U.S. patent application number 14/576343 was filed with the patent office on 2015-04-16 for methods of making containers.
The applicant listed for this patent is MeadWestvaco Corporation. Invention is credited to Barry G. CALVERT, Christopher J. PARKS.
Application Number | 20150101747 14/576343 |
Document ID | / |
Family ID | 42370927 |
Filed Date | 2015-04-16 |
United States Patent
Application |
20150101747 |
Kind Code |
A1 |
PARKS; Christopher J. ; et
al. |
April 16, 2015 |
METHODS OF MAKING CONTAINERS
Abstract
A hermetically sealed container is disclosed that may be
produced by an effective and economical process for an in-plant
system. The container comprises a coated unitary tray component
having a base portion, a side wall portion, and a flange portion;
and a lid component hermetically sealed to the flange portion of
the tray component. A selected composite polymer film is
blow-molded onto an interior surface of the pre-shaped unitary tray
structure to provide the coated unitary tray component having its
interior surface seamlessly, creaselessly and integrally bonded
with the polymeric film.
Inventors: |
PARKS; Christopher J.;
(Ellicott City, MD) ; CALVERT; Barry G.;
(Covington, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MeadWestvaco Corporation |
Richmond |
VA |
US |
|
|
Family ID: |
42370927 |
Appl. No.: |
14/576343 |
Filed: |
December 19, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13266183 |
Oct 25, 2011 |
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PCT/US10/36014 |
May 25, 2010 |
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14576343 |
|
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61180943 |
May 26, 2009 |
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Current U.S.
Class: |
156/287 |
Current CPC
Class: |
B29C 2049/2017 20130101;
B29C 49/22 20130101; B29C 2049/2429 20130101; B65D 2565/388
20130101; B29L 2031/712 20130101; B29C 2791/007 20130101; B29C
49/20 20130101; B65D 25/36 20130101; B65D 77/20 20130101; B65D
2577/2025 20130101; B29C 49/24 20130101; B29C 2049/2404
20130101 |
Class at
Publication: |
156/287 |
International
Class: |
B65D 25/36 20060101
B65D025/36 |
Claims
1-7. (canceled)
8. A method of producing a hermetically sealed container,
comprising: providing a pre-shaped unitary tray structure having
interior and exterior surfaces and an internal space to contain
packaged goods, the pre-shaped structure comprising: a base
portion; a side wall portion extending upward from the base
portion; and a flange portion extending peripherally from the side
wall portion; inserting the pre-shaped unitary structure against a
blow mold cavity wall; extruding a blow mold parison of polymeric
film into the blow mold cavity; blowing the polymeric film against
the interior surface of the pre-shaped unitary tray structure to
seamlessly, creaselessly, and integrally bond the polymeric film to
the interior surface of the pre-shaped unitary tray structure,
creating a coated unitary tray component; and hermetically sealing
a lid component to the flange portion of the coated unitary tray
component.
9. The method of claim 8, wherein providing the pre-shaped unitary
tray structure further comprises providing a pre-shaped unitary
tray structure made from paperboard.
10. The method of claim 8, forming the pre-shaped unitary tray
structure using a press-molding process.
11. The method of claim 8, wherein blowing the polymeric film
further comprises blowing a polymeric film comprising a polymer
selected from a group consisting of PET, LDPE, nylon, EVOH,
polypropylene, and combinations thereof.
12. The method of claim 8, wherein the lid component comprises a
polymer including PET polymer.
13. The method of claim 8, further comprising depositing a
heat-sealable layer onto at least a portion of the flange portion
of the coated unitary tray component prior to hermetically sealing
the lid component to the flange portion of the coated tray
component.
14. (canceled)
15. A method for producing a container, comprising: forming a
pre-shape unitary tray structure comprising an interior surface;
blow-molding a polymer film over the interior surface of the
pre-shape unitary tray structure;
16. The method of claim 15, wherein forming the pre-shape unitary
tray structure comprises forming the pre-shape unitary tray
structure from a material selected from the group consisting of
paper, paperboard, cardboard, fiberboard, paper/plastic composites
and aluminum.
17. The method of claim 15, wherein forming the pre-shape unitary
tray structure comprises forming the pre-shape unitary tray
structure from paperboard having a thickness between 250 micron and
750 micron.
18. The method of claim 15, wherein forming the pre-shape unitary
tray structure comprises forming the pre-shape unitary tray
structure using a press-molding process.
19. The method of claim 15, wherein forming the pre-shape unitary
tray structure comprises forming a pre-shape unitary tray structure
comprising fillet corners.
20. The method of claim 15, further comprising filling the
pre-shape unitary tray structure with a food-stuff.
21. The method of claim 20, further comprising adhering a lid to
the pre-shape unitary tray structure.
22. The method of claim 21, wherein adhering a lid to the pre-shape
unitary tray structure further comprises adhering a sealing film to
the pre-shape unitary tray structure about the flange portion.
23. The method of claim 21, wherein adhering a lid to the pre-shape
unitary tray structure further comprises creating a hermetic seal
between the lid and the pre-shape unitary tray structure.
24. A method for producing a container [for foodstuffs],
comprising: press-molding a pre-shape unitary tray structure, the
pre-shape unitary tray structure comprising: a base portion; side
wall portions extending up from the base portion; a flange portion
extending peripherally from the side wall portions; and wherein the
base portion and side wall portions define an interior surface of
the pre-shape unitary tray structure; blow-molding a polymer film
onto the interior surface and flange portion of the pre-shape
unitary tray structure; and trimming the polymer film coated flange
portion of the pre-shape unitary tray structure.
25. The method of claim 24, wherein the pre-shape unitary tray
structure further comprises a fillet between the side wall portions
and the base portion.
26. The method of claim 24, wherein the pre-shape unitary tray
structure further comprises a round transition between the side
wall portions and the flange portion.
27. The method of claim 24, wherein blow-molding a polymer film
onto the interior surface and flange portion of the pre-shape
unitary tray structure further comprises: inserting the pre-shaped
unitary tray structure against a blow mold cavity wall; extruding a
blow mold parison of polymeric film into the blow mold cavity; and
blowing the polymeric film against the interior surface and flange
portion of the pre-shape unitary tray structure.
28. The method of claim 24, further comprising hermetically sealing
a lid component to the polymer film on the flange portion of the
pre-shape unitary tray structure.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application relies on the filing date
of U.S. Provisional Application Ser. No. 61/180,943 filed on May
26, 2009, the entire contents of which are incorporated herein by
reference.
BACKGROUND OF THE DISCLOSURE
[0002] To preserve products such as fresh foods, it is desirable to
package these products in air-tight or hermetically sealed
containers. This prevents the ingress of gasses, liquids and solids
that could otherwise degrade or spoil the products. Such packaging
container typically comprises a thermoformed tray made of plastic
polymer and a lid made of heat-sealable plastic film, wherein the
plastic polymer contributes to both barrier and structural
properties of the finished container. Paperboard has been widely
used as a packaging material due to its low cost and
biodegradability. However, paperboard has poor barrier properties
and requires at least one barrier layer to impart barrier
performance.
[0003] U.S. Pat. No. 5,009,939 discloses a gas-tight container made
of a folded paperboard structure that is blow-molded with a barrier
film. The paperboard blank with scored fold lines (as shown in FIG.
1A) is folded and erected into a container structure. Then, the
formed container is secured by bonding the overlapped flaps of the
blank (as shown in FIG. 1B). Subsequently, the folded container
structure is inserted into a molding element of a blow-molding
machine, wherein a thermoplastic polymer structure is blow-molded
and deposited seamlessly and creaselessly onto the container
structure. The resulting composite container is then filled with
the products to be packaged, and a sealing film is sealed to the
flange edge of the container to preserve the products therein.
Although these composite containers exhibit satisfactory sealing
and barrier properties, their uses for hermetic packaging
applications still need significant improvement from the packaging
performance aspect, as well as from the efficiency and practicality
of production process aspect. For the packaging performance aspect,
the container structure formed from folding of paperboard blank
contains many overlapped seams that prevent the complete sealing
which is a critical requirement for hermetic packaging
applications. For the production process aspect, a proper insertion
of the folded container structure into the molding element and
retention of the folded container structure once disposed within
the molding element are needed for effective production and these
requirements demand substantial supervision.
[0004] UK Patent Application No. GB 2 155 770 discloses a
gas-impermeable container comprising a molded rigid porous tray
having a gas-impermeable composite plastic coherently bonded to the
inner surface of the tray, and a lid comprising a gas-impermeable
composite plastic secured around the rim of the container. The
gas-impermeable composite plastic comprises of three layers: a
layer made of gas-impermeable thermoplastic polymer sandwiched
between two layers of ionomeric polymeric materials. The
gas-impermeable composite plastic is coated onto the inner surface
of the tray by drawing-down or vacuum-forming techniques.
[0005] Another known container suggested for hermetically sealed or
gas-tight applications utilizes a paperboard sheet that is
pre-coated with a polymer film using an extrusion process. After
being coated, the paperboard is then pressed to form a container
structure. Such containers comprise creases or pleats, and in these
regions, the polymer film of the pre-coated paperboard will follow
the valleys of the creases or pleats and cause gaps or channels
between sealing film and tray flange. This particular drawback is
addressed in the U.S. Pat. No. 6,651,874. A cardboard blank is
first surface-coated with a gas barrier coating, and then the
pre-coated blank is pressed into the tray cardboard structure.
During the press forming process, the cardboard layer and the soft
weld coating layer melt together by means of heat or friction so
that the valleys of the creases or pleats on the pressed cardboard
structure are smoothed out, allowing the cardboard and coating
layers to be welded together in a gas-proof manner.
[0006] There is still a need for hermetically sealed containers
with enhanced barrier and seal performances that may be produced by
a process that is more effective and economical for the in-plant
system.
SUMMARY OF THE DISCLOSURE
[0007] A hermetically sealed container is disclosed that may be
produced by an effective and economical process for an in-plant
system. The container comprises a coated unitary tray component
having a base portion, a side wall portion, and a flange portion;
and a lid component hermetically sealed to the flange portion of
the tray component. A selected composite polymer film is
blow-molded onto an interior surface of the pre-shaped unitary tray
structure to provide the coated unitary tray component having its
interior surface seamlessly, creaselessly and integrally bonded
with the polymeric film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1A shows a pictorial view of the paperboard blank
disclosed in the U.S. Pat. No. 5,009,939
[0009] FIG. 1B shows a pictorial view of the fold-erected tray
formed from the paperboard blank of FIG. 1A, as disclosed in the
U.S. Pat. No. 5,009,939;
[0010] FIG. 2A is a perspective view from the bottom and side views
of one embodiment of the pre-shaped unitary tray structure showing
base portion 18, side wall portions 16a and 14a, and flange portion
12; and
[0011] FIG. 2B is a close-up view of an inner side of the flange
portion 12 shown in FIG. 2A.
[0012] FIG. 3 shows a schematic cross-section of one embodiment of
the pre-shaped, coated unitary tray component;
[0013] FIG. 4 illustrates a schematic cross-section of one
embodiment of the disclosed hermetically sealed container wherein
the pre-shaped, coated unitary tray component is sealed with the
lid component; and
[0014] FIG. 5 shows a schematic cross-section of one embodiment of
the disclosed pre-shaped, coated unitary tray component.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0015] The present disclosure now will be described more fully
hereinafter, but not all embodiments of the disclosure are
necessarily shown. While the disclosure has been described with
reference to exemplary embodiments, it will be understood by those
skilled in the art that various changes may be made and equivalents
may be substituted for elements thereof without departing from the
scope of the disclosure. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the disclosure without departing from the essential scope
thereof.
[0016] The hermetically sealed container of the present disclosure
comprises: [0017] (A) a coated unitary tray component, comprising:
[0018] (a) a pre-shaped unitary tray structure having an interior
and exterior surfaces, and including: [0019] (i) a base portion,
[0020] (ii) a side wall portion extending upward from the base
portion, and [0021] (iii) a flange portion extending peripherally
from the side wall portion; [0022] (b) a composite polymer film
blow-molded onto the interior surface of the tray structure such
that the composite polymer film is seamlessly, creaselessly, and
integrally bonded to the interior surface of the tray structure;
and [0023] (B) a lid component hermetically sealed to the flange
portion of the coated unitary tray component.
[0024] The term "pre-shape unitary tray structure" refers to a
unitary and intact structure that, once formed, does not require
any external influence to maintain the structure in its intact and
usable state.
[0025] Various known packaging materials may be used for forming
the pre-shaped unitary tray structure. Examples of such materials
include, but are not limited to, paper, paperboard, cardboard,
fiberboard, plastic, laminates, paper/plastic composites,
polystyrene foam, polymeric foam, and aluminum. Furthermore, the
packaging material may be pre-treated prior to formation of the
unitary tray structure. For example, when paperboard is used for
the pre-shaped unitary tray structure, the paperboard may be
extrusion coated with a selected material before being formed into
the tray structure. Alternatively, in some embodiments, the
paperboard may be uncoated when being formed into the tray
structure. In one exemplary embodiment, the unitary tray structure
is formed from a clay-coated SBS (solid bleached sulphate) sheet of
paperboard having an approximately thickness of 0.45 mm (0.018''),
with the clay-coated side providing the exterior surface of the
tray and the non-coated side providing the interior surface of the
tray.
[0026] It will be understood that in other embodiments of the
present disclosure the nature and material properties of the
packaging materials used for forming the pre-shaped unitary tray
structure may be modified and optimized according to the end use
applications of the hermetically sealed container. The thickness of
the materials used for formation of the unitary tray structure may
be varied depending on the end use and desired properties of the
disclosed hermetically sealed container. For example, when
paperboard is used for the pre-shaped unitary tray structure, the
thickness of the paperboard may be selected to satisfy the rigidity
and durability requirements of the final container. When desired,
the paperboard with a thickness range of 250 micron (10 mils) and
750 micron (30 mils) may be used.
[0027] The disclosed containers may be in numerous shapes and
formats. Examples of container shapes may include, but are not
limited to, round shape, rectangular shape with round corner,
elliptical shape, and oval shape.
[0028] In one embodiment, the packaging material may be formed into
the pre-shaped unitary tray structure by press-molding process.
However, other known techniques for the formation of tray structure
may be used. When desired, the pre-shaped unitary tray may be
molded in a shape that comprises round or fillet corners rather
than sharp creased joints.
[0029] FIG. 2A illustrates one exemplary embodiment, shown from the
bottom and side views, of the pre-shaped unitary tray structure
formed from a press-molding process. The pre-shaped unitary tray
structure 10 comprises a base portion 18, side wall portions 14 and
16 extending upward from the base portion 18, and a flange portion
12 extending peripherally from the side wall portions 14 and 16. In
one exemplary embodiment, the transition between the base portion
18 and side wall portions 14 and 16, as viewed from the inside of
the disclosed container, is a fillet. In one exemplary embodiment,
the transition between the side wall portions 14 and 16 and the
flange portion 12, as viewed from the inside of the container, is a
radius or round. When desired, the transitions between the base
portion 18, side wall portions 14 and 16, and flange portion 12 may
be a round-shaped structure to further enhance the effective
coating of the composite polymer layer 20 on to the pre-shaped
unitary tray structure 10.
[0030] FIG. 2B shows the flange portion 12 of the pre-shaped
unitary tray structure 10 in details. The flange portion 12
comprises manufacturing pleats or creases `C` that could represent
a weakness in the hermetic sealability of the disclosed container.
This weakness may be minimized, if not completely eliminated, when
the pre-shaped unitary tray structure 10 is effectively, seamless,
creaseless and integrally bonded with a selected composite polymer
layer using the blow-molding process disclosed in the present
application.
[0031] FIG. 3 illustrates one embodiment of the disclosed coated
unitary tray component, shown as a cross-section view. The coated
tray component comprises a pre-shaped unitary tray structure 10
having its interior surface blow-molded with a composite polymer
film 20. In one embodiment, the polymer film 20 may be disposed
onto the interior surface of the container 10 by a blow-molding
process. The polymer film 20 may extend beyond the extent of the
flanged portion 12 of the container. As illustrated, the polymer
film 20 and optionally a portion of the flanged portion 12 may be
trimmed at point `T` to leave a clean-cut edge of the container. In
this way, the polymer film coating 20 may be applied up to the very
outermost edge of the flanged portion 12. FIG. 4 shows the coated
unitary tray component 10 being hermetically sealed with a lid
component 22.
[0032] Due to the blow-molding process of disposing the polymer
film 20 onto the interior surface of the pre-shaped unitary tray
structure 10, the thickness of polymer film 20 across the interior
surface may not be uniform. Other processing techniques for
depositing the polymer layer may result in more uniform and less
varied polymer film thickness across the surface of the tray
structure 10. For the purposes of hermetic sealing, it may be less
important that the polymer film 20 is applied in a homogenous
manner and more important that the polymer film covers the tray
structure 10 in the areas where the tray structure 10 in itself is
or will not be gas-tight once sealed. It is also important that the
polymer film 20 covers the flange portion 12 for enabling a
hermetic seal to be created between the tray structure and a lid
component of sealing film 22. As shown in FIG. 2B, many creases `C`
are present
[0033] In one embodiment, the composite polymer film 20 may be a
co-extruded material and melted at an approximate temperature of
490.degree. F. for blow-molding process onto the interior surface
of the pre-shaped unitary tray structure 10. In other embodiments,
rather than using a co-extruded polymer film 20; a composite
polymer film 20 may be disposed onto the interior of the pre-shaped
unitary tray structure 10 by sequentially blow-molding of one
polymer layer after the others.
[0034] FIG. 5 shows one exemplary embodiment of the composite
polymer film suitable for use to coat the interior surface of the
pre-shaped unitary tray structure 10. The composite polymer film 20
comprises four layers, beginning from closest to the tray structure
10, these layers are: a tie layer 21, a low-density polyethylene
(LDPE) layer 23, a tie layer 21, and a polyethylene terephthalate
(PET) layer 25. In one embodiment, these layers (tie layer/LDPE/tie
layer/PET) may make up approximately 10%, 50%, 5% and 35% of the
polymer film composition. In one embodiment, the composite polymer
layer may have a thickness of approximately 0.1 mm (4 mils).
[0035] In other embodiments, the composite polymer film 20 may
comprise any number of layers from a single layer to a multiple
layer composition. If desired, a tie layer may be positioned
between these polymer layers to aid adhesion of one polymer layer
to another and to aid adhesion of one polymer layer to the
pre-shaped unitary tray structure. When appropriated, the tie layer
may offer an additionally benefit in that it imparts a removable
bond between the composite polymer film and the pre-shaped unitary
tray structure such that the two parts may be separated for
recycling purposes after use.
[0036] It will be understood that the composite polymer film for
the interior coating of the unitary tray structure may be modified
and optimized to accommodate the desired packaging performance. The
composite polymer film may include a variety of polymers. Examples
of these polymers include, but are not limited to, PET, LDPE,
nylon, poly ethylene-vinyl alcohol copolymer (EVOH), polypropylene,
and combinations thereof.
[0037] Various composite polymer films may be used in the disclosed
hermetically sealed container. Examples of such composite polymer
compositions include, but are not limited to, tie layer/PET; tie
layer/LDPE/tie layer/PET; tie layer/EVOH/tie layer/PET; tie
layer/nylon/tie layer/PET; tie layer/LDPE/tie layer/EVOH/tie
layer/PET; tie layer/LDPE/tie layer/nylon/tie layer/PET; tie
layer/nylon/tie layer/EVOH/tie layer/PET; tie layer/EVOH/tie
layer/nylon/tie layer/PET. When desired such as for the non-dual
ovenable applications, polypropylene could be substituted for the
PET in any of the exemplary compositions provided above.
[0038] After the composite polymer film is applied to the
pre-shaped unitary tray structure and optionally after the trimming
of the excess flange portion, the coated unitary tray component may
be shipped to a converting plant where the coated unitary tray
component may be loaded with articles to be packaged, such as fresh
food-stuffs or personal care items. At the converting plant, a lid
component 22 may be affixed to the coated flange portion of the
coated unitary tray component. Several known techniques may be used
to seal the lid component to the coated unitary tray component.
Examples of such techniques include, but are limited to, adhesion
bonding, mechanical fastening, or combinations thereof.
[0039] In one embodiment, the lid component may be adhered to the
flange portion of the coated unitary tray component by heat-sealing
process. The lid component may be made of heat sealable materials.
When desired, at least a flange portion of the coated unitary tray
component may be additionally coated with heat sealable materials
to further enhance the sealing performance.
[0040] In one exemplary embodiment, the lid component may be made
of PET polymer. When desired, the lid component may be coated with
heat-seal coating composition to enhance the sealing performance of
the lid component and the unitary tray component. Examples of such
coated films include, but are not limited to, Mylar.RTM. OL and
Mylar.RTM. RL heat-sealable polymer films. Both exemplary
heat-sealable polymer films are commercially available from
DuPont-Teijin Films. In other embodiments of the disclosure, the
lid component may be made of PET with additional barriers applied
and with or without a heat seal coating applied. When appropriate
such as for non dual-ovenable applications, non-PET sealing film
may be used for the formation of the lid component. It will be
understood that the selection of sealing film compositions for the
lid component depends on package requirements. Many polymers and
other plastics materials are known in the art for sealing
performance, and the specific polymer materials listed in this
specification are provided as examples only.
[0041] Once the lid component is applied to the loaded unitary tray
component, a hermetically sealed package containing preserved
article is produced. The exact nature of the seal created depends
upon the application of the container. For food articles, it may be
required that the unitary tray and the lid components impermeable
to critical volumes of gases that could cause degradation of the
packaged product within an unacceptable time scale. Throughout the
present disclosure, the term "hermetic seal" is used to refer to
any sufficiently leak-free or any sufficiently airtight seal that
will offer suitable protection of the packaged products. As such,
the terms "hermetic seal" and "hermetically sealable" are used to
cover any perfect seal as well as any seal comprising microscopic
leaks or imperfections that are small enough not to cause
unsatisfactory degradation of the packaged products and are
approximately of the same order of magnitude as the permeation
through the packaging materials.
[0042] In one embodiment, the disclosed container further includes
a top cover positioned over the lid component to impart rigidity
and sturdiness to the lid component and consequently the disclosed
container. The top cover may be made of a rigid or semi-rigid
material. For example, the top cover may be made of paperboard. In
one embodiment, the top cover may be adhered to the lid component
by heal sealing process. When desired, heat sealable materials may
be coated to at least the rim portion of the top cover to enhance
the heat seal adhesion between the top cover and the lid
component.
[0043] In one embodiment, the disclosed hermetically sealed
container may be produced by a process comprising steps of: [0044]
(1) providing a pre-shaped unitary tray structure having an
interior and exterior surfaces and an internal space to contain
packaged goods, the pre-shaped structure including: a base portion,
a side wall portion extending upward from the base portion, and a
flange portion extending peripherally from the side wall portion;
[0045] (2) inserting the pre-shaped unitary structure against a
blow mold cavity wall; [0046] (3) extruding a blow mold parison of
polymeric film into the blow mold cavity; [0047] (4) blowing the
polymeric film against the interior surface of the unitary tray
structure to seamlessly, creaselessly, and integrally bond the
polymeric film to the interior surface of the unitary tray
structure creating a coated unitary tray component; and [0048] (5)
hermetically sealing a lid component to the peripheral flange
portion of the coated unitary tray component.
[0049] When desired to further enhance the sealing performance, a
layer of heat-sealable coating may be applied at least onto the
flange portion of the coated unitary tray component prior to the
hermetic sealing of the lid component.
[0050] It will be understood that the specific embodiment described
represents only some examples of how the present disclosure may be
put into effect. One skilled in the art will readily recognizes
that many variations in the materials used, material combinations,
material properties, as well as size and shape of container are
possible.
[0051] It will be recognized that as used herein, directional
references such as "top", "bottom", "front", "back", "end", "side",
"inner", "outer", "upper" and "lower" do not limit the respective
panels to such orientation, but merely serve to distinguish these
panels of the container from one another.
[0052] While the disclosure has been described by reference to
various specific embodiments, it should be understood that numerous
changes may be made within the spirit and scope of the inventive
concepts described. It is intended that the disclosure not be
limited to the described embodiments, but will have full scope
defined by the language of the following claims.
* * * * *