such
items discussed herein may include a film layer bonded thereto.
Films are generally discussed later in this document.
[0236] FIG. 11 is a cross-sectional view of an alternate embodiment
of a partially-encapsulated, injection-molded flange 180. In this
embodiment, the edge 182 of the tray 184 extends outwardly from the
plane containing the top surface 186 of the tray. By encapsulating
only the underside 188 of the flange 180 as shown in FIG. 11,
stability and rigidity are added to the tray. The shape of the
injection-molded material 190 conforms generally to the shape of
the underside 188 of the flange 180. This embodiment is well suited
for trays or other devices that do not require a hermetic seal,
such as pizza trays, serving plates, and so forth.
[0237] As previously mentioned, the injection-molded material may
extend partially along the tray sidewall or sidewalls. Different
embodiments may vary the depth to which the injection-molded
material extends. FIG. 12 depicts the material 192 extending along
the sidewalls 194 of an inverted tray 196 to a relatively shallow
depth, while FIG. 13 depicts the material 192 extending
substantially farther along the tray sidewalls 194.
[0238] Referring next to FIGS. 164-173, additional embodiments 197
of the present invention are described. As discussed further below,
these embodiments 197 provide additional advantages. For example,
in the embodiments of FIGS. 164-173, the heat sealability of lid
film is improved via a recessed hot tip injection point and thick
channel projected feet 199 along the narrow edges of the tray.
Further, since the trays 197 depicted in these figures are created
using a single hot tip runner injection site 201, the cost and
complexity of the injection mold tooling is reduced. The throughput
of the injection molding process is also improved via the use of a
single hot tip runner injection site 201. Finally, as discussed
further below, resin flow control is also improved via
modifications to the flow channel design, which limits undesirable
flashing of resin onto the wrong side of the tray.
Single Point Injection and Recessed Hot Tip Injection Point
[0239] As may be seen from reviewing FIGS. 164, 168, 169, and 173,
and as shown to best advantage in FIGS. 168 and 173, the
semi-circular resin extension 203 or gate area at the hot tip
injection point has been recessed to facilitate flange 205 or rim
encapsulation and the subsequent formation of a seal between the
top surface of the flange and the lid film. Typically a remnant of
resin is present at the gate area. If the semi-circular resin
extension 203 is not recessed, it is possible that the tray may
rock back-and-forth in the lidding machine, using the resin remnant
as a pivot point. When the semi-circular resin extension 203 is
recessed, any remnant from the injection process is less likely to
detrimentally affect the creation of the complete (i.e., formed,
filled, and sealed) tray. In the embodiments depicted in FIGS.
164-173, single-point injection has been used, and the height of
the semi-circular resin extension has been reduced relative to the
thick section of resin.
[0240] Another advantage of single-point injection has to do with
polymer heat history. Polymer heat history variations can cause
problems. For example, in the embodiments depicted in FIGS.
164-173, the resin being injected to form the
partially-encapsulated rim or flange is nylon 66. With nylon 66,
the heat history can change the properties of the polymer. Even
when using one extruder and multiple injection points, there is
likely to be potentially problematic heat history variations. Also,
when using more than one injection point, the supply lines to each
injection point are designed to be of similar length and
configuration, which further complicates the machinery. Although
trays according to the present invention may be formed in tools
having more than one injection point, the trays depicted in FIGS.
164-173 have partially-encapsulated rims 205 formed in a tool
having a single point of injection. A single point injection tool
is less expensive to design, build, and operate. Further, having a
single injection point makes the rim formation process easier to
control.
Flow Channel Modifications to Improve Sealing-Thick Channel
Projected Feet
[0241] In one embodiment of a machine used to seal a lid film onto
a tray 197 having a partially-encapsulated rim or flange 205 (as
shown, for example, in FIGS. 164-168), a lid sealing device is
used. The lid sealing device may comprise, for example, one or more
heated drum seal film rollers in succession that press a heat seal
lid film onto the tray flange that is being supported from
underneath. The tray 197 is fed through the machine in the
direction of the long sides of the tray, at right angles to the
axes of rotation of the drum rollers. The drum rollers roll over
the tray flange 205 (typically, the tray moves under the drum
rollers). In this configuration, all of a tray short edge passes
under each drum roller at one time. Thus, the force applied by the
drum roller is dissipated or distributed across a greater surface
area when passing over a tray short edge than when passing over the
tray long edges, thereby reducing the effective pressure applied
since the force applied by the drum rollers remains relatively
constant whether on the long edges or one of the short edges. This
results in a higher concentration of force on the long edges of the
tray 197 than on the short edges of the tray, which results in a
better seal being formed along the tray long edges than is formed
along the tray short edges. In other words, there is relatively
less bonding on the tray short ends than on the tray long ends,
which affects seal quality/integrity.
[0242] To form a heat seal it takes a certain amount of dwell time
at a given temperature and a given pressure. If the temperature and
pressure remain relatively constant (e.g., if the temperature and
pressure are at desirable levels), seal improvement is obtained by
increasing the dwell time. Thus, to improve the seal quality along
the tray 197 short edges, the dwell time underneath the drum roller
of the heat sealer must be increased. The"feet"199 depicted in, for
example, FIGS. 164 and 169 support the flange as it passes under
the heat sealer and desirably increase the dwell time. Each pair of
feet 199 on a tray short edge also act like pillars that support a
"beam" or "bridge" between the feet with respect to the force being
applied by the drum rollers to the short edge flange. The beam or
bridge provides stability to the tray as the tray passes through
the machinery and under the drum roller or rollers. Since the free
edge of the flange 205 is thus supported by these feet 199, that
nearly doubles the dwell time of each tray short side under the
drum roller of the heat sealer without doubling the amount of
resin, which would slow the manufacturing cycle time and cost more
for plastic per tray 197, and without increasing the cycle time of
the machinery. The feet 199 minimize deflection of the thin section
of polymer (i.e., the section of polymer that extends to the edge
of the tray flange).
[0243] The feet 199 are created by extending the "deep" or thick
part of the resin channel in two locations per tray 197 short edge
(i.e., at both longitudinal ends of the tray). The feet 199 and the
rest of the thick part of the rim 207 rest on a steel receiver
plate comprising part of the machinery that transports the tray
during sealing. The steel receiver plate has a hole cut through it
that complements the perimeter of the thickened portion of the tray
rim 207, including the feet 199, thereby supporting the tray as the
tray is fed through the machinery. The tray drops down into the
steel receiver plate and is supported by only the thickened tray
perimeter, which includes four feet (two on each tray short edge)
in the embodiments shown in FIGS. 164-173. The drum roller is, or
the drum rollers are, typically mounted at a fixed gap distance
above the steel receiver plate. The feet 199 make it possible to
extract additional benefit from the nip area between the drum
roller and the tray. Further, the area across which the drum roller
force is spread is reduced as the feet pass under the drum roller.
That is, the effective roller pressure is greater over the feet
than it is over the rest of the thickened portion along the
longitudinal ends of the tray.
[0244] By adding the feet 199 to the tray 197 short edges, this
effectively increases the width of the seal along the tray short
sides without a proportional increase in the amount of plastic
being used, which is advantageous for at least the reasons
mentioned above. Thus, the benefits obtained are similar to the
benefits one would get by doubling the width of the flow channel
along the entire short edge of the tray 197, without the drawbacks
of increasing cycle time and increasing resin use that would go
along with doubling the flow channel along the entire short edge of
the tray. The feet 199 are like the pillars of a bridge and support
the section between them in a manner that results in better seal
integrity and a greater area that gets bonded. In other words, a
better seal is reached along the entire short edge of the tray,
including the section between the feet and the corner sections
between each foot and the long edge of the tray adjacent to each
foot.
Flow Channel Modifications to Reduce Flashing
[0245] When "flashing" occurs, plastic resin gets over the tray
flange 207 and onto the wrong side (i.e., the top side) of the
flange. It is undesirable to have flashing since the lid film does
not bond to the resin as well as it bonds to the material on the
inside of the tray. For example, in one embodiment of the
invention, polyester (PET) film is laminated to the paperboard to
make the base tray 197. The resin being injected to form the
partially-encapsulated rim or flange is nylon 66. The lid film
bonds to PET, but does not bond well to the nylon 66. Thus, for a
good heat seal, you cannot have nylon 66 on the portion of the
flange 207 to which the lid film is being sealed.
[0246] When the resin flow in the thick section of the flow channel
leads the resin flow in the thin section of the flow channel, this
helps prevent undesirable flashing by pressing the tray flange 207
against the tool steel as the resin advances in a manner that keeps
the flange tight against the tool steel. This relationship between
the flow in the thick section of the flow channel (i.e., the
"leading flow") and the resin flow in the thin section of the flow
channel (i.e., the "trailing flow") is known herein as the
"leading-trailing relationship."
[0247] Flashing can occur in the corner 209 areas, for example,
where the leading-trailing relationship may be lost. The
leading-trailing relationship may be lost in the corners in part
due to the greater distance that the flow in the thin section of
the flow channel must travel than the flow in the thick section of
the flow channel as the resin flows around the corners. In other
words, in the tray corners 209, the resin adjacent to the inner or
attached edge of the flange 207 must travel a shorter distance than
the distance traveled by the resin adjacent to the outer or free
edge of the flange. As the resin in the thick channel rounds a
corner, the resin starts to prematurely fill in the thin channel
ahead of the main flow front in the thin channel, which reduces or
eliminates the desired, flash-inhibiting leading-trailing
relationship. As the main flow front in the thin section catches up
with the resin flowing prematurely from the thick section into the
thin section, flashing may occur since the tray flange is thus not
being pressed against the tool steel in advance of the resin
reaching the edge of the tray flange. In the corners, the resin
flowing in the thick section is traveling in a larger area,
requiring additional resin to maintain the desired leading-trailing
relationship.
[0248] To address this undesirable flow behavior and return to the
desirable leading-trailing flow front relationship, which helps to
pin down the tray flange 205 in the corners 209 and keep the flange
in contact with the tool steel, the trays 197 depicted in FIGS.
164-173 have a modified flow channel. In a first flow channel
modification, rather than having the transition from the thick
section to the thin section of the flange to be at 90.degree., the
transition from the thick section to the thin section of the flange
in the corners is radiused. In particular, the corners have been
radiused at the point where the thick section of resin joins the
thin section of resin to help maintain the desirable flow pattern
having the leading-trailing relationship. The radiused areas allows
more polymer to flow from the thick part of the flow channel into
the thin part of the flow channel. As shown to best advantage in
FIGS. 164 and 169, the radiused areas may include more than merely
the rounded corners of the tray. For example, as shown in these
figures, radiusing may begin some distance before the tray corners.
The radiusing allows the thin section to fill in more rapidly as
the flow rounds the corners, thereby allowing the flow front in the
thin section to keep up with the flow front in the thick
section.
[0249] FIGS. 164 and 169 provide details and some possible
dimensions for the radiused corners 209 according to embodiments of
the present invention. As shown in these figures, the dimensions at
the end where the resin injection gate is located (i.e., the
right-hand end as drawn in FIGS. 164 and 169) may be different from
the dimensions at the other end of the tray.
[0250] An alternative way to alleviate the flashing problem in the
tray corners 209 and along the tray edges (rather than or in
addition to using a radiused juncture between the thick and thin
sections of the flange) is to place a flow restriction in the thick
channel and/or by placing a flow restriction in thin channel.
Formed Rim Having a Down-turned Portion or "Downturn"
[0251] FIGS. 14-18 depict various types of partially-encapsulated
flanges. In these embodiments, the tray comprises a flange having a
down-turned portion or "downturn" and various injection-molded rim
features added to the paperboard at selected locations. The flange
and downturn may extend at any angle from the sidewall and from
each other. Similarly, the downturn may extend at any angle from
the flange.
[0252] FIG. 18, which is most similar to FIG. 11, is a
cross-sectional view of an embodiment comprising a flange 198
having a downturn 200 and an injection-molded supported rim 202. In
this embodiment of the present invention, the tray 204 includes a
flange 198 shaped like an upside down, flattened "U", with the
terminus 206 of the flange 198 projecting outwardly and downwardly
from the plane defining the flange top surface 208. A portion of
the downwardly-opening cavity 210 defined by the underside 212 of
the flange 198 is filled or encapsulated with injection-molded
material 214. More specifically, the inner angle of the cavity
defined by the outer sidewall 216 of the tray 204 and the underside
212 of the flat flange top surface 218 is filled in. In the
embodiment shown in FIG. 18, the injection-molded material 214
fills a roughly triangular cross-sectional shape defined by the (1)
underside 212 of the flat flange top surface 218, (2) outer
sidewall 216 of the tray 204 to a depth approximately equal to that
of the outwardly, downwardly extending flange member 200, and (3) a
line 220 extending between these two points. This line 220 may be
either substantially straight or curved, as shown in FIG. 18. As
with previously described embodiments, the embodiment shown in FIG.
18 has increased strength and rigidity when compared with
nonencapsulated trays. It should be noted that the injection-molded
material 214 partially encapsulating the flange 198 or tray 204 not
only prevents the tray 204 from flexing outward when bearing a
load, but also from flexing upward when a tray 204 containing a
large food load is lifted.
[0253] FIG. 16 is a cross-sectional view of another embodiment of a
partially-encapsulated flange 222. The tray 224 and flange 222
depicted in FIG. 16 are of a similar shape and construction to that
shown in FIG. 18. However, the embodiment shown in FIG. 16
comprises a partially-encapsulated flange 222 having sufficient
injection-molded material 226 to completely fill the
downwardly-opening cavity 228 defined by the flange's under surface
230. In this embodiment, the injection-molded material 226 filling
the cavity 228 may define a slightly curved lower surface 232, as
shown, or may alternately define a flat lower surface. By injection
molding sufficient material to completely fill the cavity (and, in
some cases, extend downwardly below the cavity), additional
stiffness and tensile strength is provided to the tray over that
obtained from the geometry of the injection-molded material
depicted in, for example, FIG. 18. This embodiment may also be
provided with an integrally-formed, projecting handle or extended
lip 234 as shown in FIG. 17. Handle features are discussed further
below.
[0254] FIG. 14 is a cross-sectional view of a further alternate
embodiment of a partially-encapsulated injection-molded flange 236.
This embodiment is most comparable to the embodiment of FIG. 16. In
this embodiment, the edge 238 of the tray 240 again extends
downwardly and outwardly from the plane containing the top surface
242 of the tray 240. In cross-section, the outer rim 244 of the
tray 240 effectively forms an upside down "U" with a flattened
bottom. By encapsulating the underside 246 of the flange 236 in a
contoured shape following the shape of the flange 236, as shown in
FIG. 14, stability and rigidity are added to the tray 240 using a
material-saving geometry for the rim feature. In this embodiment,
the shape of the injection-molded material 248 generally conforms
to the shape of the flange 236. The flange 236 may also be folded
towards the tray sidewall 250 at approximately the point at which
the injection-molded material terminates in order to form a lower
surface 252, as shown in FIG. 14. Alternatively, this flange fold
may be omitted. This embodiment is well suited for trays or other
devices that do not require a hermetic seal, such as pizza trays,
serving plates, and so forth.
[0255] As previously discussed, the injection-molded material
encapsulating portions of the tray may be used to create a handle
or other holding surface. In FIG. 15, which is similar to FIG. 17,
but which also encompasses the conforming aspects of the
injection-molded material depicted in FIG. 14, the down-turned
portion 256 of the flange 254 is encapsulated and forms an
integrally-formed handle feature 258. Additional handles are
discussed further below. Here, the injection-molded material 260
extends beyond the underside 262 of the tray flange. Specifically,
the material 260 extends outwardly in a direction paralleling the
outer, down-turned portion 256 of the flange to form an extended
surface 266. Further, the injection-molded material 260
encapsulates the outer portion of the flange 254. Generally, this
embodiment extends the injection-molded material 260 across only a
portion of the flange 254 in order to form a conveniently-sized
handle 258. Alternate embodiments, however, may substantially
reduce the width of the injection-molded extension (i.e., how far
it extends outwardly), but continue the extension along the entire
perimeter of the tray. In this manner, a lip or rim of sufficient
width to create finger holds on the underside of the encapsulated
flange may be formed.
[0256] The injection-molded stiffening features depicted in FIGS.
14-18 could be applied to containers having flanges lacking
down-turned portions as may be seen, for example, by comparing FIG.
18 to FIG. 11.
Injection-Molded Sealing Surface
[0257] In certain situations, it may be desirable to merely add a
ring of polymer material that provides a sealing surface and
enhanced rigidity for the tray. Another benefit is that the polymer
material is unaffected in a high-moisture environment, unlike
paperboard. Therefore, the container rigidity and shape will be
maintained.
[0258] In some instances, ease or cost of manufacturing
considerations may require a tray having hermetic sealing
capabilities, but not appreciably enhanced strength. For example, a
relatively small tray bearing a light food load (such as a
microwave dinner tray) may require an airtight seal although
additional tray strength or rigidity is unnecessary. In such cases,
adding only a small portion of injection-molded material to the
upper or lower surface of a tray flange may substantially reduce
the cost and the difficulty of manufacturing the tray.
[0259] Such a tray 268 is shown generally in FIGS. 19, 20, and 21.
Turning now to FIG. 19, it may be seen that the top 270 of a tray
flange 272 may include a curved or arcuate depression or groove 274
running along the perimeter of the tray 268. By filling this groove
274 with injection-molded material 278, such as a plastic or other
similar polymer, a substantially continuous bonding surface may be
created on the upper surface 280 of the tray flange 272. It should
be noted that the arcuate depression or groove 274, and thus the
injection-molded material 278 filling same, could also be on the
lower surface 282 of the tray flange 272, rather than on the upper
surface 280 of the flange. A hermetic seal may be established by
bonding a film or lid to the injection-molded material 278 filling
the groove 274. By slightly raising the surface 284 of the
injection-molded material with respect to the flange 272, the
injection-molded material 278 is made more accessible to the lid or
film and greater surface area is provided to establish a stronger
seal.
[0260] The dimensions of the groove running along the perimeter of
the flange 272 (and thus, by implication, the dimensions of the
injection-molded material) may vary as necessary given the desired
use of the tray 268. FIGS. 20 and 21 show progressively more
elongated grooves 286, 288, filled with injection-molded material
278. Although increasing the surface area of the injection-molded
material does not in this instance add appreciable tensile strength
to the tray, it does provide greater opportunity to sealably mate
the film or lid to the tray.
Tray with Web Corners
[0261] Another commonly used tray blank in many industries is a
web-cornered tray. Generally, the corners of a web-cornered tray
blank are scored or folded in such a manner that when the tray is
fully assembled with the sidewalls in an upright position, the web
corner extends outwardly, folds along an exterior sidewall of the
tray, and lies flat. Such trays are also referred to as "gusseted"
trays. Alternately, the web corner or gusset may project into the
center of the tray and fold back along the interior of one of the
sidewalls, depending on the construction of the tray. An example of
a fragmentary portion of a web-cornered tray blank 290 is shown in
FIG. 22 in an unassembled state. A notched corner 292 is shown.
Such blanks can more readily be printed and achieve high-quality
graphic reproduction (e.g., using a four-color process) than a
blank for a press-formed tray. Web-corner blanks can also be
laminated or coated on both sides, which allows added functionality
(e.g., barrier and high gloss).
[0262] It may be seen in FIG. 22 that the corner 292 of the
web-cornered tray blank 290 (that is, the gusset) includes a pair
of notches 294 in the depicted embodiment. One notch is placed on
either side of the center fold line 296 in such a manner that the
notches 294 align when the tray is assembled.
[0263] Gusseted trays are often used in situations where the tray
must be printed with, for example, four-color process graphics or
other high image quality designs, insofar as the gusseted corner
does not distort a tray graphic. Gusseted trays, unlike
press-formed paperboard trays, accept such graphics easily. They
may also be laminated or coated on both sides with a barrier
material (not shown) to minimize moisture or vapor passage, or may
be provided with an attractive high gloss coating. Generally, such
enhancements may not be used with press-formed trays. The
web-corner tray blank 290 may have flanged panels or may be
flangeless. The blank 290 depicted in FIG. 22 has flangeless side
panels 298. As shown in cross-section in FIG. 23, an
injection-molded polymer flange 300 may be added to the formed
web-corner tray 302. The formed web-corner tray 302 is essentially
the assembled tray blank 290 of FIG. 22.
[0264] Although general reference is made throughout this
application to four-color, six-color, and other printing processes
with respect to specific trays, blanks, and so forth, it should be
understood that such references are by way of example and not
limitation. Generally speaking, any printing process may be used
with any tray described herein.
[0265] In the embodiment shown in FIG. 23, the assembled web-corner
tray 302 has no integral paperboard flange. Rather, the flange 300
is formed by injection molding appropriate material directly along
the upper edge 306 of the tray in such a manner that the
injection-molded material not only encapsulates the otherwise raw,
die-cut top tray edges, but also projects some distance beyond the
outer surface 308 of the sidewall 298 substantially perpendicularly
to the tray sidewall. Thus, the flange 300 is formed entirely of an
injection-molded polymer or other suitable material. Although the
flange is shown as substantially perpendicular to the tray
sidewall, it may also be parallel to the tray bottom or at any
other desired angle.
[0266] This, however, may present special problems at those
portions of the tray 302 where the web corners 292 or gussets
overlap the sidewalls 298. The discontinuity in thickness caused by
the overlapping gussets may mean that proportionately less
injection-molded material is placed around that portion of the
sidewall, and thus that at these points the bond between the
injection-molded material and tray body is relatively weak. The
notch 294 in each side of the gussets provides additional surface
area to bond with the injection-molded material, enhancing the bond
strength, as described further below.
[0267] A cross-section of a gusseted corner 292 of an assembled
web-cornered tray 302 having an injection-molded flange 300 is
shown in FIG. 23. The cross-section is taken through the notch 294
at the outer edge of each gusset or web 316 when the tray 302 is
assembled. Essentially, the notch 294 serves as a nesting place for
additional injection-molded polymer. By filling the notch 294, the
bonding of the injection-molded polymer to the tray blank 290 is
enhanced due to the settling of some polymer in the groove created
by the notch 294. Through this process, the web-cornered tray 302
is provided with both increased flexural strength and rigidity, and
may be sealed hermetically with a lid or film.
[0268] Accordingly, in another embodiment of the present invention,
web-cornered trays 302 may also be provided with an encapsulated
rim or flange. Generally, the encapsulated flange is injection
molded after the tray blank 290 is assembled into the web-cornered
tray 302. Further, the gusseted tray blank 290 may be provided with
a projecting flange, as previously discussed.
Press-Forming and Encapsulating a Web-Cornered Tray Blank
[0269] FIG. 24 displays an alternate embodiment of a web-cornered
tray blank 318. This tray blank 318 includes flanges 320 extending
from the trays long sidewalls 322 and short walls 324. The tray
blank 318 may be manufactured, for example, from a clay coated,
non-moisturized board. Materials of varying thicknesses may be used
to manufacture the blank 318 shown in FIG. 24.
[0270] Generally, when the flat blank 318 is inserted into an
injection-molding apparatus (as described in more detail herein),
the mold press-forms the blank 318 into a three-dimensional shape.
Generally speaking, the web corners 326 fold along a sidewall 322,
324, of the tray, such that one portion 328 of the web corner 326
is covered by the immediately adjacent portion 330. This folded
position is best shown in FIG. 25, which displays a perspective
view of the assembled blank 318 of FIG. 24. Although FIG. 25
displays the web corners 326 folded against the short sidewalls
324, alternate embodiments may fold the web corners adjacent
against the long sidewalls, or may fold different web corners
against different sidewalls 322.
[0271] Once the blank 318 is press-formed, injection-molded
material is injected along the flange to form an encapsulated rim,
as described elsewhere herein. The pressure exerted by the
injection mold on the blank 318 during press-forming (and
subsequent injection molding) generally compresses the flange 320
and tray. For example, the pressure may compress the folded
web-corner 326 shown in FIG. 25 (having three overlapping layers of
paperboard) to approximately the same thickness as the sidewall 324
or base 325 of the tray (made of a single layer of paperboard).
This minimizes discontinuities between the tray surfaces and
enhances tray 318 uniformity. Press-forming and injection molding
are discussed further below, in the section entitled "Second Method
and Apparatus for Encapsulation."
[0272] Additionally, the high pressure experienced by the tray 318
during the press-forming and injection-molding process may fuse the
layers of the clay coating or paperboard fiber located along the
web corners 326, causing a relatively vapor- and/or water-tight
seal therebetween. Thus, the corners need not be held together with
adhesive or through other sealing means, insofar as the fusing of
adjacent material layers holds the corners in an assembled
position.
[0273] Adjacent tray layers 328, 324 may be fused in a variety of
manners, depending on the composition of the tray blank 318. Where
the blank is clay-coated or otherwise includes a film or polymer
layer, the polymer chains making up the layer are typically bent or
twisted at a molecular level. The pressure exerted by the
injection-molding tool on a blank placed within the tool may cause
such polymer chains to straighten from their normally bent
arrangement. As the pressure is released, the polymer chains may
attempt to return to their initial configuration. As the
straightened or aligned polymer chains bend, they may abut and bond
to one another. Such bonds may be covalent (i.e., chemical or
molecular bonds) or noncovalent (i.e., hydrogen or ionic bonds).
Alternately, the pressure on the tray may cause fusing or a purely
mechanical "crosslinking"-an intermingling of polymer chains or
paperboard fibers crushed together by high pressure. Such
mechanical crosslinking may occur even where the tray 318 includes
no polymer film or resin.
[0274] For a true hermetic seal, a vapor-proof barrier coating may
be added to the blank 318 prior to press-forming. One example of
such a coating is ethylene vinyl acetate, or EVA. Further, such
barrier coatings, or other desired coatings, may be press-applied
prior to press-forming of the tray.
[0275] Generally, by using a clay-coated board for the blank 318,
the overall thickness of the blank may be reduced in comparison to,
for example, standard paperboard blanks. Further, varying grades of
clay-coated board may be used, such as CRB (coated recycled), SUS
(solid unbleached sulfate), and Kraft grade paperboards.
Additionally, a clay-coated blank may accept a six-color (or more)
process printing, permitting more colors to be printed on the
blank. Further, because the overlapping layers of the flange 320
may be compressed along their overlapping portions to a thickness
approximately equivalent to the tray sidewall (i.e., a single layer
of paperboard), when the flange is encapsulated it is more or less
uniform in thickness.
[0276] Finally, where the tray blank 318 shown in FIG. 24 is clay
coated, it need not be moisturized prior to die cutting.
Lid and Tray Having a Mating Feature
[0277] FIG. 26 illustrates an exploded isometric view of a tray 332
having an encapsulated rim 334 and a cross-sectional view of a lid
336 adapted to engage the encapsulated rim 334. To engage the rim
334, the lid 336 defines a channel 338 defined partially or
completely along the length of the outer portion 340 of the lid
336. FIG. 27 illustrates one example of a scored lid blank 342
adapted to be formed to define a lid 336 having a channel 338, as
shown in FIG. 26. Particularly, the lid 342 includes an inner score
line 344 and an outer score line 346. The score lines may be
continuous or intermittent. The score lines preferably do not
completely penetrate the paperboard. FIG. 28 is an alternate
embodiment of the lid shown in FIG. 27. In this embodiment, the
dual score lines 344,346 of the lid blank 342 of FIG. 27, are
replaced by a semicontinuing single score line 352. The
semicontinuing score line extends generally across the base of one
or more flanges 350 and is contiguous with one or more rounded
corners 354. Generally, the exterior edges of the rounded corners
are recessed from the exterior edge of the flanges, and aligned
with the score line.
[0278] FIG. 29 is a representative section view of the lid 336 in
engagement with the tray 332. FIG. 30 is a close-up view of the lid
336 engaged with the tray 332. As discussed herein, a tray 332 in
conformance with aspects of the present invention includes an
encapsulated rim 334. As such, the paperboard flange portion 362 of
the tray 332 may be completely or partially encapsulated in a
polymer 364 to at least partially form the encapsulated rim 334.
The embodiment depicted in FIGS. 29 and 30 has a partially
encapsulated paperboard flange 362. Particularly, the polymer
covers the outer edge and, possibly, a portion of the lower surface
368 of the paperboard flange. The inner surface 370 of the
paperboard is coated with a film 374 in which may extend along the
interior of the tray's sidewalls 378. The film covers the bottom
376 of the tray, the inner sidewalls 378 of the tray, and the upper
side 380 of the paperboard flange 362. The encapsulated rim 334 has
an upper portion, which is formed partly of a resin (such as a
polymer) and partly of the coating on the upper side of the
paperboard flange. The encapsulated rim 334 further defines an
outer rim edge 382, upper rim surface, and lower rim surface.
[0279] To form the lid 336 and channel 338 securing the lid 336 to
the tray 332, the lid blank 342 is set on the tray so that the
inner score line 344 (see FIG. 27) is aligned generally with the
outside edge 382 of the encapsulated rim 334. Next, the lid blank
is bent downwardly along the inner score line. The lid may be bent
in a die form arrangement, manually, or by other means. The first
bend causes the region between the inner 334 and outer 346 score
lines of the lid to generally abut the outer rim edge 382 of the
encapsulated rim 334. To finally form the channel 338, the lid
blank 342 is bent inwardly along the outer score line so that the
portion of the lid blank outward of the outer score line abuts the
lower side of the encapsulated rim. After forming the channel, the
non-formed lid 336 may experience some spring back such that the
channel 338 does not firmly abut either the lower side of the
encapsulated rim 334 or the outer side 382 of the rim. Nonetheless,
the arrangement may provide a fairly tight connection of the lid
336 to the tray 332. Additionally, a polymer film 384 on the
under-surface of the lid may be heat sealed to the encapsulated rim
334 or film on the tray, thus providing a tight, and possibly
hermetic seal.
[0280] FIG. 31 shows yet another embodiment of a tray 388 having an
encapsulated feature 390. In this embodiment, the tray includes a
recess feature 392 formed of injection-molded material 394 and
capable of accepting a lid (not shown). The recess, shown in
cross-section in FIG. 31, generally extends around at least three
sides 396 of the tray. One side may be left open to allow the lid
to slide into the recess, or all four sides may be encapsulated
with such a recess and the lid pressed into the recess.
[0281] FIG. 31 is a representative section view of a tray 388
having an encapsulated rim 390 defining an inwardly opening lid
engagement channel 392. FIG. 32 is a representative section view of
the tray 388 illustrated in FIG. 31 with a lid 398 in engagement
with the lid engagement channel 392. Referring to both FIG. 31 and
FIG. 32, the polymer portion 394 of the encapsulated rim 390
partially encompasses the paperboard flange 400. Particularly, the
polymer is formed along the lower side 402 and the outer side 404
of the flange. The polymer or resin also extends upwardly from the
top portion 406 of the paperboard flange. This upwardly extending
portion 408 defines the inwardly opening engagement channel
392.
[0282] The lid engagement channel 392 may be formed completely or
partially around the inner edge of the encapsulated rim 390. As
shown in FIGS. 31 and 32, the engagement channel defines a
partially circular cross-section. However, the channel may define
other shapes, such as a partially rectangular cross-section or a
generally triangular cross-section. The upper edge of the channel
392 may be aligned generally longitudinally with the outside edge
of the paperboard flange 400, may extend over the paperboard
flange, or may be positioned somewhat outwardly from the outside
edge of the paperboard flange.
[0283] Preferably, the lower edge of the channel 392 is laterally
aligned generally with the outer edge 404 of the paperboard flange
400. As best shown in FIG. 32, when the lid 398 is engaged with the
tray 388, the lower or inner side of the lid 414 abuts the top
portion 406 of the encapsulated flange 390. Arranged as such, a
seal (or at least a partial seal) is formed between the lid 398 and
the tray 388 to help prevent leaks of material in the container, to
help keep contents of the container warm, and to provide other
benefits. The opening of the channel 392 is generally dimensioned
in such a manner as to securely hold the lid in place.
[0284] FIGS. 102-105 are various views of a tray 1001 and lid 1003
forming a package 1025 according to an embodiment of the present
invention. As shown in FIG. 102, the tray has an encapsulated rim
1005 comprising an arcuate head portion 1007, a flange portion
1009, and an anchor portion 1011, all of which are formed from
injected resin. The sidewalls 1015 and bottom 1017 of the tray 1001
are lined with a film 1019 prior to injecting the resin to form the
encapsulated rim. When the resin is injected to form the
encapsulated rim, the upper end of the sidewalls may be displaced
or compressed to accommodate the anchor portion of the encapsulated
rim. The upper end of the anchor portion 1011 intersects a flange
portion 1009 of the encapsulated rim 1005, and the flange portion
terminates at its outward edge at a lid engagement channel 1021.
The lid engagement channel has an arcuate shape, the upper portion
of which is defined by an overhang 1023 comprising part of the
arcuate head portion. As shown in FIG. 103, the package is
completed by adding a lid to the tray of FIG. 102. In this
embodiment, the lid 1003 is constructed from paperboard 1027 with a
film 1029 attached to its underside. In FIG. 103, the lid 1011,
including the film attached to its lower or inner surface, is
frictionally and adhesively affixed to the tray 1001 to form the
completed package 1025. In particular, small strips of pressure
sensitive adhesive 1031 are applied along the edges of the lid as
shown in, for example, FIG. 103. Thus, when the lid 1003 is pressed
on the top of the tray 1001, the pressure sensitive adhesive 1031
acts to hold the lid on the flange portion 1009 of the encapsulated
rim 1005. When the lid is forced downwardly onto the tray, the
edges of the lid snap past the overhangs 1023 of the arcuate head
portions 1007 and frictionally engage the lid engagement channels
formed in the encapsulated rims. Thus, in this embodiment, the lid
is both adhesively and frictionally held in position on top of the
flange portions of the encapsulated rim. The tray 1001 may include
a film 1019 or other lining along its inner surface.
[0285] FIG. 104 is a fragmentary, cross-sectional view of one end
of the lid 1003 depicted in FIG. 103. In this figure it is possible
to see the paperboard 1027, the film 1029 (which may be a seal
layer), and the relatively shorter section of pressure sensitive
adhesive 1031. If the tray includes an encapsulated rim around its
entire perimeter, similar sections of pressure sensitive adhesive
would be located around the other edges of the lid and would, once
the lid was installed on a tray, secure the underside of the lid to
the flange portion 1009 of the encapsulated rim of the tray.
[0286] FIG. 105 is a fragmentary, cross-sectional view of a portion
of the tray 1001 depicted in FIGS. 102 and 103. As clearly shown in
this figure, the encapsulated rim 1005 comprises the arcuate head
portion 1007 that includes the overhang 1023, which helps to define
the lid engagement channel 1021. The encapsulated rim also includes
the flange portion 1009 that extends from a lower portion of the
arcuate lid engagement channel to an upper end of the anchor
portion 1011. In the embodiment depicted in FIG. 105, the lower,
distal end 1033 of the anchor portion 1011 terminates in a
relatively sharp point flush with the inner surface of the film
1019 attached to the sidewall of the paperboard tray.
[0287] FIG. 106 is an enlarged, fragmentary, cross-sectional view
depicting the lid 1003 of FIGS. 103 and 104 frictionally and
adhesively bonded to a first alternative embodiment of the
encapsulated rim 1035 depicted in FIGS. 102, 103, and 105. In this
embodiment, the lid is again a paperboard 1027 having a film 1029,
which may be a seal layer, on its lower or inner surface. As
clearly visible in FIG. 106, the edge of the lid 1033, including
the film 1029 adhered to the lower side of the lid, is frictionally
engaged with the lid engagement channel 1037 formed in the arcuate
head portion 1039 of the encapsulated rim. Again, a pressure
sensitive adhesive 1031 has been applied to the lower side of the
lid film and is shown adhering the lid to the flange portion 1041
of the encapsulated rim. Thus, in this embodiment, as in the
embodiment depicted in FIGS. 102, 103, and 105, the lid 1003 is
frictionally and adhesively attached to an encapsulated rim 1035 of
the tray 1001. In this embodiment, however, the anchor portion 1043
of the encapsulated rim is set back from the film 1019 affixed to
the inside surface of the tray sidewall 1015. Thus, a slightly
reduced amount of injected resin 1013 is required and the
relatively pointed distal end of the anchor portion is somewhat
shielded from whatever product is contained in the package.
[0288] FIG. 107 is similar to FIG. 106, but depicts an enlarged,
fragmentary, cross-sectional view of the lid 1003 of FIGS. 103 and
104 frictionally and adhesively bonded to a second alternative
embodiment of the encapsulated rim 1045 depicted in FIGS. 102, 103,
and 105. In this second alternative embodiment, the anchor portion
1047 of the encapsulated rim has its distal end again offset away
from the film 1029 on the inner surface of the tray sidewall.
Additionally, during formation of this particular embodiment, the
resin was injected in a manner that does not compress the upper end
1049 of the sidewall of the tray. Thus, as shown in FIG. 107, the
tray sidewall 1051 has relatively the same thickness at its upper
end as it does along the remainder of the sidewall. Here, the
offset or jog 1053 in the sidewall is more pronounced than what is
shown in FIG. 106, which allows the tray sidewall to remain at a
relatively constant thickness and allows the distal end of the
anchor portion to terminate in a less tapered or pointed
configuration.
[0289] FIG. 108 is an enlarged, fragmentary, cross-sectional view
depicting the lid 1003 of FIGS. 103 and 104 frictionally and
adhesively bonded to a third alternative embodiment of the
encapsulated rim 1055 depicted in FIGS. 102, 103, and 105. In this
embodiment, like in the embodiment depicted in FIG. 107, the tray
sidewall 1057 remains of relatively constant thickness. Here, the
jog 1059 in the sidewall is even more pronounced than the jog
depicted in FIG. 107. In fact, the sidewall slopes downwardly and
to the right in FIG. 107 for a short section before it continues
with its upwardly and rightwardly slope. With this "negative
slope," it is possible to nearly square off the distal end of the
anchor portion 1061 of the encapsulated rim. Again, the distal end
of the anchor portion is offset away from the film 1019 on the
inner surface of the tray sidewall.
[0290] FIGS. 109-113 depict the assembly and operation or use of a
package 1063 having asymmetrically-injected rims, including a
crimpable encapsulated rim 1065 and a friction-fit encapsulated rim
1067. As shown in FIG. 109, the crimpable encapsulated rim is
depicted on the left side and the friction-fit encapsulated rim is
depicted on the right side. The crimpable encapsulated rim is
relatively larger than the friction-fit encapsulated rim in this
embodiment 1063. The crimpable encapsulated rim is relatively
larger to handle the stresses of crimping and to accept more of the
lid for a more secure attachment of the lid to the tray. The
injected resin used to form the crimpable encapsulated rim is
designed to remain permanently deformed after crimping and, thus,
may include various fillers to facilitate that desired result.
Since the lid may be attached along one edge by crimping the
crimpable encapsulated rim, the lid and tray may be shipped as a
single component package to be filled and finally sealed by the
package purchaser. Also as shown in FIG. 109, the lid 1071 may
include a score line 1073 to make it easier to open and close the
lid by pivoting it about the edge being held by the crimpable
encapsulated rim.
[0291] In FIG. 110, the lid 1071 has been positioned on the tray
1075. As shown in this figure, the lid fits relatively snugly in
the lid engagement channels 1077 along the encapsulated rims
1065,1067. In the depicted embodiment, the score line 1077 in the
upper surface of the lid is located at the edge of the pressure
sensitive adhesive 1079 mounted to the film 1081 attached to the
underside of the lid. Thus, when the adhesive has been activated
and is holding the lid on the flange portion of the crimpable
encapsulated rim, the lid hinge point is along the inboard edge of
the pressure sensitive adhesive. Thus, FIG. 110 depicts the first
step of assembling the paperboard lid to the tray by inserting the
lid edges into the edge receiving channels of the encapsulated
rims. At this point, the package 1063 may have been filled.
[0292] In FIG. 111, step two of the assembly of the lid 1071 to the
tray 1075 has been completed. In this step, the crimpable
encapsulated rim 1065 has in fact been crimped on the hinge side of
the lid. If the package 1063 has been filled, pressure may then be
applied to the remaining three sides of the lid to achieve a final
seal, in which the edge of the paperboard lid being held by the
crimpable encapsulated rim is securely held by the pressure
sensitive adhesive 1079 and the crimping, and the remaining three
edges of the lid are held by both the pressure sensitive adhesive
and by frictional engagement of those three edges of the paperboard
lid in the lid engagement channels 1077. Although it is possible to
crimp more than one edge of the paperboard lid, in this depicted
embodiment, only one edge of the lid is being held by a crimped
encapsulated rim.
[0293] In FIG. 112, the crimpable encapsulated rim 1065 is depicted
fully crimped onto one edge of the lid 1071, and that edge of the
lid is scored to create a hinge feature 1083 allowing the lid to be
pivoted open as shown in FIG. 112. If, for example, the container
1063 were to be shipped empty, it could be shipped in the
configuration depicted in FIG. 112. Then, it could be opened,
filled, and then closed as shown in FIG. 113. In FIG. 113, the tray
1075 has been filled, the crimpable encapsulated rim 1065 has been
crimped along one edge of the lid 1071, and the pressure sensitive
adhesive 1079 around the remaining three edges of the lid has been
activated. Those remaining three edges of the lid are held down by
both the pressure sensitive adhesive and by frictional engagement
of the paperboard lid edges in the lid engagement channels 1077 of
the friction-fit encapsulated rims.
[0294] FIGS. 114 and 115 are enlarged, fragmentary views of the
crimpable encapsulated rim 1065. In FIG. 114, one end of the lid
1071 has been inserted under the overhang of the arcuate head
portion of the encapsulated rim and is resting on the flange
portion of the encapsulated rim. Crimping has not taken place. In
FIG. 115, the crimpable encapsulated rim has been crimped onto the
edge of the paperboard lid and is shown securely holding that edge
of the lid. FIGS. 116 and 117 depict an alternative embodiment of
the crimpable encapsulated rim 1085. In this embodiment, the lid
engagement channel is deeper 1077 since the overhang portion of the
arcuate head portion is longer than what is depicted in FIG. 114.
As shown in FIGS. 116 and 117, the score line 1073 may be
configured so that the overhang of the arcuate head portion comes
to rest at the score line, possibly making it easier to open the
lid along the hinge line.
[0295] FIG. 118 is an isometric view looking downwardly into a tray
having encapsulated rims like those discussed above in connection
with FIGS. 102-117. In this embodiment of the tray 1087, a first
opening feature recess 1089 has been formed in the corners of the
tray for purposes discussed further below. The tray depicted in
FIG. 118 may have been formed, for example, from a five-panel
blank. Thus, an injected resin seam 1091 is also present at each
corner.
[0296] The package 1093 depicted in FIG. 119 is formed from the
tray 1087 depicted in FIG. 118 in combination with a lid 1095 with
rounded corners 1097. In this embodiment of a package according to
the present invention, the opening feature recesses 1099 in each
corner allow a consumer to open the package. For example, as shown
in FIG. 121, which is an enlarged, cross-sectional view through a
corner of the package 1093, the opening feature recess 1099 allows
access to the curved corner 1097 of the lid since a consumer can
obtain a finger hold on the corner by taking advantage of the
opening feature recess. As shown in FIG. 120, which is an enlarged,
cross-sectional view through a different corner of the package,
corner hinges 1201 may be present to make it even easier for a
consumer to open the package. In particular, the lid may be scored,
creating a hinge feature, on all four corners. This hinge feature,
together with the opening feature recess, makes it easier to lift a
corner of the lid to initiate opening of the package.
[0297] FIG. 122 depicts a package 1203 that is similar to the
package depicted in FIG. 119. In this embodiment, however, an edge
score 1205 is present, creating a hinge feature for the entire lid.
In this embodiment, if a consumer were to lift on the corner 1207
or most-leftward corner as depicted in FIG. 122, the lid could then
be opened by pivoting it along the edge score. FIG. 123 depicts a
cross-sectional view of a corner of the package of FIG. 122,
showing the edge score.
[0298] FIG. 124 is similar to FIG. 118, but depicts a tray having
an alternative opening feature recess 1211 formed in the corners of
the tray. This alternative opening feature recess again provides
the consumer with access to one of the corners of the lid enabling
the consumer to, for example, initiate opening of the package. The
opening feature recess may be at least partially covered by a lid
(not shown) nested in the lid engagement channel 1213 of the
encapsulated rim 1215, and may facilitate removing the lid
therefrom.
[0299] FIG. 125 depicts yet another alternative embodiment 1215
according to the present invention. This figure is similar to FIG.
119, but depicts a dispensing feature 1217 through the center of
the lid 1219. Since the package depicted in FIG. 125 includes this
dispensing feature, it is unnecessary for a consumer, for example,
to have access to the corners 1221 of the lid to initiate opening
of the lid. Thus, the opening feature recesses depicted in FIGS.
118-124 are not present in the package depicted in FIG. 125. As
shown to good advantage in FIG. 126, which is an enlarged,
fragmentary, cross-sectional view through a portion of the
encapsulated rim 1223, this embodiment also does not have pressure
sensitive adhesive. The pressure sensitive adhesive may not be
required in embodiments like the one depicted in FIGS. 125 and 126
since, with the dispensing feature, the lid is not being opened and
reclosed. Thus, there is no need for the pressure sensitive
adhesive. Also, if the tray need not be "sealable," the added
security provided by the pressure sensitive adhesive is
unnecessary. Although the encapsulated rims depicted in FIGS. 125
and 126 are friction-fit encapsulated rims, if desired crimpable
encapsulated rims like those depicted in, for example, FIGS.
109-114 and 116 could be used. A machine could be used to insert
the lid onto the tray with the lid engagement channels 1225 on the
four straight sidewalls as shown in FIG. 125.
[0300] FIG. 127 is similar to FIG. 125, but depicts a package 1227
where the encapsulated rim 1229 extends around the entire perimeter
of the lid 1233. Since the lid again includes a dispensing feature
1231, it is unnecessary to include pressure sensitive adhesive,
which allows the lid to be opened and closed repeatedly. With the
dispensing feature in the center of the package, the lid need not
be opened (i.e., separated from the tray) at all. As mentioned in
connection with FIGS. 125 and 126, even though a friction-fit
encapsulated rim 1229 is depicted in FIGS. 127 and 128, a crimpable
encapsulated rim could be used here. In this embodiment of a
package according to the present invention, one could
ultrasonically seal the lid film 1231 to the injected resin on the
flange portion of the encapsulated rim, if desired.
[0301] In order to install the lid 1233 on the tray 1227 depicted
in FIG. 127, a heat seal machine may be used. The machine would
heat the lid as it pressed the lid toward the flange portion of the
encapsulated rim 1229 extending around the entire perimeter of the
tray. As the lid is pressed downwardly on the encapsulated rim, the
overhang of the rim 1235 (See FIG. 128) would be deflected
downwardly with a plate or a ring on the machine applicator head to
allow the edge of the paperboard lid to pass by the overhang until
it becomes frictionally engaged with the lid engagement channels
1237. Then, as the machine plate is moved away from the tray, the
overhang may spring back to its original position, helping to
retain the lid, which may now be heat sealed to the flange portion
of the tray encapsulated rim. Alternatively, it is possible to
merely press downwardly in the center region of the lid until the
give in the paperboard lid allows its edges to snap into the lid
engagement channel around the perimeter of the tray encapsulated
rim. In yet a third alternative, a crimpable encapsulated rim could
be used, wherein the crimpable encapsulated rim is open
sufficiently to permit placement of the lid on the flange portion
of the encapsulated rim. In other words, the overhang of the
arcuate head portion could be rocked backward enough to allow
insertion of the paperboard lid onto the flange portion of the
encapsulated rim. Subsequently, the overhang could be crimped onto
the lid to secure the lid in place on the tray.
Five-Panel Tray
Basic, Sloped-Wall Tray
[0302] A partially-encapsulated tray 416 may be formed from a
five-panel blank that includes a bottom 418 and four sidewalls
(420, 422), as shown in FIGS. 33-36. Each major sidewall 420 and
minor sidewall 422 is formed from a single panel, as is the tray
bottom. The sidewalls are connected only along the bottom or base
panel. Thus, when laid flat, the blank resembles a cross. FIG. 46
depicts a cross-shaped tray blank 424, while FIG. 47 depicts the
tray blank of FIG. 46 in a folded (but not yet encapsulated or
sealed) position corresponding to a tray 426 relatively narrower
than the tray shown in FIG. 33.
[0303] When the tray 416 of FIG. 33 is formed, the sidewalls 420,
422 are folded up until they are adjacent to each other, creating a
seam or spine 430 between adjacent sidewalls. FIG. 34 is a side
view of a tray assembled from a five-panel blank, and FIG. 35 is a
front view of the same tray.
[0304] Initially, the tray blank is folded into the configuration
shown in FIGS. 33-35, with the sidewalls 420, 422 adjacent to one
another, but not necessarily touching. FIG. 36 is an enlarged,
fragmentary view of a corner 428 of the five-panel blank folded to
make the basic shape of the tray 416. As can be seen, a small gap
or seam 430 may exist between adjacent sidewalls (420, 422) meeting
at the tray corner. Further, the sidewall panels do not overlap one
another, thus leaving little or no room for conventional adhesives
or fasteners to hold the sidewalls fast to one another. Rather, the
corners will be held together via injection-molded material.
Although the embodiment shown in FIGS. 33-35 includes an integral
flange 432, other embodiments may omit the flange, such as the
embodiment shown in FIGS. 46 and 47.
[0305] Next, the folded blank is placed in an injection mold tool,
similar to that shown in FIG. 74-76 or 93-96, both discussed later.
The injection mold tool suited for use with this particular
embodiment, however, pumps pressurized injection-molded material
not only along the flange 432 (if any) of the tray 416, but also
along the seam or spine 430 in each corner. The pressurized
injection-molded material flows in such a manner as to fill in the
gaps between adjacent sidewalls 420, 422 and to coat a portion of
each adjacent sidewall. Thus, each corner seam of the finished
five-panel tray is made of injection-molded material partially
encapsulating the sidewalls adjacent to the corner. If necessary, a
portion of the bottom panel of the tray may also be encapsulated in
order to provide an airtight seal.
Injection-Molded Rim
[0306] As previously discussed, there may be no separate flange
portion along the upper edges of the walls, and any desired flange
may be formed during the encapsulation process by the injected
material itself. FIGS. 37-42 show a five-panel tray 434 having
encapsulated portions. FIG. 37 is a top-down view of a five-panel
tray 434 having a flange 436 made from injection-molded material.
Molding a plastic rim onto the unflanged upper perimeter of the
tray increases tray stiffness and rigidity. FIG. 38 is an isometric
view of a similar five-panel tray 434, clearly displaying the
flange 436 made of injection-molded material and injection-molded
corner seams 442. FIG. 39 is an end view of the tray 434 depicted
in FIG. 38.
Injection-Molded Rim and Corner Beads
[0307] FIG. 40 is a side view of an assembled, encapsulated
five-panel tray 436. As shown in FIG. 40, the sidewalls (446, 448)
are joined along the seam or spine 450 using injected materials at
the same time that any rim or flange 452 is formed around the upper
edge 454 of the walls. FIG. 41 is a cross-sectional view of the
five-panel tray taken along line 41-41 of FIG. 40. Similarly, FIG.
42 is an enlarged, fragmentary, cross-sectional view through a side
wall 446 of the circled portion of FIG. 41, depicting the
injection-molded flange 452 and corner seam 450. FIG. 42
prominently displays not only the injection-molded flange (shown
with fine diagonal shading), but also the inner and outer beads 456
of injection-molded material comprising the corner seam (shown with
opposite diagonal shading).
[0308] Controlling the position of the paperboard in the mold helps
to ensure that a hermetically-sealable package is created.
Injection-molded resin may bond poorly to paperboard because of the
dissimilarities of base components (e.g., melt temperatures, etc.).
When manufacturing a package it may be important that the
paperboard edge does not get exposed to the package contents. Thus,
it is important that the injection-molded resin bonds with the
lamination film on the inside of the package. Failure to do this
will expose the paperboard edge, which in turn can lead to wicking
of the product or leakage through the resin and paperboard
interface. One fragmentary, top-down cross-sectional view of an
embodiment preventing this is shown in FIG. 43. Note the position
of the injection-molded resin 458 and the paperboard insert 460.
When manufacturing the composite package, the paperboard insert is
placed in the injection mold tool so that the position of the resin
bead 458 is on the inside of the package and not on the outside.
The resin, when injected into the mold, forces the paperboard to
the outside of the mold, allowing the resin to sufficiently bond to
the inside laminated film. FIGS. 44 and 45 depict alternative bead
configurations (462, 464).
Additional Tray Blanks
[0309] In addition to the various tray blanks described herein,
multiple other blanks may be press-formed and provided with one or
more encapsulated features by an injection-molding apparatus, in
accordance with an embodiment of the present invention. Generally,
the injection-molding apparatus may both press-form the tray and
injection-mold the encapsulated feature within the confines of a
single machine or tool, rather than requiring one tool for
press-forming and a second for injection-molding. One example of
such an apparatus is given below.
[0310] FIG. 48 depicts an alternate tray blank 466 suitable for
press-forming and injection-molding within a single apparatus.
[0311] FIG. 49 depicts a second alternate tray blank 468 that may
be both press-formed and injection-molded within a single
apparatus, while FIG. 50 depicts the tray blank in a folded state,
albeit without any injection molded or encapsulated features.
Exemplary injection-molded features that may be included on the
formed, three-dimensional tray shown in FIG. 50 include flanges,
rims, projections, handles, ribs, vanes, and any other feature
described herein.
[0312] Similarly, FIG. 51 depicts a third alternate tray blank 470
that may be both press-formed and injection-molded within a single
apparatus, while FIG. 52 depicts the tray blank 470 in a folded
state, albeit without any injection molded-features. FIG. 53
depicts a fourth alternate tray blank 472 that may be both
press-formed and injection-molded within a single apparatus, while
FIG. 54 depicts the tray blank 472 in a folded state, albeit
without any injection molded-features. FIG. 55 depicts a fifth
alternate tray blank 474 that may be both press-formed and
injection-molded within a single apparatus, while FIG. 56 depicts
the tray blank 474 in a folded state, albeit without any injection
molded-features. FIG. 57 depicts a sixth alternate tray blank 476
that may be both press-formed and injection-molded within a single
apparatus, while FIG. 58 depicts the tray blank 476 in a folded
state, albeit without any injection molded-features. Exemplary
injection-molded features that may be included on any of the
formed, three-dimensional trays shown in FIGS. 50-58 include
flanges, rims, projections, handles, ribs, vanes, and any other
feature described herein.
[0313] Still further examples of tray blanks suitable for
press-forming in an injection-molded tool such as the ones
described herein, may be found in "The Packaging Designer's Book Of
Patterns," by Roth and Wybenga.
Cylindrical Containers
[0314] FIG. 59 shows another embodiment of an injection-molded
paperboard laminate composite container 478. This embodiment
generally comprises a bottom blank 480 and at least one sidewall
blank 482. The blanks are each die cut and then bonded together by
injection molding plastic at their extremities. In particular, an
injection-molded rim 484, at least one injection-molded sidewall
bead 486, and an injection-molded bottom wall bead 488 may hold the
blanks together. This container can be formed on a single cavity
injection mold tool.
[0315] A cylindrical container as shown in FIG. 59 may be formed
using the following process:
[0316] First, prepare the paperboard laminate using conventional
means, for example, extrusion coating, extrusion laminating, or
adhesive laminating. The laminate can be chosen from, for example,
MICRO-RITE, MICRO-RITE susceptor, QWIK-WAVE susceptor, PET
(polyethylene terephthalate), EVOH (ethylene vinyl alcohol) barrier
co-extruded films, or others, depending on final composite package
requirements (e.g., oxygen or moisture barrier, microwavability,
conventional ovenability, or some combination of these attributes).
EVOH is a barrier material that is used, for example, for
nonirradiated beef. PET is thermoplastic polyester used in beverage
bottles and food trays designed for microwave and conventional
ovens.
[0317] Second, print the paperboard laminate. Printing may be by
known means such as flexography, lithography, or rotogravure.
Printing may be done on a film that is laminated to the paperboard,
trapping the ink between the paperboard and the film.
[0318] Third, die cut one or more sidewall blanks and a bottom
blank from the paperboard laminate. The sidewall can be straight or
tapered for nesting stackability.
[0319] Fourth, place the sidewall blank or blanks and the bottom
blank in an injection mold tool. If using one sidewall blank, wrap
the sidewall blank around a mandrel until its ends are in close
proximity and hold the blank in place with, for example, a vacuum.
No side seam overlap is necessary and the ends of the blank forming
the sidewall are placed in an abutting configuration. The bottom
blank is placed in correct position relative to the sidewall blank
near the bottom periphery of the sidewall blank, and held in place
by, for example, a vacuum. The bottom blank may be folded at its
periphery to form a skirt. The sidewall typically surrounds the
bottom wall because of graphics concerns. There is also no folded
overlap at the bottom edge of the sidewall where it meets the
bottom, unlike what you may see in a standard paper cup.
[0320] Fifth, inject plastic polymer to bond the abutting ends of
the sidewall blank to each other, forming a seam, and to bond the
periphery of the bottom blank to the sidewall blank. The injected
polymer also forms a rim attached to the top periphery of the
sidewall blank. Other features could be injection molded as part of
the composite package, such as stacking lugs or snap-fit lid
configurations. Where multiple sidewall blanks are used, each
sidewall blank may be bonded to an adjacent blank with polymers, as
described. This process may also be used to construct rectangular
trays (or trays having flat sidewalls) from a series of initially
unjoined, flat blanks.
[0321] Since both the outer surface and the inner surface of the
container can be made impervious to moisture and gas, the
embodiment shown in FIG. 59 is retortable. Generally, retorting the
tray involves putting the tray in a 250 degree Fahrenheit
environment in a pressure chamber and heat sterilizing the product
and food for extended shelf life.
[0322] The embodiment shown in FIG. 59 may optionally include a lid
490, in which case it is a three-piece package consisting of a
bottom panel member 480, a sidewall member 482, and a lid member
490. The three members generally consist of die-cut blanks held
together by injection-molded plastic at their extremities.
[0323] The embodiment of FIG. 59 may be formed with an
injection-molded seam 486 and periphery. FIG. 59 clearly displays
the injection-molded seam container 478 in accordance with the
present embodiment, while FIG. 60 is a cross-sectional view taken
along the injection-molded seam 486 of FIG. 59. In FIG. 60,
diagonal shading indicates injection-molded material.
[0324] The injection-molded cylindrical container 478 shown in FIG.
59 is formed from a sidewall blank 482 and a bottom blank 480.
Generally, the bottom blank is circular, while the sidewall blank
is rectangular. The blanks are prepared via conventional means
known to those skilled in the art. The blanks may be laminated with
a variety of materials, such as the MICRO-RITE and QWIK-WAVE
susceptors previously mentioned, PET, an EVOH barrier co-extruded
film, and so forth. If desired, graphics may also be printed on
either blank.
[0325] The sidewall 482 and bottom blanks 480 may then be placed in
an injection mold tool, with the sidewall blank positioned
perpendicularly to the bottom blank. The sidewall blank is wrapped
around until its ends are in close proximity, thus forming a hollow
cylinder. The space where the sidewall ends come near each other is
referred to as the sidewall space. The bottom blank is generally
positioned near the bottom portion of the curved sidewall blank.
Further, the bottom blank may be folded at its periphery to form a
skirt, if desired.
[0326] Injection-molded material is then forced into the injection
mold tool, coating a portion of the inside and outside of the
sidewall blank along its edges in close proximity, filling the
sidewall space, and forming a sidewall seam of injection-molded
material. The injection-molded material is also forced into the
space between the bottom portion of the sidewall blank and the
bottom blank, coating a portion of each and bonding the two blanks
to each other. If desired, the injection-molded material may extend
slightly downwardly beyond the bottom surface of the bottom blank
480 (as shown in FIG. 60), or may be flush with the bottom surface
of the bottom blank 480 (as shown in FIG. 61). The injection-molded
material may also form a rim attached to the top periphery of the
sidewall blank.
[0327] FIGS. 61 and 62 depict a cylindrical microwave-retort
package 494. The package could be round, as depicted, to roll in
the retort to aid in heating. Alternatively, the package could be
noncylindrical or nonround, such as a tray, and thermally processed
in a still or rotating retort.
[0328] Another embodiment of the present invention takes the form
of a cylindrical container having an injection-molded seam and
periphery. FIG. 178 displays an exploded view of an
injection-molded cylindrical container 1301 in accordance with the
present embodiment.
[0329] The injection-molded cylindrical container 1301 shown in
FIG. 178 is formed from at least one sidewall blank 1303, a bottom
blank 1305, and an optional lid 1307 or top blank. Generally, the
bottom blank is circular, while the sidewall blank is rectangular.
The blanks are prepared via conventional means known to those
skilled in the art. The blanks may be laminated with a variety of
materials, such as the MICRO-RITE and QWIK-WAVE susceptors
previously mentioned, PET, an EVOH barrier co-extruded film, and so
forth If desired, graphics may also be printed on either blank. The
sidewall blank (s) may be laminated with a film 1300 on the
interior. The film laminate is exaggerated in FIG. 178 for
clarity.
[0330] The sidewall 1303 and bottom 1305 blanks may then be placed
in an injection mold tool, with the sidewall blank positioned
perpendicularly to the bottom blank. The sidewall blank is wrapped
around until its ends are in close proximity, thus forming a hollow
cylinder. The space where the sidewall ends come near each other is
referred to as the sidewall space. The bottom blank is generally
positioned near the bottom portion of the curved sidewall blank.
Further, the bottom blank may be folded at its periphery to form a
skirt 1309, if desired.
[0331] Injection-molded material is then forced into the injection
mold tool, coating a portion of the inside and outside of the
sidewall blank 1303 along its edges in close proximity, filling the
sidewall space, and forming a sidewall seam 1312 of
injection-molded material. The injection-molded material is also
forced into the space between the bottom portion of the sidewall
blank and the bottom blank 1305, coating a portion of each and
bonding the two blanks to each other. If desired, the
injection-molded material may extend slightly downwardly beyond the
bottom surface of the bottom blank (as shown in FIGS. 59 and 60),
or may be flush with the bottom surface of the bottom blank (as
shown in FIGS. 61 and 62). The injection-molded material may also
form a rim (not shown) attached to the top periphery of the
sidewall blank.
[0332] FIG. 179 is a cross-sectional view through the middle of the
injection-molded cylindrical container 1301 shown in FIG. 178. FIG.
180 is an enlarged, cross-sectional view of the noted portion of
FIG. 179, taken through a middle of the container and showing at
least one sidewall (or connecting) seam 1312. In FIGS. 179 and 180,
diagonal shading indicates injection-molded material. The overlap
of injection-molded material along the exterior and interior of the
seam 1312 is exaggerated for ease of viewing. FIG. 180 depicts the
seam 1312, sidewall blank 1303, and laminated film 1300 in
close-up. Generally, the injection-molded material forming the seam
1312 may bond more tightly with the film. Accordingly, an overlap
of injection-molded material (such as resin or polymer) may form a
crossbar member 1314 on the film side. A similar crossbar member
1316 may be formed on the exterior of the sidewall blank to
minimize gas or liquid leakage around the seam and/or sidewall.
[0333] FIG. 63 depicts a cylindrical microwave-retort package 1311
consisting of a bottom panel member (not shown), a sidewall member
1313, and a lid member 1315. The three members generally consist of
die-cut blanks held together by injection-molded plastic 1317 at
their extremities. The package could be round, as depicted, to roll
in the retort to aid in heating. Alternatively, the package could
be non-cylindrical or non-round, such as a tray, optionally
manufactured with multiple sidewall members, and thermally
processed in a still or rotating retort.
Encapsulated or Coated Interior
[0334] This embodiment of the present invention combines the
consumer benefits of paperboard and plastic into one container. One
exemplary embodiment 496 is shown in FIG. 64. In this embodiment,
the container comprises multiple layers, including at least one
layer of paperboard and another layer of an injection-molded
polymer.
[0335] A lamination process may be used to put a polymer on the
inside or outside of the tray. Either the paperboard or paperboard
substitute may include a polymer film laminated or extruded on one
or two sides of the substrate. Both layers may cover all or most of
the surface area of the container, including any internal dividers
or walls that may be present on the interior of the container, as
shown, for example, in FIG. 64. The tray shown in FIG. 64 may be
crafted by the following exemplary process:
[0336] i) start with a press-formed, MICRO-RITE container; and
[0337] ii) injection mold a layer of black PET polymer on the
inside surfaces.
The resulting container looks like popular CPET (crystallized
polyethylene terephthalate) containers, but provides improved
cooking benefits for consumers. CPET is a heat-tolerant plastic
that can be molded into multi-compartment and single frozen food
containers, and can be heated in the microwave or conventional
oven. The resulting package is not moisture sensitive, allowing use
of the trays in a steam table environment without the typical
concern that the tray will soften and fall through the table
aperture.
[0338] A dishwasher-safe, reusable microwave package may be made as
another embodiment of the current invention. For example, a tray
including a controlled, microwave-heating layer (such as
MICRO-RITE, made by Graphic Packaging Corporation of Golden, Colo.)
may be laminated on both the inside and outside. This lamination is
generally performed before die cutting/press-forming the tray
itself. Further, the laminated tray blank may be heat plasticized
before the tray is formed. An injection-molded plastic rim, as
described above, may then be added in order to protect the
unlaminated tray edges. This protects the entirety of the tray from
water and detergents, thus allowing the tray to be easily washed
and reused.
[0339] FIG. 64 depicts a tray 496 having encapsulated interior
dividers or walls 498 and a completely coated interior surface 500.
In this embodiment, the interior surface is coated with a plastic
such as crystallized polyester (C-PET), which resists high
temperatures. The C-PET surface is especially useful in trays
intended for microwave oven use, and may be coupled with a
susceptor or controlled microwave heating/focusing layer located
beneath, the C-PET. Further, many such trays include interior
dividers or walls intended to keep foodstuffs separate from one
another. The injection mold tool may be modified to provide both an
interior lining and dividers.
Susceptor Tray Having Injection-Molded Feature
[0340] As previously discussed, trays incorporating one or more
encapsulated features may also be provided with coatings or
linings, depending on the nature of the tray's ultimate use. Trays
may, for example, be provided with a metallic susceptor layer or
pattern designed to focus radiant energy in specific portions of
the tray. Such susceptor layers are often used in trays designed
for microwave use. Exemplary susceptor trays include the MICRO-RITE
and QWIK-WAVE product lines manufactured by Graphic Packaging
Corporation of Golden, Colo.
[0341] FIG. 65 displays an embodiment of a tray 502 having both an
encapsulated feature 504 and susceptor layer 506. In this
embodiment, the encapsulated feature is an encapsulated rim.
Although a specific susceptor pattern is shown, any susceptor
pattern may be used with an embodiment of the present invention.
Further, the susceptor pattern may be specifically shaped to take
into account one or more encapsulated features of the tray. For
example, a tray may be provided with dividers or ribs formed of a
resin. In such a tray, the susceptor pattern may be arranged to
avoid focusing microwave energy into the portions of the tray
occupied by the dividers. In another embodiment, the tray may be
provided with a raised shelf or ledge of resin across a portion of
the tray base. The raised shelf may trap air between the shelf
bottom and the tray base. In this embodiment, the susceptor pattern
may be arranged to provide different heating properties for the
portion of the tray base covered by the shelf.
Compartmented Trays
[0342] Multiple deep or steep food compartments that keep several
food items separated are difficult to make by press-forming a
paperboard container. Injection-molded dividers 498 can be added to
the inside surface 500 of a single-compartment container to divide
it into multiple compartments 504, as shown in FIG. 64. These
dividers can join an injection-molded rim around the outer
perimeter of the container, or the rim may be omitted.
[0343] In the present invention, each compartment 504 can include a
microwave interactive material (e.g., susceptor laminated
paperboard) that is unique to the specific type of food to be
stored in that compartment of the container. Thus, a single
paperboard container 496 could include a plurality of different
microwave interactive materials; each designed to most-effectively
heat the specific food item associated with it.
[0344] Finally, alternate embodiments may make use of interior
dividers 498 without coating the entire interior surface 500 in a
plastic. Rather, the interior dividers may be molded uniformly with
an encapsulated rim (not shown). In this manner, many different
types of trays may include dividers. For example, a tray with an
interior susceptor layer, or a controlled microwave-heating layer,
may also have an interior divider. Further, the tray may have
different susceptors or susceptor thicknesses on each side of the
divider, thus changing the microwave heating characteristics to
optimally heat different types of food separated by the
divider.
[0345] The number of films in the marketplace makes the potential
number of compartmented trays nearly endless. Also, a hinged lid or
another style of lid could be made of a lid film that matches the
tray film (lids are discussed further below).
Handles
[0346] The injection-molded material may be formed into a variety
of features in order to accomplish multiple purposes. For example,
an encapsulated rim 506 having opposing protuberances or handles
508 may be added to a circular tray 510, as shown in FIG. 66, to
simplify carrying the tray. These handles may be formed as an
integral portion of the encapsulated rim with minimal changes to
the injection mold tool. Similar handles 512 (see, e.g., FIG. 67)
could be provided for any tray 513 shape, or even for paper
plates.
Fixed Handles
[0347] An injection-molded plastic rim 506 with handles 508 is
depicted in, for example, FIG. 66. Such handles are useful with,
for example, shallow round paperboard serving trays or containers,
such as pizza pans, and other containers. In embodiments like the
one depicted in FIG. 66, the rim 506 provides rigidity (improved
bending stiffness) and a sealing surface, and the handles 508
provide consumer convenience. In an alternative form, a single
fixed handle is formed, similar to a frying pan handle.
Foldable Handles
[0348] FIGS. 68 and 69 show a tray 514 having an encapsulated rim
516 including a folding or hinged handle 518. Foldable handles can
be designed to, for example, pivot over the container while heating
food in a microwave oven, and then pivoted downwardly and outwardly
for serving the prepared food directly from the container.
[0349] The handle 518 may be folded atop the tray 514 (as shown in
FIG. 68) in order to minimize both storage and cooking space, and
folded out (as shown in FIG. 69) when carrying the tray. Such an
encapsulated rim may be especially useful in a microwave tray,
since not only is cooking space extremely limited, but also because
the plastic handle will not react adversely with the microwave
heating process. Again, changes to the injection mold tool permit
the creation of a hinged handle integral to the encapsulated
rim.
Trivet Feature
[0350] As shown in FIGS. 70 and 71, a trivet feature 528 could be
formed by, for example, extending the injection-molded sidewall
seam material 530 (e.g., in a five-panel tray discussed above)
below the bottom surface 532 of the container 534 (like stilts) to
hold the bottom surface of the container off a microwave bottom or
to serve as a hot pad feature or trivet. This could be beneficial
not only for preventing counter tops from burning, but also to aid
in microwave cooking.
Stand-up Feature
[0351] FIG. 72 depicts a stand-up feature 1351 that can be
accomplished according to the present invention. The depicted
stand-up feature is made by extending the injection-molded resin
from the container base 1353 (and, optionally, the container's
encapsulated rim 1357) to add the stand-up feature to the package
1355.
Lids
[0352] Various container types can be manufactured using the
injection-molded, folded-style paperboard tray with a paperboard
lid.
Hinged Lids
[0353] In hinged lid containers 520, a hinge 522 connects the
primary lid 524 (as compared to lids covering dispensing features,
which are discussed below) to a sidewall 526 in a hinge-like
fashion to facilitate easy opening and closing of the tray or other
container. One example is shown in FIG. 73.
[0354] Hinged lids include lids with living hinges (see, e.g.,
FIGS. 174 and 186). FIG. 174 depicts a tray 1359 and lid 1361
combination, wherein the lid is connected to the tray by a single
long living hinge 1357. FIGS. 186 and 193 depict a tray 1359 and
lid 1361 combination wherein the lid is connected to the tray by a
pair of short living hinges 1363. The container and living hinge
features depicted in FIGS. 174, 186, and 193, wherein all flat
surfaces are paperboard and all curved or radiused surfaces are
resin, can be made in one mold.
Snap-Fit Lids
[0355] In an alternative embodiment, the lid and sidewalls may be
separate from each other and incorporate a cooperating snap fit
open and re-close feature. Trays having an encapsulated rim may be
fitted with a snap-fit lid. A lid 524 may both snap-fit and be
hinged, as shown in FIG. 73. The encapsulated rim may have a male
projection extending outwardly from the rim and shaped to accept a
female or grooved lid. The lid may be a thermoformed plastic, or
may be a reusable lid as described above.
[0356] Press-formed paperboard trays with a injection-molded
plastic rim or flange also may be fitted with a snap-fit lid (not
shown). The rim or flange may have a male projection cross section
(i.e., a snap-fit feature), which will accept a snap-fit female
cross section plastic lid. The lid may be, for example,
thermoformed plastic or a reusable MICRO-RITE lid.
Peelable Lids
[0357] Peelable film structures that are known in the flexible
packaging art may be adapted for use in combination with trays
according to the present invention. For example, such films may be
laminated to paperboard or other lid material.
[0358] Peelable lids may be constructed from polyester, which melts
at approximately 500.degree. F. and, thus, can be used as the
lidding film for tray designed for use in conventional ovens.
Peelable lids can also be made from polypropylene, which melts at
temperature that is too low for use in conventional ovens, but
which works well as the lidding film for tray designed for use in
microwave ovens.
Lids
[0359] Various container types can be manufactured using the
injection-molded, folded-style paperboard tray with a paperboard
lid.
Hinged Lids
[0360] In hinged lid containers, a hinge connects the primary lid
(as compared to lids covering dispensing features, which are
discussed below) to a sidewall in a hinge-like fashion to
facilitate easy opening and closing of the tray or other
container.
[0361] Two-piece, mechanically-hinged lids (e.g., the ball and
socket, piano-type hinge often used in other products) may be used
in combination with the present invention. Such lids are similar to
the dispensing feature 1365 lid depicted in FIG. 189.
[0362] FIG. 187 depicts an example of a two-piece package 1367. The
lid 1369 has a living hinge 1371 that is mechanically adhered to a
mounting surface 1373 comprising part of the formed tray 1375. In
FIG. 187, the living hinge is about to be attached to the hinge
mounting surface. Two separate injection molds are used: the first
to make the lid, and the second to make the tray. In this
configuration, all flat surfaces are paperboard, and all curved or
radiused surfaces are resin.
[0363] FIG. 190 depicts a hinged tray 1377 that was made in one
molding unit. Three paperboard pieces are placed into the mold and
then resin is injected to form the tray. As previously noted, all
flat surfaces are paperboard, and all curved or radiuses surfaces
are resin. This container, as depicted, also includes a mechanical
hinge providing access to a dispensing feature 1381.
Snap-Fit Lids
[0364] Separate, snap-on or snap-fit lids (for example, one used
with a large lasagna dish so it can be resealed if contents are not
completely consumed in an initial sitting) may be made according to
the present invention. FIG. 188 depicts a snap-fit lid 1383 with a
living hinge dispensing feature 1385. It is another two-piece
package made using two separate injection molds (like the one
depicted in FIG. 187). One mold makes the tray 1387, and another
mold makes the lid using paperboard and injection-molding resin.
Again, in this configuration, all flat surfaces are paperboard, and
all curved or radiuses surfaces are resin.
[0365] In an alternative embodiment, the lid 1383 and sidewalls of
the tray 1387 may be separate from each other and incorporate a
cooperating snap-fit open and re-close feature.
[0366] Trays having an encapsulated rim may be fitted with a
snap-fit lid. The encapsulated rim may have a male projection
extending outwardly from the rim and shaped to be accepted in a
female or grooved lid. The lid may be a thermo formed plastic, or
may be a reusable lid as described above.
[0367] Press-formed paperboard trays with an injection-molded
plastic rim or flange also may be fitted with a snap-fit lid. The
rim or flange may have a male projection cross section (i.e., a
snap-fit feature), which will accept a snap-fit female cross
section plastic lid. The lid may be, for example, thermoformed
plastic or a reusable MICRO-RITE lid.
Peelable Lids
[0368] Peelable film structures that are known in the flexible
packaging art may be adapted for use in combination with trays
according to the present invention. For example, such films may be
laminated to paperboard or other lid material.
[0369] Peelable lids may be constructed from polyester, which melts
at approximately 500.degree. F. and, thus, can be used as the
lidding film for tray designed for use in conventional ovens.
Peelable lids can also be made from polypropylene, which melts at
temperature that is too low for use in conventional ovens, but
which works well as the lidding film for tray designed for use in
microwave ovens.
Lids Having Dispensing Features
[0370] FIGS. 188, 189, and 190 depict various lids having
dispensing features. These lids may be made according to the
present invention, and are described elsewhere herein.
Gas Barrier Feature (i.e., Leak Resistance or "Leak Proofness")
[0371] When a moisture and gas barrier layer is incorporated into a
paperboard tray, a high-barrier paperboard tray package can be
obtained when the lid film is hermetically sealed onto the plastic
rim. Such trays are useful in, for example, modified atmosphere
packaging (MAP) of refrigerated foods for extended shelf life. MAP
is a packaging method in which a combination of gases such as
oxygen, carbon dioxide, and nitrogen is introduced into the package
at the time of closure to extend the shelf life of the product
packaged (for example, lunch meat in a blister package).
[0372] Currently, nonbarrier packages that incorporate MICRO-RITE
and other metallized microwave packaging are manufactured. These
packages use conventional, nonbarrier orientated PET as the carrier
sheet for both the foil and the metal. A barrier package that
incorporates MICRO-RITE and other metallized microwave packaging
can be created by combining the salable lid described above with
one of the following techniques for improving the barrier aspects
of the rest of the package: [0373] i) use SARAN-coated (or acrylic
or polyvinyl alcohol) PET in place of conventional PET; [0374] ii)
use a conventional microwave package but, in addition to the
conventional PET, laminate a barrier sheet such as SARAN-coated (or
acrylic or polyvinyl alcohol) PET or EVOH containing films; [0375]
iii) use a barrier adhesive to laminate conventional PET film to
paperboard; [0376] iv) extrusion laminate conventional PET films to
paperboard using EVOH (or other barrier resins).
Method of Manufacturing a Tray Having Printed Graphics
[0377] Paperboard trays, whether press-formed, folded, gusseted,
and the like, are generally formed from tray blanks. A tray blank
suitable for creating a variety of paperboard trays may be
manufactured as follows: [0378] i) Initially, a polyester film is
laminated to a foil, forming a film/foil combination. The polyester
film itself may be metalized, if desired. Next, the film/foil
combination is masked with a caustic-resistant agent in a desired
pattern. Once masked, the film/foil combination is run through a
caustic bath, which etches the unmasked portions of the
combination. The mask may then be removed, if necessary. Once the
desired pattern is etched, the film/foil combination is laminated
to an uncoated, uncut paperboard sheet. After lamination, ink may
be added to the board to form graphics. [0379] ii) To be able to
press-form a tray, the paperboard must have moisture in it. Thus,
once the ink is placed on a paperboard sheet to be press-formed, a
moisturizing process adds moisture to the paperboard. In one
embodiment, the moisturizing process adds approximately 3 to 5%
moisture to the board. This additional moisture helps expand and
swell the paperboard fibers of the sheet so that a tray may be
shaped without ripping. [0380] iii) After the moisturizing process
is completed, the paperboard sheet is die cut into individual tray
blanks. Many different types of trays may be manufactured. The
die-cutting step determines the final form of the tray blank. For
example, a five-panel tray blank (discussed above) will be die cut
differently from a tray blank for a press-formed tray. [0381] iv)
Following die cutting, the resulting tray blanks may be
press-formed, folded, or otherwise shaped into a tray.
[0382] In order to have a high fidelity, six-to-eight color
printing on the outside of a tray, it is necessary to have
clay-coated paperboard. If there is no clay, the inks are absorbed
into, and may bleed across, the paperboard. The resulting print
resolution and quality are poor, possibly including smudged or
blurred graphics. In one embodiment of the present invention,
approximately eighteen pounds of clay are added per ream of
paperboard in order to coat the paperboard. This amount of clay
facilitates high fidelity printing of the tray surface. Further,
the process just described permits graphics to be printed not only
on the top of a tray, but also on a tray's sidewalls and bottom. If
high-quality graphics are not desired, the aforementioned steps may
be eliminated.
[0383] Using the five-panel tray 434 discussed above with respect
to FIG. 41, for example, with a plastic injection-molded support
rim 436 that permits a full hermetic seal, it is possible to
manufacture a barrier tray with full color graphics on the tray
sidewalls and lid. The five-panel tray 434, which eliminates any
pleated corners, makes it possible to print the paperboard with
full graphics on surfaces and then to use the injection mold tool
itself to shape the tray and inject material that will seal the
seams between the sidewalls.
[0384] Two-side printing on surfaces that ultimately become the
outside or inside of tray sidewalls and/or a lid is also an option.
The folded style tray can be enhanced by having graphics printed on
both the inside and outside of the tray. The press-formed tray can
have two-side printed lids. This printing is done using
conventional printing processes known in the paperboard industry.
The prior art thermoformed trays are not easily printed on either
the inside or outside. Typically, pressure sensitive labels are
utilized to add graphics to these prior art trays.
In-Line Press-Forming and Injection-Molding Process
[0385] It is possible to press-form a paperboard container into a
three-dimensional tray having a flange, and then partially or fully
encapsulate the flange with injection-molded plastic in a single
tool. This improves container uniformity and reduces costs.
[0386] The injection mold tool may be a freestanding machine or may
be combined with a machine designed to form the tray body. In the
latter version, a single machine would form the tray and injection
mold the encapsulated rim. When the injection mold tool is
freestanding, trays may be conveyed to the injection mold tool by
hand or via dedicated machinery, such as a conveyor belt.
[0387] These container-forming tools are similar to the tools
commonly used to make pressed paperboard containers, such as bowls,
trays, and plates, such as Gralex and/or Peerless presses. New
features are, however, included in the tool to provide for a
polymer to be injected into the rim area and any other desired
areas of the container.
[0388] Alternatively, a two-step process can be used, wherein the
formation of the container takes place in step one, and then the
formed tray is transferred "on machine" to an adjacent location on
the same machine where the polymer is injection molded.
[0389] Although the injection mold tool described above relates
particularly to an embodiment having an encapsulated rim as a rim
feature, alternate embodiments with different rim features may be
created with some alterations to the apparatus already
described.
[0390] It should be further noted that many methods of tray
manufacture, including those discussed above and those well known
to people skilled in the art, may be combined with the
injection-molding process just described. Thus, a single production
line may be set up in order to take a tray blank, form it into a
three-dimensional tray, and injection mold the formed tray, all
without requiring the blanks or folded trays to be transferred from
one production line to another.
First Method of and Apparatus for Encapsulation
[0391] FIG. 74 displays an open injection mold tool 536 according
to a first embodiment and suitable for manufacturing a tray 100 and
encapsulated rim 124 (see, e.g., FIG. 76) according to one
embodiment of the present invention. Generally, an assembled tray
100 is inserted in the middle of the injection mold tool 536, as
shown in FIG. 74. The flange 116 rests on a barrier wall 538 (FIG.
77), thus supporting the tray 100 and suspending it above the
bottom of the injection mold tool. The barrier wall 538 comprises a
portion of the bottom member 540 of the closed injection mold tool
536.
[0392] As part of the manufacturing process, any pleats 122 spaced
along the tray 100 or flange 116 may be pressed prior to being
placed in the injection mold tool 536 in order to at least
partially flatten them. This simplifies the process of creating an
hermetic seal across the pleat surface, as described below.
[0393] Once the tray 100 is properly positioned within the
injection mold tool 536, the injection mold tool is closed, as
shown in FIG. 75. A portion of the top member 542 of the closed
injection mold tool tightly pins the flange 116 against the barrier
wall 538 to help securely position the tray 100. The top of the
closed injection mold tool 542, the flange, and the barrier wall
create a generally airtight seal, absent any gapping or
irregularities in the flange surface.
[0394] Further, the injection mold tool 100 may itself be used to
press-form a tray 100 from a tray blank by appropriately shaping
the top 542 and bottom 540 of the injection mold tool. For example,
rather than having a flat mold top 542, as shown in FIGS. 74 and
75, the top of the injection mold tool may include a press-forming
member projecting into the injection molding cavity. In one
embodiment, the distance between the press-forming member and the
base of the injection mold tool may be approximately equal to the
width of a paperboard sheet. A tray blank may be placed in the
injection mold tool, and, when the mold closes, the pressure
exerted on the blank by the top and bottom of the injection mold
tool may press-form the tray into its three-dimensional shape.
[0395] FIG. 76 depicts the injection mold tool 536 of FIGS. 74 and
75 during operation. Once the injection mold tool is closed, a
vacuum line 544 draws most or all of the air out of the injection
mold tool. Molten resin is then pressurized and piped through
injection sites 546 into the injection mold tool 536. It should be
noted that in this embodiment there are two injection sites, one at
each end of the injection mold tool. FIGS. 74-82 display vertical
cross-sections (at varying magnifications) of two different
embodiments of the injection mold tool 536, and accordingly display
only the portions that lay on the cross-section line. Alternate
embodiments may use multiple injection sites, or a single injection
site 546, feeding molten resin. Similarly, alternate embodiments
may vary the pressure differential between the injection mold tool,
and pressurized reservoir of molten resin.
[0396] Generally, the number and placement of injection sites 546
affects the injection and flow of the injection-molded material.
Multiple injection sites permit lower pressurization and allow a
more uniform distribution of injection-molded material throughout
the mold 536. Further, the way in which the flange 116 or tray 100
is clamped in the injection mold tool affects the flexing of the
flange during the injection-molding process. In order to minimize
flexing, the flange or tray is typically clamped near the injection
sites 546.
[0397] The pressurized injection sites 546 force molten plastic
into the injection mold tool 536 to coat the flange 116. As can be
seen in FIGS. 77 and 79, the flange may be suspended substantially
in the middle of the injection mold tool injection cavity 548,
thereby permitting its top, outer side, and bottom to be coated
with molten plastic. Further, because the flange 116 occupies the
approximate center of the injection mold tool, the molten plastic
may be dispersed above and below the flange. Accordingly, the
flange may be enclosed approximately in the middle of the
encapsulated rim, rather than having the majority of the
encapsulated rim located above or below the flange. This ensures
that (a) the rim 124 surrounds the flange in a stable manner, and
(b) the flange is unlikely to break through a wall of the
encapsulated rim weakened due to a minimal amount of plastic.
Generally, however, the length of the flange is less than the
distance from the flange surface to the top of the cavity 548, in
order to prevent the flange 116 from being deflected out of the
resin due to the pressure exerted on the flange by the resin. All
portions of the flange 116 (i.e., corner flanges and sidewall
flanges) are generally uniformly coated with molten plastic. Again,
alternate embodiments may vary the thickness or other dimensions of
the plastic coating.
[0398] FIGS. 80 and 81 are enlarged, cross-sectional views along
line B-B of FIG. 79 and show folds, creases, and other
irregularities 122 inherent in a press-formed tray 100 that make it
difficult to achieve a hermetic seal. During injection, a crimped
or pleated corner flange 116 is suspended in the injection mold
tool 536. As molten plastic is pushed into an airflow path, it
cools on the surface of the irregularities 122. Once a sufficient
amount of plastic is pushed into and cools in the irregularity, a
seal is formed between the injection mold tool 536. Typically, a
seal forms only when the irregularities 122 are substantially
filled with cooling plastic. This ensures that each irregularity is
generally completely coated with molten plastic, thus eliminating
any potential breaks in the encapsulated rim's 124 hermetic seal
and ensuring that the rim is of a relatively uniform thickness and
strength across the entire flange. FIG. 81 depicts molten plastic
being forced into the flange irregularities 122 by the pressure
generated during injection molding.
[0399] FIG. 82 is a cross-sectional view of an alternate injection
mold tool 550. The injection mold tool includes an inner lip 552,
which presses the tray sidewalls outwardly. By exerting outward
pressure on the tray sidewalls, the inner lip 552 ensures that the
flange 116 is completely inserted into the injection mold tool 550.
The lateral pressure also effectively locks the tray sidewalls 114
against the barrier wall 538, thus immobilizing the tray 100 once
the injection mold tool 550 is closed. This minimizes the flange's
movement while being coated with molten plastic, for example,
movement that might otherwise result from the pressure of the
molten plastic against the flange 116.
[0400] The encapsulated rim 124 is produced by placing a pressed or
folded paperboard tray 100 into an injection molding cavity 548 and
them injecting molten plastic onto the perimeter of the tray so
that the perimeter of the tray is enveloped by the molten plastic.
The vacuum in the mold merely holds the paperboard tray 100 in
position while the mold is open, closed, being opened, being
closed, and while the injectant is being injected. The vacuum is
not used to move the polymer through the mold.
[0401] Complete encapsulation of the flange 116 may be performed
using a single-step or a multi-step injection process. The single
step process uses a mold like that depicted in FIGS. 74-82. In the
multi-step process, the flange 116 initially may be positioned
within the injection mold tool as shown in FIG. 78, with the top of
the flange placed flush against the top of the injection mold tool
554. In the first step according to this embodiment, the
injection-molded material coats only the outer edge and bottom of
the flange 116, resulting in a partially encapsulated flange (the
partially-encapsulated flange resulting from the mold configuration
shown in FIG. 78 would look similar to the partially-encapsulated
flange 158 depicted in FIGS. 8 and 9 except that, in these latter
two figures, a portion of the tray sidewall 152 is also coated, and
the injection-molded material is flush with the upper surface of
the flange). After the first step, the encapsulating material is
substantially flush with the bottom surface of the paperboard
flange 116. Then, once the polymer at least partially solidifies, a
second step is used to complete the encapsulation of the
flange.
[0402] It is also possible to use an articulated injection-molded
tool to fully encapsulate the flange. The articulated injection
tool could take care of multiple injections in sequence. For
example, a multi-step process may include: [0403] i) pressing the
blank into the three-dimensional tray having a flange; and [0404]
ii) moving the formed tray 100 to another tool for the partial or
full encapsulation of its flange 116.
Second Method and Apparatus for Encapsulation
[0405] Additional aspects of the present invention involve a tool
capable of press forming a paperboard item, such as a container or
tray, from a flat blank of paperboard and injection molding a
polymer to form a partially or completely encapsulated rim of the
tray or container. An "in-mold" forming tool eliminates the
preforming step required for conventional injection molding tools
resulting in a substantial cost savings.
[0406] Generally, an injection-molding (or "in-mold") tool
conforming to the present invention typically requires lower
forming tool temperatures than conventional forming processes
because the forming pressure and dwell time are substantially
greater than they are for the traditional forming process for
pressed paperboard containers. For example, one in-mold tool in
accordance with the present invention may apply a forming pressure
of between 1425 lb/in2-2850 lb/in2 on a paperboard blank. A
traditional forming tool only applies about 240 lb/in2 on a blank
during formation. Moreover, the dwell time of an embodiment of the
present invention may be six seconds, which is about three times
greater than the dwell time of conventional press forming
processes. As such, laminates and coatings may be applied to both
sides of the paperboard blank with only a minimal tendency for
these coatings to stick to the tool. Thus, a strong container with
a polymer film on the inside and a graphic lamination on the
outside is possible.
[0407] In addition, the requirement for high moisture levels in the
paperboard blank is greatly reduced since the shape of the
container is held together by, and additional strength imparted to
the container through, the injection of a polymer onto the rim or
flange of the container at approximately 500 degrees Fahrenheit
with a pressure of approximately 2000 lb/in2, for example. As such,
the "in-mold" forming process and tool of the present invention
provides a container or other item that is not dependent on
moisture to achieve fiber bonding within the cellulose structure of
the paperboard. Some moisture, however, may be added to the
paperboard to plasticize the cellulose structure so that uniform
pleats or required edge compression folds can be made. For
containers, which require two sides of the paperboard to be coated,
laminated, extruded, or sealed in any way, the low temperature of
this forming process will not create blisters in the container.
[0408] A paperboard item of the present invention is fabricated at
substantially greater pressures, longer dwells, and lower
temperatures than in conventional paperboard forming processes and
may also incorporate graphics and food packaging features not
equally achievable by the traditional pressed paperboard forming
process.
[0409] Additionally, a container formed in accordance with the
present invention may be sized as required in the injection molding
process. Although the exact shape of the tools may include
corrections for polymer shrinkage, the finished containers can be
produced with very small size variation. The significantly higher
pressure and dwell levels of this new pressed paperboard forming
process also result in a substantially higher level of cellulose
fiber bonding within all of the pleats, folds, and/or bends
throughout the entire shape of the paperboard structure. All of
these combined container benefits provide new market opportunities
for a broad range of applications.
[0410] FIG. 83 displays a bottom perspective view of a tray 556
having a partially formed encapsulated flange 558. Such
partially-formed encapsulation generally corresponds to a partially
injected state during the injection-molding process occurring in
the injection-molding apparatus described below. That is, the tray
shown in FIG. 83 generally represents the state of a tray after the
injection-molding has begun, but before it is complete. FIG. 84 is
a bottom-up view of the tray 556 of FIG. 83, while FIG. 85 is a
top-down view showing the tray of FIG. 83 with a completely
encapsulated rim 560.
[0411] As shown generally in FIGS. 93-96, and as will be described
in further detail below, one embodiment of the injection-molding
tool 562 injects resin along the underside of the tray 556 flange.
When blank is clamped in the tool and press-formed into a
three-dimensional shape, the top of the flange is generally pressed
snugly against a shut-off wall 564 of the tool (see, for example,
FIG. 95). The shut-off wall prevents resin from flowing over the
top of the flange and beyond the wall, thus assisting in dictating
the outer geometry of the injection-molded rim. It should be noted
that, throughout this document, the terms "injection-molding
apparatus" and "injection-molding tool" are used
interchangeably.
[0412] The cavity 566 into which resin is injected (the "injection
cavity") generally runs around the outer edges of the tray when the
blank is clamped in the tool 562, extending outwardly from the
sidewalls a distance beyond the edge of the flange. The exact
geometry of the injection cavity 566 varies depending on the
injection-molded feature desired. A side shut-off wall prevents
resin flow beyond the injection cavity.
[0413] Generally, liquid resin is injected at high pressure and
temperature into the injection cavity through one or more
pressurized gates. FIG. 86, for example, depicts a view of a
section of the injection cavity 566 displaying a gate 568 location.
The view of FIG. 86 is shown looking towards a cavity portion of an
injection-molded tool. Such a tool is described in greater detail
with respect to FIGS. 93-96, below. In this view, the sidewall of a
tray would run along the top edge of the injection cavity. As shown
in FIG. 86, the injection cavity 566 is typically divided into at
least two sections, namely an advanced-flow section 570 and
delayed-flow section 572. The delayed flow section may be further
subdivided into a flange region 574 and a resin-only region 576.
The advanced-flow section is labeled "A", the flange region of the
delayed-flow section is labeled "B", and the resin region of the
delayed-flow section is labeled "C". The subdivision between the
flange and resin-only regions is represented by a dashed line. In
this embodiment, the gate 568 is located in the advanced-flow
portion 570 of the injection cavity.
[0414] FIG. 87 is a cross-sectional view taken along line 87-87 of
FIG. 86, showing the cross-sectional geometry of the injection
cavity 566. As can be seen, the cross-sectional area (and thus the
overall volume) of the advanced-flow channel section 570 is greater
than the cross-sectional area of the delayed-flow channel section
572. In the present embodiment, the ratio of the cross-sectional
area (or "volumetric area") of the advanced-flow section to the
delayed-flow section is approximately 3 to 2.
[0415] FIG. 87 also shows the placement of a portion of a tray 578
within the injection cavity 566 in phantom. Generally, the outer
edge of the tray flange corresponds to the division between the
flange 574 and resin-only 576 region of the delayed-flow section
572. The tray sidewall runs along the edge of the advanced-flow
section 570 opposite the delayed-flow channel area 572.
[0416] As resin is injected through the gate 568, it generally
spreads to fill the entirety of the injection cavity 566. However,
because the volumetric area of the advanced-flow section 570 is
greater than the volumetric area of the delayed-flow section 572,
resin generally flows faster in the advanced-flow section. This is
shown to better advantage in FIGS. 83 and 84. In FIG. 83, the
projecting stubs 567 may generally correspond to gate 568
positions, and may also indicate where resin projects downward from
the flange 558 due to excess resin remaining in the gates during
cooling. As resin is injected, it flows in the direction indicated
by the arrows. In the tray 556 shown in FIGS. 83 and 84, the stubs
567 representing gate 568 locations along the short sidewalls 580
of the tray are the primary injection points for resin (also
referred to as "primary gates"). As previously mentioned, the
advanced-flow section 570 is generally positioned next to the tray
sidewall 580 in this embodiment. Alternate embodiments may change
the positioning of the advanced-flow section in order to change the
configuration of an encapsulated feature.
[0417] Typically, the gate 568 is sized to have an injection area
equal to or exceeding 50% of the cross-sectional area of the
advanced-flow section 570. This enhances the flow differential
between the advanced-flow section 570 and the delayed-flow section
572.
[0418] Still with respect to FIG. 83, resin flows more quickly in
the advanced-flow section 570 than in the delayed-flow section 572.
Thus, until the entirety of the injection cavity is filled, the
"flow front" of the molten resin (as measured from the primary
gates) generally resembles an S-curve, with the resin in the
advanced-flow section occupying the top portion of the S-curve and
resin in the delayed-flow section occupying the bottom portion of
the S-curve. When the encapsulation process is stopped before the
entire flange is encapsulated, as in FIG. 83, the S-curve may be
clearly seen as a first flow front 582.
[0419] As the resin flow extends from a primary gate, the
difference in flow fronts may gradually diminish. Compare, for
example, the first flow front 582 and the second flow front 584
shown in FIG. 83. The first flow front is immediately adjacent to a
stub 567 corresponding to a gate 568. Accordingly, the difference
between the advanced-flow section and the delayed-flow section is
clearly seen, and the S-curve shape of the flow front is elongated.
As the resin travels further from the primary gates 568, however,
the delayed resin flow may begin to catch up to the increased resin
flow. This forms a more gentle S-curve shape, illustrated by the
second flow front 584. The point from the top of an S-curve to the
inflection point along the body of the S-curve is generally
referred to as the "advance flow front." The portion of an S-curve
from the inflection point to the bottom of the curve may be
referred to as the "delay flow front."
[0420] FIG. 92 displays a bottom-up view of the injection cavity
566 of FIG. 86 during operation. In this view, the "top" surface of
the injection cavity again corresponds to the placement of a tray
sidewall, and the tray flange generally extends to the edge of the
flange portion of the delayed-flow section 572. The flow front of
the resin may be seen, forming the previously-discussed S-curve
shape. Resin generally flows in the direction indicated by the
arrow. The flow front extends farthest in the advanced-flow section
570. The gate 568 may be located at any point in the advanced-flow
section behind the flow front.
[0421] FIG. 88 shows a cross-sectional view of a tray having an
encapsulated rim formed by injection-molding in the injection
cavity of FIGS. 86 and 87. The vertical arrow indicates the
horizontal position of the gate when the tray is placed in the
injection-molding apparatus. Here, the region marked "A"
corresponds to the advanced-flow section 570, the region labeled
"B" corresponds to the flange section 574 of the delayed-flow
section 572, and the region labeled "C" corresponds to the
resin-only section 576 of the delayed-flow section. As can be seen,
the "A" region generally has a greater thickness of resin 590
coating the tray flange 588, matching the greater cross-sectional
area of the advanced-flow section of the injection cavity 566.
[0422] FIG. 89 displays a view of another embodiment of an
injection cavity 566. In this embodiment, the advanced-flow section
570 is expanded into a portion of the delayed-flow section 572 by
creating a semi-ovoid protrusion 594 extending the advanced-flow
section away from the wall of the injection cavity 590. The gate
568 is located within this protrusion, in a portion of the
injection cavity that would otherwise comprise part of the
delayed-flow section in, for example, the embodiment of FIG. 86. By
moving the gate to the semi-ovoid protrusion, greater clearance
between the gate and tray sidewall may be achieved, permitting the
use of gates larger in cross-section and thus allowing more rapid
resin injection into the injection cavity.
[0423] FIG. 90 displays a cross-sectional view taken along line
90-90 of FIG. 89. The cross-section is taken partially through the
semi-ovoid protrusion 594. As can be seen in FIG. 90, the
protrusion 594 has a curved wall 596 in cross-section, sloping from
the depth of the delayed-flow section 572 to the depth of the
advanced-flow section 570. In alternate embodiments, the
protrusion's wall may be linearly sloped, stepped, or vertical.
Similarly, the protrusion 594 may be square, triangular, circular,
and so on when viewed in top-down fashion.
[0424] Generally, outside the semi-ovoid protrusion 594, resin flow
through the injection chamber 590 of FIG. 89 is identical to flow
through the injection chamber 566 of FIG. 86. When resin is
initially pumped through the gate 568, it moves down the sloped or
curved wall 596 of the protrusion and into the advanced-flow
section 570. The volume of the protrusion is sized to encourage
initial resin flow into the advanced-flow section and away from the
decreased-flow section 572. Once the protrusion 594 fills, the
resin flow path is as previously described with respect to FIGS.
86, 87, and 92.
[0425] FIG. 91 is a cross-sectional view of a tray 598 having an
encapsulated rim 600 formed in the injection chamber 590 shown in
FIG. 89. The present cross-sectional view is taken substantially
through the middle of the portion of the tray 598 corresponding to
the semi-ovoid protrusion 594. The resin gathering in the
protrusion creates a similarly-shaped resin protrusion 602 on the
surface of the encapsulated tray rim 600. As the rim extends from
the resin protrusion, it assumes a cross-section similar to the
tray shown in FIG. 88. The arrow indicates the location of the gate
568 inside the cavity 590.
[0426] Generally, a ratio of the length of the advance flow front
to the thickness of the advance flow front may be calculated for
the injected molten resin, yielding an advance length/thickness ("A
L/T") ratio. Similarly, a ratio of the length of the delayed flow
front to the thickness of the delayed flow front may be calculated
to yield a delayed length/thickness ("D L/T") ratio. If an L/T
ratio is greater than 200, a high flow resin may be used to
completely fill the corresponding flow section of the injection
cavity. For example, when the A L/T ratio is 300, a high flow resin
may be used to ensure the advance flow section is completely filled
with resin. Generally, a "high flow" resin is defined as a
thermoplastic or other material having a meltflow value above 20
grams/10 minutes. The higher a resin's meltflow value, the more
easily the resin flows when in a molten state. Various high flow
resin types exist for each of the resins shown in the resin table
in the section entitled "Tool Deformation," below.
[0427] FIG. 93 displays a cross-sectional view of an
injection-molding apparatus 562, taken along the long axis of the
apparatus. Generally, the apparatus consists of a male side 604
(also referred to as a "punch" or "core") and female side 606 (or
"cavity"). The core 604 may move toward, and mate with, the
stationary cavity 606. Typically, the injection-molding tool 562 is
mounted in a horizontal press position, with the core and cavity
essentially side-by-side. Alternate embodiments may vertically
mount the tool.
[0428] Generally, the tool 562 may both press-form a tray blank 608
into a three-dimensional tray and injection mold one or more
features onto the tray. The exact encapsulated feature or features
formed by the tool depend on the configuration of the injection
cavity 566.
[0429] Initially, the tool 566 (both core 604 and cavity 606 sides)
is heated near the melting point of the resin that will be injected
along the blank 608 surface to form one or more encapsulated
features. By heating the tool, premature cooling of molten resin
due to contact with cool tool surfaces is minimized. Generally, the
temperature to which the tool 562 is heated varies with, among
other things, the resin used, the thickness of the tray blank 608,
the thickness of the encapsulated feature to be formed, and the
distance between injection gates 568. This, in turn, minimizes
bunching of the resin or irregularities in the surface of the
injection-molded feature. The tool 562 may be heated to any
temperature within a temperature range varying for each type of
resin employed to create an injection-molded feature. Generally
speaking, when the tool 562 is heated to the lower end of a
temperature range, the resin flows more sluggishly, but the cycle
time required to create a tray having an injection-molded feature
is minimized. Conversely, when the tool is heated to the upper end
of a temperature range, the resin flow through the injection cavity
is quicker, but the overall cycle time is lengthened.
[0430] After heating (or, in some embodiments, prior to heating), a
tray blank 608 (such as those shown in FIGS. 3, 22, 24, 48, 49, 51,
53, 55, and 57) is inserted between the core 604 and cavity 606.
The blank is flat at this point. Generally, the blank 608 is
oriented with its bottom side (the exterior of the tray formed by
the blank) facing the cavity 606, and its topside facing the core
604. One or more blank guides 610 position the tray blank for
receipt within the cavity. The blank guides 610 may be
perpendicular, parallel, or at an angle to the longitudinal axis of
the tray blank 608. Typically, the guides are positioned along the
exterior of the cavity 606 or core 604 in positions permitting the
blank 608 to rest against one or more guides as the tool is
closed.
[0431] FIG. 94 displays the injection-molding apparatus 562 in a
partially closed position. In this position, the core 604 extends
partially into the cavity 606. As the core enters the cavity, it
deforms the tray blank 608, beginning the press-forming process
that shapes the blank into a three-dimensional tray. The tray may
deform in a variety of ways, dictated at least partially by both
the score pattern on the tray blank and the configuration of the
cavity 606 and punch 604.
[0432] Next, the injection-molding apparatus 562 completely closes,
as shown in FIG. 95. When completely closed, the core 604 extends
fully into the cavity 606. Generally, the core is shaped to
substantially completely fill the cavity, with the walls of the
core sloped, angled, and/or shaped congruently with the cavity
walls. When fully closed, the tray blank 608 is held rigidly in
place by pressure exerted by both cavity 606 and core 604. Further,
one or more vacuum ports 610 may induce a negative pressure on the
base of the blank 608 when it contacts the cavity interior wall,
assisting in holding the blank in place during the
injection-molding process. When the tool 562 is fully closed, the
blank 608 is press-formed into the three-dimensional shape of the
eventual tray, lacking only one or more injection-molded
features.
[0433] As may also be seen in FIG. 95, one or more shut-off walls
564 may mate with corresponding surfaces on the opposing portion of
the injection-molding apparatus. The shut-off walls 564 minimize
resin flow beyond the wall during the injection-molding process
(i.e., flash), as previously discussed. Essentially, the shut-off
walls aid in creating the geometry of the injection-molded feature.
Additionally, spacing between the mating surfaces of the core 604
and cavity 606 may define the injection cavity 566 into which resin
is introduced.
[0434] Once the injection-molding tool 562 is completely closed,
resin may be injected through one or more gates 568 into the
injection cavity. Although only a single gate is shown in FIG. 95,
two or more gates may be used. If multiple gates are used to inject
resin, they are generally equidistantly spaced along the perimeter
of the injection cavity 566 and/or press-formed tray, when the tray
is clamped inside the tool. This aids in evenly distributing resin
across the flange and/or other encapsulated portion of the
tray.
[0435] In the present embodiment, the resin injected to form an
encapsulated feature is typically nylon 6/6, although other
polymers may be used. Several suitable polymers, for example, are
given in the section immediately below entitled "Tool Deformation."
Further, various additives may be mixed with the resin to enhance
certain resin features or create new functionality. For example,
fiberglass particles may be added to the resin to increase the
resin's resistance to heat and raise the heat deformation
temperature (HDT) of the resin. Similarly, nucleating or release
agents may be added to the resin.
[0436] When the tray is secured between the punch 604 and cavity
606 and the injection-molding tool is fully closed, the pressure
exerted on the top of the flange by the injection-molding tool and
subsequent resin flow along the flange bottom compresses the top of
the flange, minimizing pleats and irregularities in the flange
surface. Generally speaking, this resin flow takes places at a high
temperature of approximately 550 degrees Fahrenheit and
approximately 2000 lbs/sq. in. Further, the pressure exerted by the
tool 562 and resin injection process forces the flange against the
shut-off wall, ensuring that no resin flows along the side and over
the top of the flange. This aids in creating more precise
geometries for injection-molded features.
[0437] For reference, the ram pressure used to close the
injection-molding apparatus is approximately 170 tons/square inch.
This pressure is spread across the surface area of the core.
Accordingly, although the blank does not experience a pressure of
170 tons/square inch, the pressure is nonetheless substantial. The
surface area of the core 604 varies, depending on the configuration
of the tray blank 608 being press-formed and injection molded, as
well as the configuration of the core and cavity 606. In one
embodiment of the tool 562, the core face is approximately six
inches wide, eight and five-eighths inches long, and one and
three-quarters inches deep. Accordingly, the face area is
approximately 50 square inches.
[0438] Once the injection molding process is complete and the resin
hardens, the injection-molding apparatus 562 opens, as shown in
FIG. 96. Effectively, the apparatus returns to the start or ready
state initially displayed in FIG. 93. Now, however, the tray blank
608 has been formed and provided with one or more encapsulated
features.
Center-Point, Resin-Injection Process
[0439] FIGS. 129-131 are top down views looking at a tray 1501 and
lid 1503 combination (i.e., a "lidded tray" 1505). Moving from FIG.
129 to FIG. 131, these figures depict, in general, flow front
progression during a center-point, resin-injection process. During
this process, resin is injected in the center area 1505 of the tray
and moves outwardly in two directions from that center point. In
one embodiment, as shown in FIG. 130, the resin moving in each
direction splits again and branches toward each corner 1507 of the
tray. In FIG. 131, resin is accumulating in the corners and
beginning to travel up the tray sidewalls 1509. One of the benefits
of using this type of process is that the moving resin presses the
tray against the mold or tool as the resin heads toward the edges
of the tray. Since the tray is pressed against the mold in advance
of the resin reaching the tray edge, "flashing" is reduced or
eliminated. "Flashing" occurs when the resin escapes around a side
or to some other portion of the tray to which it was not intended
to reach. In other words, if a tray edge is not held firmly against
a mold, the resin may escape to the "wrong side" of the tray.
[0440] FIGS. 132-139 are similar to FIGS. 129-131, but depict in
greater detail how the resin flow front 1511 may progress during a
center-point 1513, resin-injection process designed to minimize
flashing while encapsulating portions of a lidded tray 1521. In
FIG. 132, the center-point, resin-injection process has just begun,
and resin has begun to travel in opposite directions away from the
injection point 1513. In FIG. 133, the resin has reached two
primary branches 1515. At each primary branch, the resin flow
divides, with approximately half of the resin heading toward one
corner of the tray, while the other half of the resin flows toward
a different corner of the tray. In FIG. 134, the resin flowing down
each primary branch has reached a secondary branch 1517, where the
flow is again split in this embodiment of a center-point,
resin-injection process. At each secondary branch, the flow is
again approximately split in half. As shown in FIG. 135, the resin,
after being split at the secondary branch, is reunited before
traveling up the sidewalls 1519 of the tray. The four white
sections 1523 in the middle of the flow paths depicted in FIG. 135
represent areas that do not receive resin. For example, tool steel
may be present at those locations, and the resin must flow around
the tool steel before becoming reunited at the back side of the
tool steel and then traveling up the sidewalls of the tray.
[0441] In FIG. 136, the resin has traveled up the tray sidewalls
1519 and has begun to travel around the perimeter 1525 of the tray
1521 to encapsulate the upper edges 1535 of the tray sidewalls. In
FIG. 137, the entire upper perimeter of the tray has been
encapsulated, and the flow is beginning to travel through the hinge
regions 1527 toward the lid 1529. In FIG. 138, the resin continues
to flow through the hinges, has encapsulated one long edge 1531 of
the lid, and has begun to travel down the two shorter edges 1533 of
the lid. In FIG. 139, the entire perimeter of the lid has been
encapsulated. Finally, FIG. 140 is an isometric view of the
resulting lidded tray 1521 at the end of the process depicted in
FIGS. 132-139.
[0442] FIGS. 141-146 are enlarged, fragmentary views showing corner
flow details of the flow stages also depicted in FIGS. 134-136.
Again, the resin flow front 1509 progression depicted in FIGS.
141-146 is designed to prevent "flashing" of the flow front by
pressing the paperboard against the tool before the resin gets to
an edge of the tray 1521. As previously described and as shown in
FIGS. 141 and 142, the resin must flow around tool steel 1523
before it can reunite and begin flowing up the tray sidewalls 1519
as shown in FIG. 142. In FIG. 143, the resin has reached the upper
edge 1535 of the sidewalls. In FIG. 144, the resin has begun to
encapsulate the upper edge of the tray sidewalls. In FIGS. 145 and
146, the progression continues and the resin flows around and
encapsulates the upper edge of the tray sidewalls.
[0443] FIG. 147 is a plan view of a blank 1537 for a press-formed
tray. In FIG. 148, the blank of FIG. 147 has been formed into a
tray 1539 having an encapsulated rim 1541 and pleated corners
1543.
[0444] FIG. 149 is a five-panel, folded formed blank that may be
used to form a tray according to the present invention. In FIG.
150, the blank of FIG. 149 has been formed into a tray 1547, and
resin has been injected using a center-point, resin-injection
process similar to what is depicted in FIGS. 132-139. In FIG. 150,
however, the injected resin is immediately sent to each corner 1549
of the tray. After the resin forms the corners, it flows around the
upper edge of the tray thereby creating an encapsulated rim 1551.
The resin thus follows more of an "X" pattern 1553 than what is
shown in, for example, FIGS. 132-139.
[0445] FIG. 151 is a plan view of a press-formed folded blank 1555
that may be used to make a tray according to the present invention.
FIG. 152 is an isometric view of a tray 1557 formed from the blank
depicted in FIG. 151 and having injected-resin features. In
particular, the tray depicted in FIG. 152 has resin corners 1559
and a resin encapsulated rim 1561. Again, the center-point,
resin-injection process has been used to form the tray of FIG.
152.
[0446] FIG. 153 depicts an eight-panel, rounded corner blank 1563
that may be used to form a tray according to the present invention.
As shown in this figure, the blank includes a bottom panel 1565,
two side panels 1567, two end panels 1569, and four corner panels
1571. FIG. 154 is an isometric view of a tray 1573 formed from the
blank depicted in FIG. 153. As shown in FIG. 154, the corner panels
become pleated corners 1575, each of which is straddled by a pair
of resin, corner-panel seams 1577. The tray depicted in FIG. 154 is
formed using a center-point, resin-injection process that is
similar to the processes described above. In the process used to
form the tray of FIG. 153, the resin is again immediately divided
into four resin distribution channels 1579 (i.e., the "X" pattern),
each of which is directed toward one of the four tray corners. Each
of these four initial resin distribution channels branches adjacent
to a corner at a secondary branch 1581 before traveling up the tray
side walls to form the resin, corner-panel seams.
[0447] FIG. 155 depicts a web-corner blank 1583. As shown in this
figure, the web-corner blank includes a bottom panel 1585, two side
panels 1587, two end panels 1589 and four webbed corners 1591. From
the blank depicted in FIG. 155, the tray 1593 depicted in FIG. 156
maybe formed. As shown in FIG. 156, a center-point, resin-injected
process is used to form four resin corner beads 1595 and to create
the encapsulated rim 1597.
[0448] FIG. 157 depicts an eight-panel, straight-corner blank 1599.
This blank includes a bottom panel 1601, two side panels 1603, two
end panels 1605, and four corner panels 1607. FIG. 158 depicts a
tray 1609 according to one embodiment of the present invention that
has been constructed from the blank depicted in FIG. 157. A
center-point, resin-injection process has been used to form the
tray depicted in FIG. 158. In particular, the center-point,
resin-injection process used to form the tray of FIG. 154 could
also be used to form the tray of FIG. 158.
[0449] The trays 1539, 1549, 1557, 1573, 1593, 1609 depicted in
FIGS. 148, 150, 152, 154, 156, and 158 could be manufactured using
in-mold, forming processes. In particular, the blanks depicted in
FIGS. 147, 149, 151, 153, 155, and 157 could be both shaped (or
formed) and encapsulated in one tool.
[0450] FIG. 159 is a cross-sectional view of a tray 1611 according
to another embodiment of the present invention and having an
encapsulated rim 1613 with a flange portion 1615 and an anchor
portion 1617. In this embodiment, a resin bead 1619 has been
created between adjacent tray sidewalls 1621. Although the
encapsulated rim depicted in FIG. 159 does not include a lid
engagement channel (see, e.g., FIGS. 102 and 103) it does include
an anchor portion similar to what is described above. Encapsulated
rims having other cross-sectional shapes can also be formed having
similar anchor portions.
Minimizing Tray Deformation Resulting from Resin Shrinkage
[0451] Currently, the design of the tray may have the paperboard's
edges encapsulated by the injection-molded resin in the injection
mold tool 554 as shown in, for example, FIG. 79. When most, if not
all, injection-molded resins cool, there is some shrinkage of the
resin. The paperboard will not shrink at the same rate that the
injection-molded resin shrinks. This situation may be remedied by
sizing the paperboard blank to compensate for resin shrinkage.
[0452] The present invention addresses this problem by changing the
make-up of the paperboard 610 as shown in FIG. 97. This embodiment
shows the use of an extrusion laminated, or a polymer coated,
paperboard, and directs the injection-molded resin 612 to the
laminated or coated paperboard. The polymer 614 is a thermoplastic
material that will melt and reset itself into another position.
When the injection-molded resin is heated and attached to the
polymer surface, the polymer will also melt. As both the
injection-molded resin 612 and paperboard's polymer 614 cool
together they will set into the relatively the same positions. The
shrink rate of the polymers used for this product and the resins
for injection molding are very comparable. The polymer 614 that is
on the surface of the paperboard 610 repositions itself on the
paperboard to prevent a warped or "wavy" appearance. This method
works with any thermoplastic resin that bonds to the laminating
film 614 or coats the paperboard 610. As shown in FIG. 97,
according to this embodiment, the paperboard is not encapsulated.
Some adhesive laminated polymer films employing acrylic or PET
adhesive chemistry may not work in this instance, because they are
not of a sufficiently thermoplastic nature.
[0453] As shown to good advantage in FIGS. 38, 42, and 44, when
injection-molded resin is used to join adjacent sidewalls in, for
example, a five-panel tray 434, the injection-molded resin 456 may
extend past the exterior surface of the sidewalls. It may be
desirable for certain applications to prevent this from occurring,
thereby improving the appearance of the tray by placing or bonding
the injection-molded resin 456 only on the interior surface of the
tray 434. As shown in FIG. 45, for example, the injection-molded
resin 464 has been prevented from taking the configuration depicted
in FIG. 44, and it remains flush with the outside surfaces of the
panels comprising the tray. In FIG. 43, the mold has been modified
so that the polymer 458 takes a curved configuration as it joins
the outer surface of the panels comprising the sidewalls of the
tray. Finally, in the embodiment depicted in FIG. 98, the mold
cavity 620 has been modified to ensure that the injection-molded
resin remains inward of the outer surface of the panels 618
comprising the tray and, as shown in this figure, follows an
arcuate contour between adjacent tray panels. Further, as shown in
FIG. 98, the recessed area in the mold cavity 620 helps to ensure
that the injection-molded resin 616 stays to the inside of a
paperboard tray. This also permits the sidewalls of the tray to
slide into the mold until they seat properly in the recesses of the
mold cavity 620.
[0454] In the embodiment depicted in FIG. 98, the paperboard 618 is
not fully encapsulated. It may be desirable to avoid encapsulating
the paperboard when injection molding, for example, sealing and
locking mechanisms.
[0455] Additionally, the injection-molded resin may be impregnated
with glass or fiberglass fibers to assist in minimizing deformation
due to resin shrinkage. With glass-reinforced polymers, glass
fibers are chopped to a small size and mixed directly with the
polymer in a compounding step. When glass fibers of a particular
configuration (length and diameter combination) are added to the
polymer in a particular ratio, the glass-reinforced polymer
actually requires less pressure to flow through the tool. The glass
fibers change melt elasticity causing the combined material to be
less "stretchy." When the material is less "stretchy," it takes
less energy (pressure) to move the material through the mold.
However, even though less pressure may be required to inject resin
into the injection cavity, the resin flow is generally slower along
the cavity due to the embedded glass fibers.
[0456] On the other hand, if the wrong glass fiber length and
diameter combination is selected or if too much glass fiber is
added to the polymer, the performance in the tool degrades. (When
long fibers are used, that affects the flow of the polymer since
the long fibers cannot pass through the narrow channels in the
mold, which increases the cycle time for the production.)
Tool Deformation
[0457] Another aspect of the present invention involves the
formation of a tray 620 that is distorted or "overmolded" to
compensate for the shrink factor of the resin used for the
encapsulated rim. Such a tray is shown in FIG. 99. Generally, the
resin used for injection molding will experience some degree of
shrinking as the formed resin cools. The degree of shrinkage for a
particular resin is referred to as the "shrink factor." For
example, a high flow nylon 6/6 resin has an average shrink factor
of. 014 inch/inch (in/in) in the direction of flow for a 0.10 inch
thick formation under typical forming conditions.
[0458] Various embodiments of the present invention discussed
herein may employ any number of resins in the formation of an
encapsulated rim, whether precurved or not, such as amorphous
polymer and crystalline polymer type resins. The following table
illustrates some resins that may be employed in embodiments of the
present invention. The table also illustrates the shrink factor of
the resins, the melting temperature of the resins, and the heat
distortion temperature ("HDT") of the resins.
TABLE-US-00001 TABLE 1 Resins Melting Resin Shrink Factor
Temperature (F.) HDT (F.) Acylonitrile 0.003-0.009 425-500 180-195
Butadiene styrene ("ABS") Acetal 0.015-0.023 400-440 200-300
Acrylic 0.002-0.008 425-440 180-200 Nylon 6 0.01-0.025 450-550
250-300 Nylon 6/6 0.01-0.022 520-560 430-460 Polycarbonate
0.005-0.008 530-610 250-280 Polypropylene 0.009-0.029 375-525
220-250 Polyester PBT 0.017-0.023 480-500 250-300 Polyester PET
0.017-0.023 540-570 400-460 Liquid Crystal 0.003-0.005 640-680
530-580 Polymer
[0459] Other suitable resins include polystyrene, polyvinyl
chloride, styrene acrylonitrile, and polyethylene.
[0460] As discussed above, various embodiments of the present
invention involve an encapsulated rim or flange. In accordance with
one embodiment of the present invention, a tool is configured so
that an encapsulated rim or flange type tray 620 formed will have
distorted or curved sidewalls 622 and a distorted or curved
encapsulated rim 624. FIG. 99 is a top view of a tray having
outwardly deflected precurved sidewalls and an outwardly deflected
precurved rim. In this example, the tray includes an encapsulated
rim employing a nylon 6/6 resin. Without precurving the sidewalls,
a formed tray (after adding injection-molded features) may exhibit
somewhat inwardly curved sidewalls. To compensate for the inwardly
curved sidewalls and the shrink factor of the nylon 6/6 resin, in
one particular implementation, the sidewall and rim along the width
of the tray has an outward deflection of about 0.018 inches, and
the sidewall and rim along the length of the tray has an outward
deflection of 0.03 inches. Besides the shrink factor of the resin
used in the encapsulated rim and the inward deflection tendency of
the sidewalls, the amount of deflection of the sidewalls of the
tray also relates to the length of the sidewalls, the temperature
of the mold and the dwell time during formation, and other
factors.
[0461] In one embodiment, the tray 620 is not precurved, but
instead is biased into having curved sidewalls substantially like
those shown in FIG. 99 by bowing or curving the mating surfaces of
the core 604 and cavity 606 of the injection-molding tool 562
(either the tool shown in FIGS. 93-96 or in FIG. 76). When the tray
620 is press-formed in the injection-molding tool 562, the curved
tool surfaces impart the curvature of the mating surfaces to the
tray sidewalls 622. Such a method of biasing the tray sidewalls 622
is especially useful where the tray 620 is both press-formed and
provided with one or more injection-molded features 624 in a single
machine 562.
[0462] The paperboard material used to form the tray 620, and
particularly the sidewalls 622 of the tray, does not shrink when
removed from an in-mold press forming tool 562. However, the
polymer of the encapsulated rim 624 will experience some degree of
shrinkage depending on the shrink factor of the resin used. As the
encapsulated rim 624 cools and shrinks, it will deflect inwardly.
The encapsulated rim at least partially encompasses the paperboard
flange, and the paperboard flange is integral with outwardly
precurved paperboard sidewalls 622. Thus, as the encapsulated rim
624 deflects inwardly, it causes the inward deflection of the
outwardly precurved sidewalls 622. When the polymer forming the
encapsulated rim has cooled and is no longer shrinking, the
sidewalls 622 and rim 624 of the container 620 will be
substantially straight. Accordingly, the precurvature or bias
imparted to the tray sidewalls 622 offsets the warping or
deflection otherwise caused by the cooling, shrinking resin.
Blank Stabilization Using One Or More Articulated Sections
[0463] FIG. 160 is a schematic, cross-sectional view of a typical
prior art forming tool 1623 having a core 1625 (or punch) and a
cavity 1627 (or die). A gap is defined between the core and the
cavity. A tray would be inserted in the gap before the core is
moved toward the cavity to hold the blank during an
injection-molding process. Using the forming tool depicted in FIG.
160, it is possible that the tray may shift leftwardly or
rightwardly in FIG. 160 leading to potential problems. For example,
if the tray were to shift leftwardly in FIG. 160, the left flange
of the tray may end up longer than the right flange of the tray,
and the tray height may be affected. The invention described in
this section provides improved positioning of a paperboard blank or
formed tray onto the core of an injection mold, which has a tight
shutoff (clearance) in the upper area of the mold. It is desirable
to provide an articulated section or sections in the bottom of the
cavity to push the bottom area of a blank or preformed tray onto
the core of an injection-molding tool, which requires a tight upper
sidewall clearance.
[0464] FIG. 161 is a schematic, cross-sectional view of a forming
tool 1631 incorporating single stage cavity articulation. The
articulated section 1633 grabs the bottom and lower sidewall of the
tray 1635 as the core approaches the cavity, before the tray
becomes fully seated in the closed tool. This creates a more
positive way to position the tray in the tool. For example, since
press-formed trays have variable thicknesses in the pleats (e.g.,
plus or minus 30%), the tray may get shifted leftwardly or
rightwardly as the core pushes toward the cavity, depending upon
how the pleat thicknesses are distributed around the lower portion
of the tray. In the embodiment of FIG. 161, the articulated section
grabs the bottom and lower sidewall of the tray as the core
approaches the cavity. Thus, the articulated section depicted in
FIG. 161 allows more positive positioning of the tray in the tool,
which allows, for example, for more precise control of the tray
depth. Without being able to thus control the point in the closing
cycle when the tray is pinched, the tray may get pushed around,
which can cause asymmetrical flanges and lead to inconsistent tray
heights. If a tray flange shifts too far either leftwardly or
rightwardly (as shown in FIG. 161), it may be impossible to cover
the end of the flange with injected-resin material, resulting in
paperboard at the edge of the flange. In FIG. 161, the articulated
section pushes the blank on other core as the core approaches the
cavity. The articulated section subsequently descends to the bottom
of the cavity, possibly under the influence of a hydraulic-loaded
or spring-loaded system.
[0465] FIG. 162 is a schematic, cross-sectional view of a forming
tool 1637 incorporating a multi-stage cavity articulation. In this
embodiment, as the core 1639 approaches the cavity 1641, dual
articulation occurs. A first articulated section 1643 grabs only
the bottom, flat area of the tray 1645 as the core drives the tray
toward the cavity. This helps stabilize the tray's position in the
tool. As the core continues to travel toward the cavity, the first
articulated section travels downwardly, moving relative to a second
articulated section 1647. Upon sufficiently pressing the core
toward the cavity, the second articulated section eventually begins
to grab the lower portions of the sidewalls of the tray. Thus, the
tray is initially stabilized by the first articulated section and
then is further stabilized by the second articulated section. This
multi-stage cavity articulation results in more accurate tray
positioning within the tool.
[0466] FIG. 163 is a schematic, cross-sectional view of another
embodiment or forming tool 1649 according to the present invention.
This forming tool uses single-stage cavity articulation at the
bottom of the tray 1651 only. Thus, the articulated section 1657
depicted in FIG. 163 grabs the tray bottom as the core 1653 is
driven toward the cavity 1655, thereby stabilizing the tray in the
tool. In this embodiment, the articulated section in the female
cavity is larger (wider) than the bottom of the tray. When the mold
is fully closed, the side corners 1659 are not compressed, which
allow the tray to slightly bulge out at full closure.
[0467] By properly controlling the clearance, the shape of the
articulated section or sections, the downward force driving the
core toward the cavity, and the speed at which the core is driven
toward the cavity, among other parameters, it is possible to
accurately control the tray formation and subsequent
encapsulation.
Manufacture of a Reusable, Dishwasher Safe Package
Having a Paperboard Base and Susceptor Layer
[0468] The following steps may be performed to manufacture a
reusable, dishwasher safe package with a paperboard base and
susceptor layer: [0469] i) Laminate film (or extrusion coat
paperboard) on one side. The paperboard or film may be printed.
[0470] ii) Manufacture a susceptor film/foil structure (such as the
previously-mentioned MICRO-RITE structure) in the commercially
known process. [0471] iii) Laminate the susceptor film/foil
structure to the second side of the paperboard from step (1).
[0472] iv) Die cut a package blank from the step (3) material.
[0473] v) Optionally heat plasticize the step (4) blank. [0474] vi)
Fold or press-form the step (5) blank into a three-dimensional
package shape. [0475] vii) Injection-molded plastic that
encapsulates the unprotected edges of the step (6) package.
[0476] The resulting package is protected on both sides and along
all edges by a plastic film, coating, or injection-molded resin.
The plastic renders the paperboard moisture resistant and thus
dishwasher safe. Further, the susceptor layer imparts desired
focusing capabilities for microwave use.
Cored Encapsulated Flanges
[0477] In many cases, preventing resin from flowing to specific
areas of an encapsulated rim 630 or other feature may reduce the
overall weight of the finished tray, as well as aid in limiting
flex and movement of the encapsulated rim. This process is referred
to as "coring" the rim. Coring may be accomplished by adding one or
more raised spaces to portions of the shut-off walls 564 of the
tool 562. Generally, the raised spaces correspond to points 632
along the encapsulated rim where no resin is desired. The raised
portion of the injection-molding tool 562 wall prevents resin flow
to the portion of the tray 626,628 overlaid by the raised
portion.
[0478] FIGS. 100 and 101 depict two examples of trays 626, 628
having cored encapsulated rims 630.
Co-Extrusion
[0479] FIG. 174 depicts a folded-style, injection-molded polymer
paperboard composite package 1359 manufactured using a co-extrusion
injection-molded process for improved gas barrier properties.
[0480] In the co-extrusion injection molding process, multiple
polymer resins are separately melted and then extruded into a
manifold where they are combined for co-extrusion in laminar flow
fashion. The co-extrusion of laminar flow is directed from the
manifold to the injection mold cavity where the co-extrusion is
bonded to the paperboard forming the finished composite
container.
[0481] The co-extrusion laminar flow ensures that the barrier
polymer layer forms a continuous gas barrier at the joints and in
the flange area of the composite container, if it is shaped into a
tray configuration.
[0482] The individual polymer resins are selected for the
properties they contribute to the co-extruded polymer product.
Thus, at least one of the polymers is selected for its gas barrier
properties, for example, low permeability to oxygen and carbon
dioxide. Nylon 6, Nylon 6, 6, Polyvinylidene chloride, and ethylene
vinyl alcohol are examples of high oxygen barrier polymers. Other
polymers are selected for co-extrusion which have other properties,
such as increased adhesion to the gas barrier polymer, increased
adhesion to the paperboard, low temperature durability, high
temperature resistance, or low cost. Examples are polyolefins, such
as polyethylene or polypropylene. There are many known examples of
polymer co-extrusion combinations in the flexible film
industry.
Rounded Corners
[0483] Referring again to FIG. 174, aesthetic quality of the
composite injection-molded paperboard container 1359 can be
improved by providing smooth rounded injection-molded polymer
corners 1661. This is accomplished by adjusting the paperboard tray
blank by reducing the length of the upright wall panels 1663 to
less than the length of the adjacent bottom panel 1665. In addition
the corners of the bottom be can be radiused.
[0484] When the five-panel tray blank, previously discussed, is
held in a three-dimensional folded state inside the injection mold
tool, injection-molded polymer is formed into a tapering curve to
fill in the corner 1661 of the composite tray. A container thus
formed will have a smooth tapered corner as shown in FIG. 174,
which is aesthetically pleasing. A non-tapered version is also
possible. FIG. 175 is an enlarged, fragmentary cross-sectional view
of a portion of FIG. 174.
Supporting Ribs
[0485] Another type of injection-molded stiffening feature is
supporting ribs 1667 like those depicted in FIG. 176. In
particular, the structural integrity of packages 1669 like that
shown in FIG. 174 can be enhanced without compromising the
aesthetics of the package by placing injection-molded supporting
ribs on the inside of the package as shown in FIG. 176. As shown in
FIG. 177, the supporting ribs need not be visible from outside the
package. The injection-molded ribs will bond to the polymer film
1671 that has been laminated to the paperboard in the tray
interior. The combination of the injection-molded supporting ribs
and inside laminated film gives enough package strength to preclude
the use of a higher basis weight board. The use of a lower board
weight allows for a lower price package.
[0486] FIGS. 178-182 depict examples of cylindrical containers
1301, 1673 that can be made with the same technology. The
cylindrical container of FIG. 178 may include a connecting rib.
FIG. 182 is a cross-sectional view of the cylindrical container
1673 of FIG. 181, taken along line 182-182, and showing another
supporting rib 1304 bonded to a film 1306 affixed to the interior
of the paperboard container 1673.
Compartmented Trays
[0487] Multiple deep or steep food compartments that keep several
food items separated are difficult to make by press-forming a
paperboard container. Injection-molded dividers can be added to the
inside surface of a single-compartment container to divide it into
multiple compartments. These dividers can join an injection-molded
rim around the outer perimeter of the container.
[0488] By combining injection molding with paperboard lamination,
it is possible to create packages that have different
characteristics in different compartments of the same tray. FIGS.
184 and 185 depict an example of a compartmented tray 1675
according to the present invention. In the depicted tray, it is
unnecessary to use internal secondary packages 1677 like those
shown in the prior art compartmented tray 1679 depicted in FIG.
183. FIG. 183 is an open package revealing compartments including a
first compartment 1681 with curved sidewalls surrounding a
cylindrical, secondary container (e.g., a dip tub) within the first
compartment, and a second compartment 1683 having a soft-sided
secondary package (e.g., a chip bag) in it. In this prior art
package, where different compartments do not have different
characteristics, it is necessary to use internal secondary
packages, in this case the chip bag and the dip tub.
[0489] In the present invention 1675, each compartment 1685 can
include a microwave interactive material (e.g., susceptor laminated
paperboard) that is unique to the specific type of food to be
stored in that compartment of the container. Thus, a single
paperboard container could include a plurality of different
microwave interactive materials, each designed to most-effectively
heat the specific food item associated with it.
[0490] Finally, alternate embodiments may make use of interior
dividers 1687 without coating the entire interior surface in a
plastic. Rather, the interior dividers may be molded uniformly with
an encapsulated rim 1689. In this manner, many different types of
trays may include dividers. For example, a tray with an interior
susceptor layer, or a controlled microwave-heating layer, may also
have an interior divider. Further, the tray may have different
susceptors or susceptor thicknesses on each side of the divider,
thus changing the microwave heating characteristics to optimally
heat different types of food separated by the divider.
[0491] The number of films in the marketplace makes the potential
number of compartmented trays nearly endless. Also a hinged lid or
another lid (lids are discussed further elsewhere herein) could be
made of a lid film that matches the tray film.
Windows
[0492] FIG. 187 depicts a sample container 1375 with a pair of
windows 1691 in the tray lid.
[0493] Such windows could also be formed in the tray sidewall 1693.
All of the configuration depicted in FIGS. 186-190 could be
modified further by adding a window feature into the lid or
sidewall.
Incorporation of Eating/Serving Utensils
[0494] Another feature which may be incorporated to enhance
products made according to the present invention is depicted in
FIGS. 191 and 192. FIG. 191 is a plan view looking at the inside
surface of a lid 1695 that incorporates a two-piece, break-out
serving utensil 1697. As depicted in FIG. 191, the handle portion
1701 of the break-out spoon 1697 and the serving portion 1699 of
the break-out spoon can be directly incorporated into the container
lid. As shown in FIG. 192, which is a plan view of the outer
surface of the lid depicted in FIG. 191, a sealing film 1703 is
fixed over the break-out serving utensil to allow the container on
which the lid is placed for sale to a consumer to be hermetically
sealed. According to the lid embodiment depicted in FIGS. 191 and
192, injection-molded resin is used to create the primary lid
surfaces as well as the break-out serving utensil.
Easy-Opening Features
[0495] FIG. 193 depicts an easy-opening feature comprising an
extended tab 1705 on both the lid and tray. The lid's tab 1705 when
molded will have a lower caliper area 1707 as shown. When the
consumer lifts on the tab to open the container, the tab will bend
in this area and help impart a higher opening force on the sealed
area between the lid and tray, helping to release the lid from the
tray.
[0496] FIG. 194 is a cross-sectional view of the tab 1705 of FIG.
193, showing the score line 1709 defining the lower caliper area
1707.
[0497] FIG. 195 depicts a tray 1709 and lid 1711 sealing and
locking mechanism 1713, including an easy-open, raised sealing
ridge 1715 on the tray flange 1717. When the lid and tray are
pressed together to create the seal, the raised ridge acts as a
seal area limiter to help control the amount of surface area that
actually gets sealed. The amount of surface area that actually gets
sealed and the amount of opening force necessary to break that seal
are directly related. The easy-open, raised sealing ridge on the
tray flange results in a package that is easy to open, but yet
retains enough surface area on the flange to maintain a locking
mechanism and hermetic seal.
[0498] As shown in FIG. 196, injection-molded/paperboard composite
trays 1719 may look warped or distorted or have "wavy" sidewalls
1721 when finished or formed. This unappealing look can most likely
be explained by the differences in the inherent nature of
injection-molded resin and the paperboard. Currently, the design of
the tray preferably has the paperboard's edges 1723 encapsulated by
the injection-molded resin in the injection mold tool as shown in,
for example, FIG. 79. When most (if not all) injection-molded
resins cool there is some shrinkage of the resin. The paperboard
will not shrink at the same rate that the injection-molded resin
shrinks. Therefore, the "wavy" or distorted appearance seen in FIG.
196 results. The prior art attempts to remedy this situation by
sizing the paperboard blank to compensate for resin shrinkage.
[0499] The present invention addresses this problem by changing the
make-up of the paperboard as shown in FIGS. 97 and 198, which show
the use of an extrusion laminated, or a polymer coated, paperboard
1725 and directing the injection-molded resin 1727 to the laminated
or coated paperboard. As shown in FIG. 197, the resulting composite
tray is without distortion or a "wavy" appearance. The polymer is a
thermoplastic material that will melt and reset itself into another
position. When the injection-molded resin is heated and attached to
the polymer surface, the polymer will also melt. As both the
injection-molded resin and paperboard's polymer cool together they
will set into the relatively the same positions. The shrink rate of
the polymers used for this product and the resins for injection
molding are very comparable. The polymer that is on the surface of
the paperboard repositions itself on the paperboard to prevent the
warped or "wavy" appearance. This method works with any
thermoplastic material that bonds on the laminating film or coats
the paperboard. As shown in FIGS. 97 and 198, according to this
embodiment, the paperboard is not encapsulated. Most adhesive
laminated polymers employing acrylic or PET chemistry will not work
in this instance because they are not of a thermoplastic
nature.
[0500] As shown to good advantage in FIGS. 38, 42, and 44, when
injection-molded resin is used to join adjacent sidewalls in, for
example, a five-panel tray, the injection-molded resin may extend
past the exterior surface of the sidewalls. It may be desirable for
certain applications to prevent this from occurring, thereby
improving the appearance of the tray by placing or bonding the
injection-molded resin only on the interior surface of the tray. As
shown in FIG. 45, for example, the injection-molded resin has been
prevented from taking the configuration depicted in FIG. 44, and it
remains flush with the outside surfaces of the panels comprising
the tray. In FIG. 43, the mold has been modified so that the
polymer takes a curved configuration as it joins the outer surface
of the panels comprising the sidewalls of the tray. Finally, in the
embodiment depicted in FIG. 98, the mold cavity has been modified
to ensure that the injection-molded resin remains inward of the
outer surface of the panels comprising the tray and, as shown in
this figure, follows an arcuate contour between adjacent tray
panels. Further, as shown in FIG. 98, the recessed area in the mold
cavity helps to ensure that the injection-molded resin stays to the
inside of a paperboard tray.
[0501] In the embodiment depicted in FIG. 98, the paperboard 1731
is not fully encapsulated. It may be desirable to avoid
encapsulating the paperboard when injection molding sealing and
locking mechanisms. For example, in the sealing and locking
mechanism depicted in FIG. 195, the paperboard has been
encapsulated. Similarly, as shown in FIG. 201, the paperboard 1733
comprising the lid 1735 has been encapsulated. In the embodiment
1737 depicted in FIG. 202, on the other hand, the injection-molded
feature 1739 on the lid 1741 does not encapsulate the paperboard
1743 comprising the lid. Rather, the injection-molded feature has
been moved to the lower surface 1745 of the lid and has been moved
inward of the outer end of the lid to provide a mold clamp off
area. Similarly, on the flange 1747 of the tray depicted in FIG.
202, the injection-molded feature 1749 sits on the upper surface of
the flange, away from the outer edge of the tray, to again provide
a mold clamp off area. The flange and clamp-off features are needed
to ensure that the position of the injection-molded resin is proper
in relation to the paperboard. FIG. 203 depicts an alternative
embodiment 1751 wherein an injection-molded piece 1753 is again
attached to the lower surface of the lid 1755, and a complimentary
injection-molded piece 1757 is attached to the flange portion 1759
of the tray. When the lid is pressed downward in FIG. 203, the
bottom portion of the injection-molded piece attached to the under
surface of the lid extends below the flange of the tray, and a
protruderance on the inward surface of the injection-molded piece
attached to the under surface of the lid locks into a complimentary
indented region on the outer facing surface of the injection-molded
piece attached to the upper surface of the tray flange. A seal is
thus affected between the lower surface of the lid and the upper
surface of the injection-molded piece attached to the tray
flange.
[0502] FIGS. 204-235 depict a folded, paperboard tray 1761 that has
a flange 1763 extending outwardly from the sidewall 1765. The
addition of this outwardly-folded flange enhances the ability to
injection mold an encapsulated rim 1769 onto the tray. The
injection mold tool clamps onto both sides of the outwardly-folded
paperboard flange, which permits more efficient control of the flow
of molten polymer. FIGS. 209-213 depict an alternate embodiment
1767 of the tray 1761 shown in FIGS. 204-208. FIGS. 214-216 depict
trays 1761, similar to those shown in FIGS. 204-208, nested within
one another. The encapsulated rim 1769 may enhance denesting
operations.
[0503] In the embodiments depicted in FIGS. 202, 203, and 204-235,
the folded tray may be composed of any type of paperboard (e.g.,
SBS, SUS, Kraft, CRB), printed or plain, that is adhesively
laminated or extrusion coated with a polyolefin material or any
other material such as paper, another paperboard, CPET, or the
like.
Venting Feature
[0504] According to yet another embodiment of the present
invention, a venting feature 1771 like that depicted in FIGS. 199
(in top view) and 200 (in partial cross-section) may be
incorporated into the package 1773. In this embodiment, a recessed
area or micro channel is formed in the flange 1775 to allow for
pressure equalization of the package. This recessed area may be
clearly seen in FIG. 199, which is a plan view looking downwardly
on a tray incorporating this venting feature. As depicted in FIG.
200, which is a fragmentary, cross-sectional view of the portion of
the flange that incorporates the venting feature, the mold included
a protruding portion that prevented resin from being deposited
during the injection-molded process at this location on the flange.
Thus, once a lid film is attached to the completed tray, an opening
from the inside of the tray to the outside of the tray remains
present. This venting feature makes it possible for the pressure in
the package to equalize with the atmospheric pressure when the
package is being transported over a mountain pass, for example. The
venting feature includes one or more micro channels in the flange,
each configured to permit gas pressure equalization and to prevent
liquid leaks from the package.
[0505] FIGS. 217-221 depict a lid 1777 having a pull tab 1779
formed by injection-molded resin. The pull tab may facilitate
removing the lid from a tray 1781 (shown in FIG. 22), where the lid
encloses an encapsulated feature 1783 such as a protrusion defined
in the lid (FIG. 219), or nests within a channel on the tray. FIG.
219, for example, is a detailed view of the end of the pull tab.
FIG. 220 is an end view of the lid showing the pull tab, while FIG.
221 is a side view of the lid.
[0506] FIGS. 222-228 depict the aforementioned lid 1777 and pull
tab 1779 affixed to a tray 1781. For example, FIG. 222 is an
isometric view showing the pull tab projecting outwardly from the
lid and extending beyond a sidewall of the tray. FIG. 225 is a
detail view of the lid enclosing the encapsulated flange of the
tray, and a male protrusion nesting within a receiving channel
within the flange.
[0507] FIGS. 229-235 depict the aforementioned lid 1777 and pull
tab 1779 affixed to a second tray 1783 of differing depth.
General Remarks
[0508] The trays used in the above embodiments may be formed by a
variety of methods, including folding, press-forming, and injection
molding.
[0509] The present invention can be used to make a broad range of
containers, including deep, rectangular containers for frozen
foods; shallow round trays (e.g., pizza trays); disposable paper
plates; and cylindrical containers or cups.
[0510] In all of the above applications and embodiments, the
plastic used is selected with the end use service temperature of
the tray in mind. For example, trays intended for food preparation
in a conventional oven could use a PET polyester rim, and trays
intended for use at room temperature could use a high-density
polyethylene rim.
[0511] Further, for a tray to be heated in a conventional or
microwave oven, the tray material and the encapsulated rim must be
heat resistant to a high temperature. Generally, both the tray and
encapsulated rim, when accompanied by a food load, may withstand
temperatures up to about 425.degree. F. for approximately thirty
minutes without charring, warping, or losing structural integrity.
Where a tray is intended for use in a microwave oven, a metallic
susceptor layer may be added to the interior of the tray to focus
microwave radiation on certain portions of the contents, thus
speeding up the cooking process. Also, interactive foil circuits
(e.g., aluminum circuits) may comprise part of the tray to control
microwave power distribution in foods. Examples of metallic
susceptor layers include the QWIK-WAVE and MICRO-RITE products
available from Graphic Packaging Corporation of Golden, Colo.
Alternate embodiments may have different heat tolerances, depending
on the final application intended for the embodiment.
[0512] Generally, the encapsulated rim features discussed above are
made of a polyolefin, such as polyethylene or polypropylene; nylon;
polyester; polycarbonate; or other engineering grade resin. In some
embodiments described above, the injected material also may be
nylon. Nylon is used due to its relatively inexpensive
manufacturing costs (e.g., nylon is cheaper than polyester) and its
ability to survive in high temperatures, such as those found in a
conventional oven. In other embodiments herein described, a
polyvinyl dichloride such as SARAN may be used. In yet other
embodiments, other barrier materials, such as EVOH, may be
employed, or a mixture of barrier materials may be used. By
creating a flange, tray lining, or partial tray encapsulation as
well as a fitted lid or film containing SARAN or another polyvinyl
dichloride, a package having good hermetic sealing capabilities may
be achieved through the intermolecular mixing of the encapsulating
and lidding materials. In yet other embodiments that will be
subjected to high heat, polyester may be used. In still other
embodiments, such as those intended for microwave use,
polypropylene is used as the encapsulating or injection-molded
material.
[0513] Further, high-stiffness resins, including glass-reinforced
(or glass-fiber stiffened) polymers, may be used as the injectant,
providing at least the following several benefits:
[0514] (1) reinforcement-glass-reinforced polymers are stiff for
their weight and volume;
[0515] (2) stronger part with less part weight;
[0516] (3) the injectant flows better in the tool, better
distributing itself in a shorter cycle time;
[0517] (4) glass-reinforced polymers reduce part shrinkage and
warpage on cooling (NB: the prior art, which recognized the problem
of warpage on cooling, used predistortion of the mold and other
techniques to accommodate or account for shrinkage and warping.
Thus, they recognize the problem but address it differently);
[0518] (5) they are approved for food contact;
[0519] (6) they are GRAS (generally recognized as safe);
[0520] (7) they are ovenable (conventional or microwave); and
[0521] (8) they can be combined with polypropylene, nylon,
polyethylene, and other polymers.
[0522] Alternate materials may be used to either construct the tray
or flange, or to create the encapsulated rim, without departing
from the spirit or scope of the present invention. For example, a
metallic susceptor may be used to construct a microwave tray, while
a temperature-resistant material might be used to form an ovenable
tray. Similarly, different types of plastic, such as nylons or
polyesters, may be used to create the encapsulated rim. The
encapsulated rim may be of any color desired, or may be clear or
translucent.
CONCLUSION
[0523] As can be seen, the present invention provides many
advantages over the prior art. Additional embodiments and
advantages will occur to those skilled in the art upon reading this
disclosure. Further, the present invention may be modified in many
different ways without departing from the spirit or scope of the
invention as set forth in this disclosure. For example, different
tray shapes may be used, or different materials employed, to create
the tray body or the rim feature. As an additional example, the
encapsulated rim may be provided with a step or groove located on
the top or bottom surfaces or the outer edge in order to provide a
secure seal with a similarly-shaped lid. Accordingly, the scope of
the invention is properly defined by the claims set forth
below.
* * * * *