U.S. patent application number 15/275016 was filed with the patent office on 2018-03-29 for food packaging with multi-layer structure.
This patent application is currently assigned to Amazon Technologies, Inc.. The applicant listed for this patent is Amazon Technologies, Inc.. Invention is credited to Dave Lefkow, Marcus McDuffie.
Application Number | 20180086531 15/275016 |
Document ID | / |
Family ID | 60009720 |
Filed Date | 2018-03-29 |
United States Patent
Application |
20180086531 |
Kind Code |
A1 |
Lefkow; Dave ; et
al. |
March 29, 2018 |
FOOD PACKAGING WITH MULTI-LAYER STRUCTURE
Abstract
Packaging for a food item can comprise a container configured to
contain a food item, at least a portion of the container comprising
a multi-layer structure configured to protect the food item against
damage during transit from a fulfillment center to a delivery
location. The multi-layer structure can comprise a first layer of
fluid resistant material, a second layer comprising pliable pockets
filled with a fluid medium, and a third layer of polymer material,
wherein the first layer, the second layer, and the third layer are
laminated together to form the multi-layer structure. An inner
layer that is proximate the food item when the food item is
disposed within the container can comprise a food grade material
that is safe to bring into contact with food.
Inventors: |
Lefkow; Dave; (Bellevue,
WA) ; McDuffie; Marcus; (Phoenix, AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amazon Technologies, Inc. |
Seattle |
WA |
US |
|
|
Assignee: |
Amazon Technologies, Inc.
|
Family ID: |
60009720 |
Appl. No.: |
15/275016 |
Filed: |
September 23, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 43/02 20130101;
B65D 1/34 20130101; B65D 81/03 20130101; B65D 31/02 20130101; B65D
31/10 20130101; B65D 81/052 20130101 |
International
Class: |
B65D 81/05 20060101
B65D081/05; B65D 30/20 20060101 B65D030/20; B65D 1/34 20060101
B65D001/34; B65D 43/02 20060101 B65D043/02 |
Claims
1. A container for containing a food item that is susceptible to
damage during transit from a fulfillment center to a delivery
location, the container being in the form of a bag comprising: a
front lateral wall having a multi-layer structure including an
inner layer, a middle layer, and an outer layer, wherein: the inner
layer: (i) is a first distance from the food item at a time at
which the food item is disposed within the container, and (ii)
comprises a fluid resistant material; the middle layer: (i) is a
second distance from the food item that is greater than the first
distance at the time at which the food item is disposed within the
container, and (ii) comprises an array of plastic, air-filled
pockets; and the outer layer: (i) is a third distance from the food
item that is greater than the second distance at the time at which
the food item is disposed within the container, and (ii) comprises
a plastic film; and a rear lateral wall attached to the front
lateral wall, the rear lateral wall having the multi-layer
structure.
2. The container of claim 1, wherein: the front lateral wall
comprises a first portion and a second portion; the rear lateral
wall comprises a first portion and a second portion; the
multi-layer structure is included in the first portion of the front
lateral wall and the first portion of the rear lateral wall; and
the second portion of the front lateral wall and the second portion
of the rear lateral wall are configured to be sealed together to
enclose the food item within the container.
3. The container of claim 2, further comprising: a bottom wall; a
gusset disposed around a periphery of the bottom wall to allow the
container to stand upright on a flat surface; and a two-part
attachment mechanism for resealing the container after opening, the
two-part attachment mechanism comprising: a first part attached to
the second portion of the front lateral wall; and a second part
attached to the second portion of the rear lateral wall.
4. The container of claim 1, wherein the middle layer of the
multi-layer structure comprises: a plurality of first air-filled
pockets facing outward toward the outer layer, the plurality of
first air-filled pockets being arranged such that a plurality of
first spaces are defined between the plurality of first air-filled
pockets; and a plurality of second air-filled pockets facing inward
toward the inner layer, the plurality of second air-filled pockets
being arranged such that a plurality of second spaces are defined
between the plurality of second air-filled pockets.
5. The container of claim 1, wherein the fluid resistant material
of the inner layer comprises at least one of a metallized film or
an ethylene vinyl alcohol (EVOH) film.
6. An apparatus comprising: a container configured to contain an
item, a portion of the container comprising a multi-layer structure
including: a first layer of fluid resistant material; a second
layer comprising pliable pockets filled with a fluid medium; and a
third layer of polymer material, wherein the first layer, the
second layer, and the third layer are laminated together to form
the multi-layer structure.
7. The apparatus of claim 6, wherein: the first layer is a first
distance from the item at a time at which the item is disposed
within the container; the second layer is disposed between the
first layer and the third layer; and the third layer is a second
distance from the item at the time at which the item is disposed
within the container, the second distance being greater than the
first distance.
8. The apparatus of claim 6, wherein: the second layer is a first
distance from the item at a time at which the item is disposed
within the container; the first layer is disposed between the
second layer and the third layer; and the third layer is a second
distance from the item at the time at which the item is disposed
within the container, the second distance being greater than the
first distance.
9. The apparatus of claim 8, wherein the pliable pockets of the
second layer comprise ethylene vinyl alcohol (EVOH).
10. The apparatus of claim 6, wherein the fluid resistant material
of the first layer comprises at least one of a metallized film or
an ethylene vinyl alcohol (EVOH) film.
11. The apparatus of claim 10, wherein the metallized film
comprises aluminum film.
12. The apparatus of claim 6, wherein: the container is in the form
of a bag having at least one of: (i) a continuous lateral wall or
(ii) multiple lateral walls attached at respective lateral edges
thereof; and the portion of the container that comprises the
multi-layer structure includes the continuous lateral wall or the
multiple lateral walls of the bag.
13. The apparatus of claim 12, wherein the bag comprises: a bottom
wall; a gusset disposed around a periphery of the bottom wall to
allow the bag to stand upright on a flat surface; and a two-part
attachment mechanism at a top of the lateral wall or the multiple
lateral walls for resealing the bag after opening.
14. The apparatus of claim 6, wherein: the container is in the form
of a tray containing the item and a lid attached to the tray; and
the portion of the container that comprises the multi-layer
structure includes the lid.
15. An apparatus comprising: containing container configured to
contain an item, at least a portion of the container comprising:
first means for resisting ingress of fluid to, or egress of the
fluid from, the container after the container has been sealed with
the item contained therein; second means for cushioning the item at
a time at which the item is disposed within the container, the
second means for cushioning being disposed on the first means for
resisting the ingress or the egress of the fluid; and third means
for protecting the second means for cushioning, the third means for
protecting being disposed on the second means for cushioning.
16. The apparatus of claim 15, wherein: the first means for
resisting the ingress or the egress of the fluid is a first
distance from the item at a time at which the item is disposed
within the container; and the third means for protecting is a
second distance from the item at a time at which the item is
disposed within the container, the second distance being greater
than the first distance.
17. The apparatus of claim 15, wherein the first means for
resisting the ingress or the egress of the fluid comprises at least
one of a metallized film or an ethylene vinyl alcohol (EVOH)
film.
18. The apparatus of claim 15, wherein the second means for
cushioning comprises a plurality of means for holding a fluid
medium.
19. The apparatus of claim 15, wherein the plurality of means for
holding the fluid medium is a first plurality of means for holding
the fluid medium, the means for cushioning further comprising: a
second plurality of means for holding the fluid medium coupled to
the first plurality of means for holding the fluid medium such that
the second plurality of means for holding the fluid medium occupy
first spaces defined between the first plurality of means for
holding the fluid medium, and the first plurality of means for
holding the fluid medium occupy second spaces defined between the
second plurality of means for holding the fluid medium.
20. The apparatus of claim 15, wherein the container further
comprises: fourth means for allowing the container to stand upright
on a flat surface; and fifth means for resealing the container
after opening.
Description
BACKGROUND
[0001] Food items are commonly sold to consumers through grocery
stores and restaurants. It is only recently that consumers have
started purchasing food items online for delivery to their home or
business address. When food items are delivered to the consumer's
home via the electronic commerce (e-commerce) supply chain, the
food items are handled differently than their counterpart food
items that are placed on grocery store shelves. For example, food
items purchased online are often handled more frequently by
couriers as they are delivered to the consumer's home. As a
consequence, fragile food items are often damaged during transit. A
bag of chips, for example, will often arrive at a consumer's
doorstep as a bag full of crumbs.
[0002] A food item that is delivered via the e-commerce supply
chain can also sit on a doorstep for a long period of time before
the consumer brings the food item into his/her home, thereby
exposing the food item to the outdoor environment for longer
periods of time than its counterpart food item on the grocery store
shelf. Exposure to extreme temperatures can also damage food items.
For instance, a chocolate bar can melt if left in the hot sun for
too long, or a jar of mayonnaise can separate into a layer of oil
and a layer eggs upon freezing.
[0003] Existing food packaging is insufficient for protecting food
items from damage that can occur during transit through the
e-commerce supply chain. Furthermore, existing packaging for
non-food related items cannot be used as a solution because such
packaging is not made of food grade materials that are safe to
bring into contact with the food items. Furthermore, existing ad
hoc solutions, such as over-bagging (or double bagging), are
prohibitively expensive from a manufacturing standpoint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The detailed description is described with reference to the
accompanying figures. In the figures, the left-most digit(s) of a
reference number identifies the figure in which the reference
number first appears. The use of the same reference numbers in
different figures indicates similar or identical components or
features.
[0005] FIG. 1 illustrates a perspective view of an example
container in the form of a bag, a portion of the bag having a
multi-layer structure for protecting a food item disposed within
the container.
[0006] FIG. 2 illustrates a partial cross-sectional view of the
example container of FIG. 1 along section A-A according to one
embodiment.
[0007] FIG. 3 illustrates a partial cross-sectional view of the
example container of FIG. 1 along section A-A according to another
embodiment.
[0008] FIG. 4 illustrates a partial cross-sectional view of the
example container of FIG. 1 along section B-B according to another
embodiment.
[0009] FIG. 5A illustrates a perspective view of an example
container in the form of a bag, a portion of the bag having a
multi-layer structure for protecting a food item disposed within
the container, the bag further comprising a gusset and a two-part
attachment mechanism for resealing the bag after opening.
[0010] FIG. 5B illustrates a bottom plan view of the example
container of FIG. 5A, showing the gusset in more detail.
[0011] FIG. 6 illustrates a perspective view of an example
container in the form of tray and a lid, the lid having a
multi-layer structure for protecting a food item disposed within
the container.
DETAILED DESCRIPTION
[0012] Disclosed herein is packaging for a food item that is
configured to protect the food item against damage during transit
from a fulfillment center to a delivery location. The packaging can
comprise a container configured to contain a food item, at least a
portion of the container comprising a multi-layer structure. The
multi-layer structure can comprise a first layer of fluid resistant
material, a second layer comprising pliable pockets filled with a
fluid medium, and a third layer of polymer material, wherein the
first layer, the second layer, and the third layer are laminated
together to form the multi-layer structure. An inner layer that is
proximate the food item when the food item is disposed within the
container can comprise a food grade material that is safe to bring
into contact with food.
[0013] The food packaging described herein protects food items that
are susceptible to damage during transit from a fulfillment center
to a delivery location by virtue of the multi-layer structure
included as part of the food packaging. In this manner, fragile
food items, such as chips or crackers, will be less prone to
breaking and crumbling as the food items are transported from a
fulfillment center to a delivery location. This is at least partly
due to the layer of pliable pockets filled with a fluid medium that
cushions the food item upon impact with an external object (e.g.,
the ground, a human hand, etc.). Meanwhile, the packaging is made
to be "food safe" by use of a food grade material (i.e., a material
that is deemed safe, as determined by a compliance agency, such as
the Food and Drug Administration (FDA) (e.g., compliance with ISO
9000 from the International Organization for Standardization) to
bring into contact with food) for the inner layer that can come
into contact with the food item.
[0014] In some configurations, the layer of fluid resistant
material comprises a metallized film, such as an aluminum film.
Such a metallized layer can slow the rate of heat transfer to or
from the food item in the container, which allows packaged food
item to be exposed to extreme temperatures for longer periods of
time without damaging the food item inside the packaging.
[0015] The techniques, systems, and devices described herein may be
implemented in a number of ways. Example implementations are
provided below with reference to the following figures.
[0016] FIG. 1 illustrates a perspective view of an example
container 100 in the form of a bag, a portion of the bag having a
multi-layer structure for protecting a food item disposed within
the container 100. In general, the container 100 can be used for
packaging one or more food items that can be ordered by a consumer
online (e.g., by completing a transaction via an electronic
marketplace) and delivered, within the container 100, to a delivery
location associated with the consumer. For example, an electronic
marketplace can offer food items that are available to consumers
for purchase. The electronic marketplace can be made accessible to
consumers through any suitable technology and/or computing device,
such as a website that is accessible to a client computing device
of the consumer, or a client application (e.g., a mobile
application) executing on the client computing device that allows a
user to search and browse food items available from a food item
catalog maintained by a provider of the electronic marketplace. In
some configurations, a consumer can access the electronic
marketplace using a digital assistant executing on a client
computing device, the digital assistant being configured to receive
voice input from the user, find food items available from the
electronic marketplace based on the received voice input, and
purchase selected food items for the user.
[0017] Food items that are purchased by consumers can be packaged
and delivered to consumers in the food packaging described herein,
such as the container 100 shown in FIG. 1. Different food packaging
can be utilized for different food items depending on the fragility
of the food items to be delivered. In general, the term "food
item," as used herein, may include any type of tangible food or
drink product that is consumable by a human or animal as food. It
is to be appreciated that the food packaging described herein,
which comprises the disclosed multi-layer structure, can be used to
package any type of food item for delivery via the e-commerce
supply chain to a delivery location. Although the disclosed food
packaging can be used for any type of food item regardless of how
susceptible it is to damage during transit, the multi-layer
structure described herein affords added protection to food items
that are particularly susceptible to damage during transit from the
fulfillment center to the delivery location, such as breakable
chips, crackers, or cookies, or fresh fruit that is easily bruised
upon impact with other objects.
[0018] Examples of food items that are prone to breakage (or
"crumblage") during transit can include, without limitation,
fragile food items such as chips (tortilla, potato, etc.),
crackers, pretzels, dried fruit, cookies, pasta shells, popcorn,
cereal, chocolate bars, and the like. Other fragile food items
include, without limitation, fresh fruit, which can be easily
bruised if handled too often and/or too roughly during transit.
Some types of food items are additionally, or alternatively, prone
to melting in hot temperatures, such as chocolate food items, and
other types of sugar-based candies, etc. Some types of food items,
such as mayonnaise, salad dressing, and the like, are susceptible
to damage when exposed to cold temperatures. For example, if
mayonnaise, which consists of an emulsion of oil and eggs, reaches
a temperature that is below a threshold temperature (e.g., below 0
degrees Celsius (.degree. C.)), the emulsion in the mayonnaise can
break, leaving a consumer with a jar containing a layer of oil and
a layer of eggs that can be inedible, in some instances.
[0019] The food packaging described herein, such as the container
100 shown in FIG. 1, comprises a multi-layer structure that is
configured to protect these types of "fragile" food items during
transit. This is at least partly due to the layer of pliable
pockets filled with a fluid medium, which is configured to protect
against breakage (or bruising) by cushioning the food item(s)
within the packaging. Additionally, a metallized film used for the
fluid resistant material in the multi-layer structure can decrease
the rate of heat transfer to or from the food item during transit
within the container 100 so as to prevent damage to the food item
caused by exposure to extreme temperatures. Meanwhile, a food grade
material used for the inner layer of the multi-layer structure that
can come into contact with the food item provides a food-safe
package for the food item.
[0020] When a food item(s) is packaged for shipment within the
container 100, the food item(s) can be inserted through an opening
102 defined in the container 100 in order to fill the container 100
with the food item. For example, a plurality of potato chips can be
provided through the opening 102 of the container 100 and disposed
within the container 100. After filling the container 100, at least
partially, with one or more food items, the container 100 can be
closed, such as by sealing the opening 102 of the container 100, in
order to enclose the food item(s) within the container 100. Closure
of the container 100 by sealing the opening 102 can create an
air-tight food package so that the food item(s) is preserved within
the container 100. The container 100 is the mechanism by which the
food item(s) can be transported to a customer in a protected
manner.
[0021] The container 100 can comprise a plurality of walls that
define a cavity in which the food item can be disposed. FIG. 1
shows a front wall 104 of the container 100 that can be attached to
a rear (or back) wall 106 to form a cavity in which one or more
food items can be placed. The front wall 104 and the rear wall 106
make up multiple lateral walls of the container 100 shown in FIG.
1. It is to be appreciated that the container can comprise a
single, continuous lateral wall, as opposed to the multiple lateral
walls 104 and 106 shown in FIG. 1, without changing the basic
characteristics of the food packaging described herein.
Furthermore, the container 100 can comprise any number of lateral
walls (e.g., more than two lateral walls, such as a front wall, a
rear wall, and two side walls).
[0022] The front wall 104 of the container 100 can be attached to
the rear wall 106 of the container 100 by attaching a first lateral
edge 108(1) of the front wall 104 to a corresponding lateral edge
108(3) (See FIG. 2) of the rear wall 106, and by attaching a second
lateral edge 108(2) of the front wall 104 to a corresponding
lateral edge of the rear wall 106. Any suitable attachment
mechanism can be utilized for this purpose, such as an adhesive on
one or more inside surfaces of the lateral edges 108, heat sealing
the lateral edges 108(1)/(2) of the front wall 104 to corresponding
lateral edges (See 108(3) of FIG. 2) of the rear wall 106, or any
other suitable attachment mechanism. In order to create an
air-tight enclosure when the opening 102 of the container 100 is
sealed, an attachment mechanism at the lateral edges 108(1)/(2) of
the front wall and corresponding lateral edges (See 108(3) of FIG.
2) of the rear wall, such as heat sealing or adhesives, can be used
to provide such an air-tight enclosure.
[0023] In the example of FIG. 1, a continuous piece of material is
shown as being folded at a bottom end 110 of the container 100 to
create the front wall 104 and the rear wall 106, which can then be
sealed at the lateral edges thereof. However, it is to be
appreciated that two separate pieces of material can be used for
the front wall 104 and the rear wall 106, respectively, and the
separate front wall 104 can be attached to the separate rear wall
106 at both lateral edges, as well as a bottom edge at the bottom
end 110 of the container. In other words, separate pieces of
material that make up the front wall 104 and the rear wall 106 of
the container 100, respectively, can be attached together at three
adjacent or contiguous edges thereof. In such a configuration, the
front wall 104 can include a bottom edge that is attached to a
corresponding bottom edge of the rear wall 106 in a similar manner
to that described herein for attachment of the lateral edges
108(1)/(2) of the front wall 104 to corresponding lateral edges
(See 108(3) of FIG. 2) of the rear wall 106, as shown in FIG. 1.
Alternatively, the container 100 can include a bottom wall at the
bottom end 110 of the container 100, as will be described in more
detail below with reference to the following figures.
[0024] The front wall 104 can comprise multiple portions, such as a
first portion 112(A) and a second portion 114(A). The rear wall 106
can similarly comprise multiple portions, such as a first portion
112(B) and a second portion 114(B). The first portions 112(A) of
the front wall 104 can be partially surrounded by the first lateral
edge 108(1), the bottom end 110, and the second lateral edge 108(2)
of the front wall 104. Similarly, the first portion 112(B) of the
rear wall 104 can be partially surrounded by corresponding lateral
edges (See 108(3) of FIG. 2) and the bottom end 110 of the rear
wall 106. Furthermore, the first portions 112(A)/(B) can make up a
substantial percentage of the front wall 104 and rear wall 106,
respectively (e.g., the first portion 112(A) of the front wall 104
can comprise about 90% of the front wall 104). The second portions
114(A)/(B) can make up a relatively smaller portion of the front
wall 104 and the rear wall 106, respectively (e.g., the second
portion 114(A) of the front wall 104 can comprise about 10% of the
front wall 104). The second portions 114(A) and 114(B) of the front
wall 104 and the rear wall 106, respectively, can be configured to
be sealed together in order to enclose the food item within the
container 100. For example, the second portion 114(A) of the front
wall 104 can be heat sealed together with the second portion 114(B)
of the rear wall 106. However, any suitable attachment mechanism,
such as adhesive, can be used to seal the second portion 114(A)/(B)
together after one or more food items have been placed within the
container 100.
[0025] FIG. 1 also shows a cutaway view 116 on the inside surface
of the first portion 112(B) of the rear wall 106 of the container
100, which exposes the construction of part of the multi-layer
structure that makes up a first portion 112(B) of the rear wall
106. A similar construction would be exposed if a cutaway view of
the first portion 112(A) of the front wall 104 were shown in FIG.
1. The cutaway view 116 illustrates part of a multi-layer structure
that can be included in at least a portion of the container 100. In
FIG. 1, the portion of the container that includes the multi-layer
structure includes the first portion 112(A) of the front wall 104,
and the first portion 112(B) of the rear wall 106 of the container
100. The multi-layer structure will be described in more detail
below with reference to the following figures. In general, the
multi-layer structure used in at least a portion of the container
100 (e.g., in one or more walls of the container 100) can include a
first layer of fluid resistant material, a second layer comprising
pliable pockets filled with a fluid medium, and a third layer of
polymer material, wherein the first layer, the second layer, and
the third layer are laminated together to form the multi-layer
structure. The cutaway view 116 of FIG. 1 shows that some of the
inner layer of fluid resistant material has been cut away to expose
a middle layer of pliable pockets filled with fluid medium. In some
embodiments, the pliable pockets filled with fluid medium can
comprise an air cellular material, such as Bubble Wrap.RTM., sold
by Sealed Air Corporation.RTM.. Accordingly, the first portions
112(A)/(B) of the front wall 104 and the rear wall 106,
respectively, can include the multi-layer structure described
herein, while the second portions 114(A)/(B) of the front wall 104
and the rear wall 106, respectively, do not include the multi-layer
structure, so as to enable the opening 102 of the container 106 to
be sealed after one or more food items have been placed within the
container 100. For example, the second portions 114(A)/(B) of the
first wall 104 and the second wall 106, respectively, can comprise
a layer of fluid resistant material, and a layer of polymer
material, without the layer of pliable pockets filled with a fluid
medium that is otherwise included in the multi-layer structure of
the first portions 112(A)/(B).
[0026] FIG. 2 illustrates a partial cross-sectional view of the
example container 100 of FIG. 1 along section A-A according to one
embodiment. Notably, section A-A of FIG. 1 "cuts through" the first
portions 112(A)/(B) of the front wall 104 and the rear wall 106,
respectively, of the container 100 to expose the construction of
the multi-layer structure included in the first portions
112(A)/(B). For instance, FIG. 2 shows a multi-layer structure
200(A) included in the front wall 104 of the container 100, and a
multi-layer structure 200(B) included in the rear wall of the
container 106. FIG. 2 also depicts a cavity 202 where one or more
food items can be contained within the container 100. The first
lateral edge 108(1) of the front wall 104 is shown as being
attached to a corresponding first lateral edge 108(3) of the rear
wall 106, which enables attaching the front wall 104 to the rear
wall 106 to define the cavity 202 of the container 100.
[0027] The multi-layer structure 200(A) included in the front wall
104 can comprise a first (inner) layer 204(A) of fluid resistant
material (sometimes referred to herein as a "barrier layer") that
is proximate the food item when the food item is disposed within
the container 100 (i.e., within the cavity 202), a second (middle)
layer 206(A) disposed on the first layer 204(A) and comprising a
plurality of pliable pockets filled with a fluid medium, and a
third (outer) layer 208(A) of polymer material that is disposed on
the second layer 206(A), and is farther from the food item than the
first layer 204(A) when the food item is disposed within the cavity
202 of the container 100. Said another way, the first (inner) layer
204(A) of fluid resistant material can be a first distance from the
food item at a time at which the food item is disposed within the
container 100, the second (middle) layer 206(A) comprising a
plurality of pliable pockets filled with a fluid medium can be a
second distance from the food item that is greater than the first
distance at the time at which the food item is disposed within the
container 100, and the third (outer) layer 208(A) of polymer
material can be a third distance from the food item that is greater
than the second distance at the time at which the food item is
disposed within the container 100.
[0028] The individual pairs of adjacent layers within the
multi-layer structure 200(A) can be attached via an adhesive layer
(sometimes called a "tie layer"). As such, the multi-layer
structure 200(A) is shown as including a first adhesive layer
207(A) and a second adhesive layer 209(A). The first adhesive layer
207(A) can be interposed between the first (inner) layer 204(A) and
the second (middle) layer 206(A) in order to bond (or otherwise
attach) the first layer 204(A) to the second layer 206(A). The
second adhesive layer 209(A) can be interposed between the second
(middle) layer 206(A) and the third (outer) layer 208(A) in order
to bond (or otherwise attach) the second layer 206(A) to the third
layer 208(A). It is to be appreciated that the multi-layer
structure 200(A) can include any suitable number of layers,
including adhesive layers. Accordingly, the multi-layer structure
200(A) is not limited to the five layers comprising the first layer
204(A), the first adhesive layer 207(A), the second layer 206(A),
the second adhesive layer 209(A), and the third layer 208(A), and
fewer or greater layers (e.g., additional adhesive layers,
additional layers of films, etc.) can be included within the
multi-layer structure 200(A).
[0029] The fluid resistant material of the first (inner) layer
204(A) can comprise any suitable fluid resistant material that is
configured to restrain or resist the ingress of fluid to and/or
egress of fluid from the container 100. Such fluids that are
restrained from crossing the first (inner) layer 204(A) can
include, without limitation, water (e.g., in the form of moisture),
oxygen, or any similar liquid or gaseous fluid. For example, when
oxygen penetrates food packaging, it can spoil the food items
within the packaging. Thus, the fluid resistant characteristics of
the first (inner) layer 204(A) can act as a barrier (e.g., by
having a relatively low fluid transmission rate) to such fluids in
order to extend the shelf life and prevent rapid spoilage of the
food item contained in the container 100. For example, the fluid
resistant material of the first (inner) layer 204(A) can have an
oxygen transmission rate of no greater than about 1 cubic
centimeters (cc or cm.sup.3) per 100 square inches (in.sup.2) per
day, no greater than about 0.8 cc/100 in.sup.2/day, no greater than
about 0.6 cc/100 in.sup.2/day, no greater than about 0.4 cc/100
in.sup.2/day, no greater than about 0.2 cc/100 in.sup.2/day, or no
greater than about 0.1 cc/100 in.sup.2/day. Similarly, the fluid
resistant characteristics of the first (inner) layer 204(A) can act
as a barrier for locking moisture, flavor, aroma, and so on, in the
container 100 so as to preserve the food item(s) and keep the food
item(s) fresh for longer periods of time. The fluid resistant
material of the first (inner layer) 204(A) can also be resistant to
organic solvents, such as hydrocarbons, oils, and similar organic
solvents often found in food items.
[0030] The fluid resistant material of the first (inner) layer
204(A) can comprise any suitable fluid resistant material that is
also food grade, meaning it is a material that is safe (unlikely to
contaminate food with harmful materials or chemicals above a
threshold contamination level), as determined by a compliance
agency, such as the FDA to bring into contact with food. Suitable
fluid resistant materials for the first (inner) layer 204(A)
include, without limitation, a metallized film (e.g., aluminum
film), an ethylene vinyl alcohol (EVOH) film, or films made from
thermoplastic material, polyolefins, polyethylene terephthalate
(PET), polyvinyl chloride, polyvinylidene chloride, polystyrene,
and so on. EVOH is an example of an fluid (e.g., oxygen) resistant
copolymer that can be provided as a film for lamination in the
multi-layer structure 200(A), and it is a food grade material. EVOH
can also be made to be transparent in order for light to pass there
through. In some embodiments, the first (inner) layer 204 of fluid
resistant material can have a thickness that is no greater than
about 50 microns (or micrometers (.mu.unm), no greater than about
40 microns, no greater than about 30 microns, no greater than about
20 microns, or no greater than about 10 microns. This allows the
first layer 204(A) to be provided as a film that can resist
cracking and is otherwise rather flexible for use in a container
100 in the form of a bag.
[0031] In configurations where the first (inner) layer 204(A)
comprises a metallized film, any suitable metal that is food grade
can be utilized, such as aluminum, tin, and the like. Use of a
metallized film, such as an aluminum film, for the first (inner)
layer 204(A) can provide an added thermal insulation benefit to the
food item contained within the container. For example, although
aluminum is a good conductor of heat via conduction, an aluminum
film can act as a heat insulator to convection and radiation, which
are other mechanisms by which heat is transferred. Thus, a
metallized film used for the first (inner) layer 204 can prevent
thermal shock of the food item by slowing the rate of heat
dissipation to and from the food item(s) within the container 100
as it is exposed to extreme environmental temperatures (i.e.,
ambient temperatures that reach extreme hot or cold temperatures)
during transit from a fulfillment center to a delivery location.
For example, the container 100 can be made more thermally tolerant
(insulated) for an extended time period (e.g., 72 hours) by virtue
of a metallized first (inner) layer 204(A). This is particularly
beneficial in instances where the container 100 sits for several
hours or more on a front porch, where the container 100 is exposed
to extreme hot or cold environmental temperatures, depending on the
delivery location. For instance, food items may be rendered
inedible if frozen and subsequently thawed, or if allowed to become
too warm or hot, leading to spoilage.
[0032] The second (middle) layer 206(A) that is disposed on the
first layer 204(A) can comprise a plurality of pliable pockets,
such as the pocket 210, filled with a fluid medium 212. Commonly
referred to as Bubble Wrap.RTM., this second (middle) layer 206(A)
of pliable pockets 210 filled with the fluid medium 212 can
comprise a sheet having an array of plastic air-filled bubbles. Any
pliable material, such as polymer (plastic), can be utilized for
pockets 210 in the second layer 206(A), and the pockets 210 can be
filled with any suitable fluid medium, such as air, water, or any
other suitable fluid. FIG. 2 illustrates how the second layer
206(A) can comprise a first layer 214 of pockets 210 (e.g.,
protruding air-filled hemispheres), attached to a second,
planarized layer 216 of polymer material to seal the pockets 210
after being filled with the fluid medium 212. When the pockets 210
are filled with the fluid medium 212, the second layer 206(A) acts
as a cushioning mechanism for the food item(s) by absorbing the
impact from objects (e.g., the ground, a hand of a human being,
etc.) external to the container 100, thereby protecting the food
item(s) within the container 100 from damage (e.g., breakage,
bruising, etc.). The material of the second layer 206(A) can be
made transparent in order for light to pass there through.
[0033] The third (outer) layer 208(A) of polymer material can be
disposed on the second (middle) layer 206(A), and can comprise a
plastic film that is printed on an outside surface of the second
layer 206(A) during manufacturing. In some embodiments, the third
(outer) layer 208(A) of polymer material can have a thickness that
is no greater than about 50 microns, no greater than about 40
microns, no greater than about 30 microns, no greater than about 20
microns, or no greater than about 10 microns. Thickness of the
third (outer) layer 208(A) can be varied to produce various effects
and characteristics of the package. For example, a very thin third
(outer) layer 208(A) (e.g., about 10 microns) can reveal the
pattern of the pockets in the second (middle) layer 206(A), and/or
provide a more tactile (e.g., rough) surface on the outside of the
food package to enable a human to better grip the container 100. A
thicker third (outer) layer 208(A) can provide a smoother outside
surface for printing labels, which may be more legible on a smooth
surface than on a rough surface that reveals the pattern of pockets
in the second (middle) layer 206(A).
[0034] The third (outer) layer 208(A) can act as a protective layer
that protects the second (middle) layer 206(A) from being damaged
(e.g., torn, ripped, punctured, etc.), and can offer a medium on
which to print labels, such as a brand name for the food item, and
other information related thereto (e.g., nutrition information,
etc.). Accordingly, the third (outer) layer 208(A) can comprise an
opaque plastic film that hides the contents of the container 100
and offers a canvas for printing logos and other textual
information on the package. Alternatively, the third (outer) layer
208(A) can comprise a transparent plastic film that allows light to
pass there through. A fully transparent package can be desirable in
some scenarios, such as fruit, which may ripen at a desirable rate
if exposed to sunlight via the transparent packaging, or when it is
desirable to reveal the contents of the container 100 to the
consumer before the package is opened by the consumer.
[0035] The rear wall 106 can comprise a multi-layer structure
200(B) of similar construction to that of the multi-layer structure
200(A) included in the front wall 104. For brevity, the multiple
layers in the multi-layer structure 200(B) included in the rear
wall 106 will not be repeated herein. It is to be appreciated,
however, that the layers 204(B), 207(B), 206(B), 209(B), and 208(B)
may be similar to the corresponding layers 204(A), 207(A), 206(A),
209(A), and 208(A) of the front wall 104, except that they are
reversed in orientation when the front wall 104 is attached to the
rear wall 106.
[0036] In some embodiments, the second layers 206(A)/(B) can be
omitted from the multi-layer structures 200(A)/(B), and a similar
cushioning effect can be provided by adhering the first layer
204(A)/(B) to the third layer 208(A)/(B) at multiple different
locations to create/define pockets between the points of
attachment. For example, in addition to attaching the front wall
104 to the rear wall 106 at the lateral edges 108 thereof, a middle
of the front wall 104 can be attached to a middle of the rear wall
106 along the length of the lateral edges 108 thereof, creating at
least two spaces, pockets, or voids, that can be filled with a
fluid medium, such as the fluid medium 212. Thus, the multi-layer
structure 200(A)/(B) can still provide a cushioning effect for the
food items contained within the container 100 without adding the
material for the layers 214 and 216 that define the plurality of
pliable pockets 212 of the second layer 206(A)/(B) shown in FIG.
2.
[0037] In general, the layers 204(A)/(B), 206(A)/(B), and
208(A)/(B) of the multi-layer structure 200(A)/(B) can be laminated
together using adhesive layers 207(A)/(B) and 209(A)/(B) to form
the multi-layer structure 200(A)/(B) using any suitable
manufacturing process. For example, the first (inner) layer
204(A)/(B) can be provided as a roll of film that can be cut to
size and laminated on an inner surface of the second (middle) layer
206(A)/(B) with the first adhesive layer 207(A) there between, and
the third (outer) layer 208(A)/(B) can be printed as a film on an
outer surface of the second (middle) layer 206(A)/(B) with the
second adhesive layer 209(A) there between to form the front wall
104 and the rear wall 106. Portions around the periphery of the
front wall 104 and the rear wall 106 can be made without the second
(middle) layer 206(A)/(B) in order to attach the lateral edges 108
of the front wall 104 to the lateral edges 108 of the rear wall 106
by, for example, heat sealing the lateral edges, and in order to
seal the opening 102 of the container 100 after one or more food
items have been placed inside the container 100.
[0038] FIG. 3 illustrates a partial cross-sectional view of the
example container 100 of FIG. 1 along section A-A according to
another embodiment. In the example of FIG. 3, the multi-layer
structure 300(A) included in the front wall 104 comprises a middle
layer 304(A) of fluid resistant material disposed between an inner
layer 306(A) comprising a plurality of pliable pockets filled with
a fluid medium, and an outer layer 308(A) of polymer material.
Thus, the inner layer 306(A) comprised of a plurality of pliable
pockets is proximate the food item when the food item is disposed
within the container 100 (i.e., within the cavity 302), while the
outer layer 308(A) of polymer material is farther from the food
item than the inner layer 306(A) comprised of the plurality of
pliable pockets filled with the fluid medium. The materials of the
respective layers 304(A), 306(A), and 308(A) of the multi-layer
structure 300(A) can be similar to those described above with
respect to FIG. 2, except that the inner layer 306(A), which is
comprised of a plurality of pliable pockets filled with fluid
medium, can be made of a food grade material, such as EVOH, because
the inner layer may come into contact with the food item(s)
contained in the container 100. The middle layer 304(A) of fluid
resistant material can, like the layer 204(A) of fluid resistant
material described with reference to FIG. 2, be made of a
metallized film or EVOH film to lock in freshness and otherwise act
as a barrier layer to extend the shelf life of the food item(s)
within the container 100. Furthermore, adhesive layers 307(A) and
309(A) can be disposed between adjacent pairs of layers within the
multi-layer structure 300(A) in order to attach the respective
layers together in a lamination process. The alternate
configuration of the multi-layer structure 300(A) of FIG. 3 can
provide protection to the food item(s) within the container 100 in
a similar manner to the multi-layer structure 200(A) of FIG. 2.
However, the different order of the layers within the multi-layer
structure 300(A) relative to the multi-layer structure 200(A) can
provide for easier lamination of the layers by providing a planar
outer surface of the inner layer 306(A) on which the additional
layers 304(A) and 308(A) can be laminated.
[0039] The rear wall 106 can comprise a multi-layer structure
300(B) of similar construction to that of the multi-layer structure
300(A) included in the front wall 104. For brevity, the multiple
layers in the multi-layer structure 300(B) included in the rear
wall 106 will not be repeated herein. It is to be appreciated,
however, that the layers 304(B), 307(B), 306(B), 309(B), and 308(B)
may be similar to the corresponding layers 304(A), 307(A), 306(A),
309(A), and 308(A) of the front wall 104, except that they are
reversed in orientation when the front wall 104 is attached to the
rear wall 106.
[0040] FIG. 4 illustrates a partial cross-sectional view of the
example container 100 of FIG. 1 along section B-B according to
another embodiment. The partial cross-sectional view only shows the
front wall 104 (and not the rear wall 106), but it is to be
appreciated that the rear wall 106 can comprise a similar
construction to that of the multi-layer structure 400(A) shown in
FIG. 4, except that the layers can be reversed in orientation when
the front wall 104 is attached to the rear wall 106 to form the
container 100.
[0041] The multi-layer structure 400(A) included in the front wall
104 of FIG. 4 includes a first (inner) layer 404(A) of fluid
resistant material that is proximate to the food item when the food
item is disposed within the container 100, a second (middle) layer
406(A) disposed on the first layer 404(A) and comprising a
plurality of pliable pockets filled with a fluid medium, and a
third (outer) layer 408(A) of polymer material that is disposed on
the second layer 406(A), and is farther from the food item than the
first layer 404(A) when the food item is disposed within the
container 100. Furthermore, adhesive layers 407(A) and 409(A) can
be disposed between adjacent pairs of layers within the multi-layer
structure 400(A) in order to attach the respective layers together.
For example, a first adhesive layer 407(A) can be interposed
between the first (inner) layer 404(A) and the second (middle)
layer 406(A), and a second adhesive layer 409(A) can be interposed
between the second (middle) layer 406(A) and the third (outer)
layer 408(A).
[0042] In the example of FIG. 4, the second (middle) layer 406(A)
is comprised of multiple layers of pliable pockets filled with
fluid medium. Accordingly, the second (middle) layer 406(A) can
comprise a plurality of first fluid-filled (e.g., air-filled)
pockets 410(A) filled with first fluid 412(A), and a plurality of
second fluid-filled (e.g., air-filled) pockets 410(B) filled with a
second fluid 412(B). The arrangement of the plurality of first
fluid-filled pockets 410(A) can define a plurality of first spaces
between each of the first fluid-filled pockets 410(A), and the
arrangement of the plurality second fluid-filled pockets 410(B) can
likewise define a plurality of second spaces between each of the
second fluid-filled pockets 410(B). The two sub-layers of
fluid-filled pockets within the second (middle) layer 406(A) can
then be fit together like a puzzle during manufacturing, where the
plurality of first fluid-filled pockets 410(A) are disposed in the
second spaces defined by the plurality of second fluid-filled
pockets 410(B), and the plurality of second fluid-filled pockets
410(B) are disposed in the first spaces defined by the plurality of
first fluid-filled pockets 410(A), as illustrated in FIG. 4. This
can provide for extra cushioning in the second (middle) layer
406(A), as well as planarized surfaces on the inner surface and the
outer surface of the second layer 406(A) to laminate the first
layer 404(A) and the third layer 408(A) onto, respectively.
Flexibility of the front wall 104 may be compromised by added
stiffness, but the added protection to the food items can be
beneficial if stiffness of the container 100 is not a concern.
[0043] FIG. 5A illustrates a perspective view of an example
container 500 in the form of a bag, a portion of the bag having a
multi-layer structure for protecting a food item disposed within
the container 500. For instance, a front wall 504 of the container
500 can include a multi-layer structure, such as any of the
multi-layer structures 200(A), 300(A), or 400(A) described herein.
Likewise, a rear wall 506 of the container 500 can include a
similar multi-layer structure, as described herein. Furthermore,
the front wall 504 can comprise a first portion 512(A) that
includes the multi-layer structure and a second portion 514(A) that
does not include the multi-layer structure, and the rear wall 506
can comprise a first portion 512(B) that includes the multi-layer
structure and a second portion 514(B) that does not include the
multi-layer structure. Thus, in a similar manner to the container
100 described with reference to FIG. 1, a top end of the container
500 can be sealed after one or more food items are placed within
the container 500.
[0044] The example container 500 of FIGS. 5A and 5B further
comprises a gusset 502 disposed around a periphery of a bottom wall
508 of the container 500. The gusset 502 can comprise any suitable
piece of material that comprises a rigid, or semi-rigid, material,
such as a plastic (e.g., acrylonitrile butadiene styrene (ABS)
plastic), metal, or any similar material. The gusset 502 can be
pre-formed into any suitable shape, such as the elongated,
hexagonal shape shown in the bottom plan view shown in FIG. 5B of
the container 500 of FIG. 5A. The gusset 502 can, of course, be
provided in any suitable polygonal shape, such as a circular shape,
a triangular shape, a rectangular shape, or any type of polygonal
shape, whether symmetrical or asymmetrical. The gusset 502 provides
structure to the container 500 such that the container 500 can be
set atop a flat surface, such as a table, and can stand upright
without falling over on its side. This might allow a consumer to
eat from the container 500 without holding the container 500, or to
better situate the container 500 on a pantry shelf.
[0045] The example container 500 of FIGS. 5A and 5B also comprises
a two-part attachment mechanism 510 for resealing the container 500
after opening. The two-part attachment mechanism 510 can comprise a
first part 510(A) attached to the second portion 514(A) of the
front wall 504, and a second part 510(B) attached to the second
portion 514(B) of the rear wall 506. The first part 510(A) can
represent a "male" part of the two-part attachment mechanism 510,
and the second part 510(B) can represent a "female" part that
receives the male part to join the front wall 504 with the rear
wall 506 of the container 500. In some embodiments, the two-part
attachment mechanism 510 is in the form of a zipper attachment
mechanism that can be pressed by the fingers of a user to reseal
the container 510 after initially opening the sealed container 500.
The resealable container 500 of FIGS. 5A and 5B can allow for a
consumer of the food items to consume some, but not all, of the
food items within the container 500, and to save any remaining food
items in the container 500 for later consumption.
[0046] FIG. 6 illustrates a perspective view of an example
container 600 in the form of tray 602 and a lid 604. In the example
of FIG. 6, the portion of the container 600 that comprises a
multi-layer structure can include the lid 604 of the container 600.
For example, the lid 604 of the container 600 can comprise any of
the multi-layer structures described herein, such as the
multi-layer structures 200, 300, or 400. One or more food items to
be delivered to a customer that purchased the food item(s) can be
placed in the tray 602 of the container, and the lid 604 comprising
the multi-layer structure 200, 300, or 400, can be attached to the
tray 602 at a periphery of a top portion of the tray 602. The tray
602 can be made of any suitable material, such as plastic.
Alternatively, the tray 602 itself can be made, at least partially,
of any of the multi-layer structures described herein to provide
added protection to the food item(s) within the container 600.
[0047] It is to be appreciated that unwrapped food items, such as
chips, crackers, condiments, dressings, etc., can be placed in the
food packaging described herein. Alternatively, individually
wrapped food items, such as chocolate bars wrapped in foil and/or
paper can be placed in the food packaging described herein.
[0048] It is to be appreciated that the specific dimensions,
proportions, shapes and configurations of the components described
herein are not specific to the embodiments described and
illustrated herein. For example, the containers can be of various
sizes (length and/or width), and shapes (e.g., rectangular, square,
triangular, cylindrical, etc.) without changing the basic
characteristics of food packaging described herein.
[0049] Although the subject matter has been described in language
specific to structural features, it is to be understood that the
subject matter defined in the appended claims is not necessarily
limited to the specific features described. Rather, the specific
features are disclosed as illustrative forms of implementing the
claims.
* * * * *