U.S. patent application number 17/013526 was filed with the patent office on 2021-04-15 for high strength corrugated carton design and lid for modified atmosphere packaging of fresh produce and fresh-cut flowers.
The applicant listed for this patent is IFOOD HOLDINGS, INC.. Invention is credited to Perry Lidster.
Application Number | 20210107698 17/013526 |
Document ID | / |
Family ID | 1000005311710 |
Filed Date | 2021-04-15 |
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United States Patent
Application |
20210107698 |
Kind Code |
A1 |
Lidster; Perry |
April 15, 2021 |
HIGH STRENGTH CORRUGATED CARTON DESIGN AND LID FOR MODIFIED
ATMOSPHERE PACKAGING OF FRESH PRODUCE AND FRESH-CUT FLOWERS
Abstract
A container assembly including, a carton base having a
substantially planar bottom surface, a lid having a top surface and
a plurality of sidewalls extending therefrom. The lid is releasably
engaged with the carton base and forms an interior space when
engaged with the carton base. The top surface of the lid includes:
a plurality of raised platforms, each raised platform having a
substantially planar top surface, and a plurality of channels
extending between each of the raised platforms such that each of
the plurality of channels continuously extends to a perimeter of
the lid. Additionally, the carton base is formed of three distinct
laminate layers, with at least one of the laminate layers including
a resin and a board weight of 200 g/m.sup.2 to 300 g/m.sup.2.
Inventors: |
Lidster; Perry; (Summerland,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IFOOD HOLDINGS, INC. |
Kinnelon |
NJ |
US |
|
|
Family ID: |
1000005311710 |
Appl. No.: |
17/013526 |
Filed: |
September 4, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2020/014171 |
Jan 17, 2020 |
|
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17013526 |
|
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62793559 |
Jan 17, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2543/00537
20130101; B65D 2205/02 20130101; B65D 5/56 20130101; B65D
2543/00425 20130101; B65D 2543/00398 20130101; B65D 51/1616
20130101; B65D 85/505 20130101 |
International
Class: |
B65D 5/56 20060101
B65D005/56; B65D 51/16 20060101 B65D051/16; B65D 85/50 20060101
B65D085/50 |
Claims
1. A container assembly, comprising: a carton base having a
substantially planar bottom surface; a lid having a top surface and
a plurality of sidewalls extending therefrom; wherein the lid is
releasably engaged with the carton base and forms an interior space
when engaged with the carton base; wherein the top surface of the
lid includes: a plurality of raised platforms, each raised platform
having a substantially planar top surface, and a plurality of
channels extending between each of the raised platforms such that
each of the plurality of channels continuously extends to a
perimeter of the lid, and wherein the carton base includes a liner,
wherein the liner is formed of three distinct laminate layers.
2. The container assembly of claim 1, wherein at least one of the
laminate layers includes a resin.
3. The container assembly of claim 1, wherein the liner is attached
to a cardboard base layer.
4. The container assembly of claim 1, wherein the liner has a board
weight of 200 g/m.sup.2 to 300 g/m.sup.2.
5. The container assembly of claim 1, wherein the carton base
includes a plurality of sidewalls, each sidewall having at least
one scallop configured to receive a corresponding channel of the
lid when the lid is engaged with the carton base.
6. The container assembly of claim 5, wherein each of the carton
base sidewalls includes at least one support surface immediately
adjacent to the at least one scallop, wherein the support surface
abuts an interior surface of the raised platform of the lid, when
the lid is engaged with the carton base.
7. The container assembly of claim 1, further comprising: a tape
layer overlapping and sealing the lid and the carton base when the
lid is engaged with the carton base.
8. The container assembly of claim 1, wherein the lid includes a
countersunk surface having a plurality of ventilation holes.
9. The container assembly of claim 8, wherein the lid includes an
antimicrobial sheet secured over the ventilation holes.
10. A container assembly, comprising: a carton base having a
substantially planar bottom surface and a plurality of sidewalls
forming an interior space, wherein the plurality of sidewalls of
the carton base are formed of a cardboard base layer and a liner
attached to an interior surface of the carton base, and wherein the
liner includes a resin layer intermediate to two paper layers; a
lid having a top surface and a plurality of sidewalls extending
therefrom; and wherein the lid is releasably engaged with the
carton base and encloses the interior space when engaged with the
carton base.
11. The container assembly of claim 10, wherein the liner has a
board weight of 200 g/m.sup.2 to 300 g/m.sup.2.
12. The container assembly of claim 10, wherein the top surface of
the lid includes: a plurality of raised platforms, each raised
platform having a substantially planar top surface, and a plurality
of channels extending between each of the raised platforms such
that each of the plurality of channels continuously extends to a
perimeter of the lid.
13. The container assembly of claim 10, wherein a plurality of
containers may be stacked vertically on one another.
14. The container assembly of claim 10, further comprising: a tape
layer overlapping and sealing the lid and the carton base when the
lid is engaged with the carton base.
15. The container assembly of claim 10, wherein the liner is also
attached to an exterior surface of the carton base.
16. The container assembly of claim 10, wherein the carton base
includes at least one corner adjoining two adjacent sidewalls,
wherein at least one of the sidewall is folded to form a double
layer at the at least one corner.
17. The container assembly of claim 10, wherein the lid includes a
countersunk surface having a plurality of ventilation holes.
18. The container assembly of claim 10, wherein the lid includes an
antimicrobial sheet secured over the ventilation holes.
19. The container assembly of claim 12, wherein each sidewall of
the carton base having at least one scallop configured to receive a
corresponding channel of the lid when the lid is engaged with the
carton base.
20. The container assembly of claim 19, wherein each of the carton
base sidewalls includes at least one support surface immediately
adjacent to the at least one scallop, wherein the support surface
abuts an interior surface of the raised platform of the lid, when
the lid is engaged with the carton base.
Description
BACKGROUND
Cross-reference to Related Applications
[0001] This application is a continuation of PCT International
Patent Application No. PCT/US2020/014171 filed on Jan. 17, 2020,
which claims priority to U.S. Provisional Application No.
62/793,559 filed on Jan. 17, 2019, the entirety of each of which is
incorporated by this reference.
Field of the Invention
[0002] The present invention relates generally to reusable
containers used to transport goods in modified atmospheric
conditions, specifically goods such as vegetables, fruit, flowers
and plants.
State of the Related Art
[0003] The use and manufacture of containers to transport produce,
flowers and plants is an old and well-known art. Corrugated Paper
Cartons (CPC), both waxed and unwaxed, and Reusable Plastic
Containers (RPC) have been used to transport produce in ambient
atmospheres. RPC conventionally rely extensively on a porous
construction to provide cooling of the goods housed therein, such
as produce, which often desiccates the produce, resulting in shrink
and loss of postharvest distribution and shelf life of the
produce.
[0004] As an alternative to CPC and RPC, Modified Atmosphere
Packaging (MAP) has been used in an attempt to better prevent
produce loss by reducing water loss, produce respiration, and in
some cases decay, through the application and utilization of active
antimicrobials. However, the use of active antimicrobials can pose
other problems and expenses related to potential contamination and
storage and use of active antimicrobial inventory.
[0005] In conventionally used CPC, RPC and MAP products, container
damage is also often a chief concern, as during shipping, transit,
and/or storage, these products are often stacked one on top of
another, on pallets or on floors. In these situations the container
products endure, sometimes significant, structural stresses that
can cause failure of the containers, which can result in a total
loss of goods stored within the damaged containers.
[0006] The use of modified atmosphere packaging can actually extend
the useful distribution and shelf life by about 4 to 5 times that
of produce packed in conventional corrugated cartons. With extended
cool chain transportation that is often used to ship produce or
other product, the shipping cartons are typically subject to high
relative humidity that reduces the structural strength of the
cartons. In addition, transport of these cartons, either by road,
rail or ocean carriers, can subject the produce and the cartons to
lateral and vertical forces which reduce the strength of the
cartons. The current cartons are not designed to sustain the
vertical weight bearing over a long, cool chain transportation.
[0007] Thus, there exists a need in the art to provide a reusable
container which utilizes modified atmospheric packaging to better
preserve the quality goods, such as, produce, flowers and plants,
after transport. The present application provides for a high
strength container design for modified atmosphere packaging of
quality goods, such as, produce, flowers and plants, before, during
and after transport.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the invention, a container
assembly includes, a carton base having a substantially planar
bottom surface, a lid having a top surface and a plurality of
sidewalls extending therefrom. The lid is releasably engaged with
the carton base and forms an interior space when engaged with the
carton base. The top surface of the lid includes: a plurality of
raised platforms, each raised platform having a substantially
planar top surface, and a plurality of channels extending between
each of the raised platforms such that each of the plurality of
channels continuously extends a perimeter of the lid. Additionally,
the carton base may be formed by corrugation of three distinct
layered laminates to the medium (flute), with at least one of the
laminate layers including a resin and a laminate weight of 200
g/m.sup.2 to 300 g/m.sup.2.
[0009] In another embodiment of the invention, a plurality of
containers may be stacked vertically on one another.
[0010] These and other aspects of the present invention may be
realized in an improved container assembly as shown and described
in the following figures and related description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] When considered in connection with the following
illustrative figures, a more complete understanding of the present
invention may be derived by referring to the detailed description.
In the figures, like reference numbers refer to like elements or
acts throughout the figures. Various embodiments of the present
invention are shown and described in reference to the numbered
drawings.
[0012] FIG. 1 is a perspective view of a container in accordance
with the principles of the present invention;
[0013] FIG. 2 is a side view the container shown in FIG. 1;
[0014] FIG. 3 is a side cross-sectional view of the container shown
in FIG. 1;
[0015] FIG. 4A is a magnified side view of the container shown in
FIG. 1;
[0016] FIG. 4B is a magnified side view of a liner shown in FIG.
4A
[0017] FIG. 5 is a side view of two disclosed containers stacked
vertically;
[0018] FIG. 6 is a top view of another embodiment of a container in
accordance with the principles of the present invention;
[0019] FIG. 7 is a side cross-sectional view of the container shown
in FIG. 6;
[0020] FIG. 8 is a top view of a carton base of the container shown
in FIG. 5; and
[0021] FIG. 9 is a top view of carton base sheet, prior to
assembly.
[0022] It will be appreciated that the drawings are illustrative
and not limiting of the scope of the invention, which is defined by
the appended claims. The embodiments shown accomplish various
aspects and objects of the invention. It is appreciated that it is
not possible to clearly show each element and aspect of the
invention in a single figure, and as such, multiple figures are
presented to separately illustrate the various details of the
invention in greater clarity. Similarly, not every embodiment need
accomplish all advantages of the present invention. Elements and
acts in the figures are illustrated for simplicity and have not
necessarily been rendered according to any particular sequence or
embodiment.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0023] The invention and accompanying drawings will now be
discussed in reference to the numerals provided therein so as to
enable one skilled in the art to practice the present invention.
The drawings and descriptions are exemplary of various aspects of
the invention and are not intended to narrow the scope of the
appended claims. Unless specifically noted, it is intended that the
words and phrases in the specification and the claims be given
their plain, ordinary, and accustomed meaning to those of ordinary
skill in the applicable arts. It is noted that the inventor can be
his own lexicographer. The inventor expressly elects, as his own
lexicographer, to use only the plain and ordinary meaning of terms
in the specification and claims unless they clearly state otherwise
and then further, expressly set forth the "special" definition of
that term and explain how it differs from the plain and ordinary
meaning. Absent such clear statements of intent to apply a
"special" definition, it is the inventor's intent and desire that
the simple, plain and ordinary meaning to the terms be applied to
the interpretation of the specification and claims.
[0024] The inventors are also aware of the normal precepts of
English grammar. Thus, if a noun, term, or phrase is intended to be
further characterized, specified, or narrowed in some way, then
such noun, term, or phrase will expressly include additional
adjectives, descriptive terms, or other modifiers in accordance
with the normal precepts of English grammar. Absent the use of such
adjectives, descriptive terms, or modifiers, it is the intent that
such nouns, terms, or phrases be given their plain, and ordinary
English meaning to those skilled in the applicable arts as set
forth above.
[0025] Further, the inventors fully informed of the standards and
application of the special provisions of 35 U.S.C. .sctn. 112(f).
Thus, the use of the words "function," "means" or "step" in the
Detailed Description of the Invention or claims is not intended to
somehow indicate a desire to invoke the special provisions of 35
U.S.C. .sctn. 112(f), to define the invention. To the contrary, if
the provisions of 35 U.S.C. .sctn. 112(f) are sought to be invoked
to define the inventions, the claims will specifically and
expressly state the exact phrases "means for" or "step for" and the
specific function (e.g., "means for filtering"), without also
reciting in such phrases any structure, material or act in support
of the function. Thus, even when the claims recite a "means for . .
. " or "step for . . . " if the claims also recite any structure,
material or acts in support of that means or step, or that perform
the recited function, then it is the clear intention of the
inventor not to invoke the provisions of 35 U.S.C. .sctn. 112(f).
Moreover, even if the provisions of 35 U.S.C. .sctn. 112(f) are
invoked to define the claimed inventions, it is intended that the
inventions not be limited only to the specific structure, material
or acts that are described in the illustrated embodiments, but in
addition, include any and all structures, materials or acts that
perform the claimed function as described in alternative
embodiments or forms of the invention, or that are well known
present or later-developed, equivalent structures, material or acts
for performing the claimed function.
[0026] In the following description, and for the purposes of
explanation, numerous specific details are set forth in order to
provide a thorough understanding of the various aspects of the
invention. It will be understood, however, by those skilled in the
relevant arts, that the present invention may be practiced without
these specific details. In other instances, known structures and
devices are shown or discussed more generally in order to avoid
obscuring the invention. In many cases, a description of the
operation is sufficient to enable one to implement the various
forms of the invention, particularly when the operation is to be
implemented in software. It should be noted that there are many
different and alternative configurations, devices and technologies
to which the disclosed inventions may be applied. Thus, the full
scope of the inventions is not limited to the examples that are
described below.
[0027] FIGS. 1-4 illustrate a container 100 which may include a
carton base 102 and a lid 104 which can be engaged to and seal an
interior space within the carton base 102. The carton base 102 and
lid 104 may be configured to utilize a water vapor barrier
construction and the carton base 102 may be formed or manufactured
from a corrugated material. Furthermore, additional material may be
added to the corrugated material of the carton base which resists
water transfer and absorption by the corrugated material.
[0028] The carton base 102 may be formed as box having a
substantially planar bottom surface 102a, and a plurality of
sidewalls 102b extending upwardly therefrom. The carton base 102
may alternatively include individualized compartments or sections
that may be customizable in shape and size depending on the
products to be stored and shipped therein. The carton base 12 may
also be formed having a quadrilateral cross-sectional shape, such
as a rectangle, as shown in FIGS. 1-5, or in any other desired
shape. The carton base 102 may also be configured to both protect
and insulate products stored within the container 102, from the
ground and/or floor environment and elements such as extreme
temperatures, moisture, or substantially arid climates which may
cause the products to dry out.
[0029] The lid 104 of the container 100 may be configured to create
a seal when connected or secured to the carton base 102, forming a
sealed interior space. The lid 104 may be of any known transparent
or colored material that can also provide a water vapor barrier.
The lid 102 may also be formed of, at least in part, a permeable
material that can regulate the atmospheric conditions within the
container 100. The seal formed by the lid 104 and the carton base
102 may be a liquid-tight seal and/or an air-tight seal, thus
preserving and maintaining a specific desired environment within
the container 100. The lid 104 may be formed having a quadrilateral
cross-sectional shape, such as a rectangle, as shown in FIGS. 1-4A,
or in any other desired shape. The lid 104 may include sealing
protrusions 106 that may extend from an interior surface of each of
the corners of the lid 104. These protrusions 106 may then actively
engage with a corresponding outer surface of the carton base 102,
thereby forming a seal. The engagement between the protrusions 106
and carton base 102 may be a friction fit, snap fit, taped or glued
or any other desired engagement that may facilitate an air-tight
and/or water-tight seal between the carton base 102 and the lid
104.
[0030] The lid 104 may include a plurality of sidewalls 108, such
as the four sidewalls 108 shown in FIG. 1, and a stop surface 110.
Each of the sidewalls 108 may extend from the top surface 110 in a
tapered, non-perpendicular direction, such that the sidewalls 108
are not squared, or at 90 degrees, from the top surface 110. These
tapered sidewalls 108 can provide easier removal from a fabrication
mold, for example, and may also allow multiple lids 104 to be
stacked in an overlapping manner during storage or shipping of the
lids 104 when not engaged with corresponding carton bases 102.
[0031] The top surface 110 of the lid 104 may include a plurality
of raised platforms 112. The raised platforms 112 may include
substantially planar, or planar, top surfaces 112a. Each of the top
surfaces 112a may also be coplanar, or substantially coplanar, with
one another, thereby providing a series of substantially flat,
planar surfaces that can provide a foundation for stacking multiple
cartons 100 on top of one another. The raised platforms 112 may be
evenly and symmetrically spaced from one another. As shown in FIG.
5, by having each of the top surfaces 112a being substantially
coplanar, and symmetrically spaced apart, the raised platforms 112
can provide a strong, stable foundation for a second carton 100
stacked thereon. Therefore, the present carton base 102 and lid 104
configuration provide a greater load bearing surface by multiple
points of contact, via the raised platforms 112, supporting
multiple cartons in a vertical stacked configuration.
[0032] The top surface 110 may also include a series of flow
passages 114, or channels, dividing each of the raised platforms
112 from one another. These flow passages 114 may be continuous
throughout the top surface 110 such that each flow passage may
extend to an outer perimeter of the lid 104. This flow passage
configuration can provide ample air flow between stacked containers
100, as shown in FIG. 5. By providing ample air flow between
stacked containers 100, the temperature of each container 100 may
be more easily regulated when stacked, for example, on a pallet.
Keeping each stacked container 100 individually cooled can be
imperative in preserving the integrity of certain products stored
within the containers 100, such as plants and produce, for
example.
[0033] The carton base 102 and lid 104 may be formed from any
desired material, such as plastic, cardboard, resin, or any other
composite or desired material, and may be opaque or transparent.
However, the present carton base 102 may also be formed using three
distinct layered laminates, 120, 121, and 122, combined as a single
liner 152, as shown in FIG. 4B. A cardboard base layer 150 may be
used as the main structure of the carton base 102, however, the
liner 152 may be bonded to an interior surface of the cardboard
base layer 150, or to an exterior surface of the cardboard base
layer 150, or both the interior and exterior surfaces, as shown in
FIG. 4A. It should be noted that the cardboard layer 150 and liner
152 are not illustrated to scale in FIGS. 4A, 4B or FIG. 7
(discussed in more detail below), and are simple shown
schematically to show their relative positioning and use.
[0034] The liner 152 may have a board weight of 200 g/m.sup.2 to
300 g/m.sup.2, for example, and may also include a range of
individual resins including: PETE, polypropylene, nylon, and/or
combinations or mixtures thereof, or additional types of resins
that may provide a water vapor barrier. The three layers 120, 121,
and 122, also called a linerboard, can then be bonded together
using a laminate process or any other desired bonding process known
in the art. Having the liner 152 bonded to a cardboard base layer
150 can provide the requisite strength to maintain the structural
integrity of carton base 102, while also maintaining a relatively
light weight and flexibility, particularly during shipping or
transport.
[0035] FIGS. 6-8 illustrate another container embodiment. Container
200 may include a carton base 202 and a lid 204 which can be
engaged to and seal an interior space within the carton base 202.
The carton base 202 and lid 204 may be configured to utilize a
water vapor barrier construction and the carton base 202 may be
formed or manufactured from a corrugated material. Furthermore,
additional material, or a linerboard or liner, may be added to the
corrugated material of the carton base which resists water transfer
and absorption by the corrugated material.
[0036] The carton base 202 may be formed as a box having a
substantially planar bottom surface 202b, and a plurality of
sidewalls 202a extending upwardly therefrom. As shown in FIG. 8, in
each corner of the carton base 202 a folded double layer 220a,
220b, 220c, 220d, may be formed. These folded double layers may be
formed during assembly of the container base 220 and may provide
significant additional structural support to the integrity of the
carton base 202. Each folded double layer 220a, 220b, 220c, 220d,
may extend substantially diagonally across each corner of the
container base 202 and extend from an interior bottom surface of
the carton base 202 to a terminating end of the adjacent sidewalls
202a. Each of the folded double layers 220a, 220b, 220c, 220d, may
be composed of the same material or combination of materials as the
sidewalls 202a and the "folded" design of these layers not only
increases the structural strength of the carton base 202, but it
improves assembly time, as additional material pieces are not
needed to form the folded double layers 220a, 220b, 220c, 220d.
[0037] Referring to FIG. 9, each of the sidewalls 202a of the
carton base include at least one or more scallops 203, or cutout
portions, at a terminating end of each sidewall 202a. As
illustrated, the scallops 203 may be curved, but may also have any
other desired shape, such as semicircular, rectangular, square, or
triangular, for example. On each side of each scallop 203, along
the terminating end of the respective sidewalls 202a are
substantially planar support surfaces 205. As shown in FIG. 7, each
scallop 203 is configured to receive a corresponding flow passage
214 (discussed in more detail below) formed in the lid 204 and each
support surface 205 abuts an undersurface of a corresponding raised
platform 212 (discussed in more detail below) formed in the lid
204. Accordingly, the support surfaces 205 may add significant
structural and vertical support around the perimeter of the lid
204. This added structural support may be particularly important as
containers 200 are stacked vertically, which can significantly
increase the loads on the lids 204 and the cartons bases 202.
[0038] Similarly to container 100 discussed above, carton base 202
may be formed using the three distinct layer laminates, 120, 121,
and 122, combined as a single liner 152, as shown in FIG. 4B. A
cardboard base layer 250 may be used as the main structure of the
carton base 202, however, the liner 152 may be bonded to an
interior surface of the cardboard base layer 250, or to an exterior
surface of the cardboard base layer 250, or both the interior and
exterior surfaces, as shown in FIG. 4A. It should be noted that the
cardboard layer 250 and liner 152 are not illustrated to scale in
FIG. 7 and are simply shown schematically to show their relative
positioning and use.
[0039] The carton base 202 may alternatively include individualized
compartments or sections that may be customizable in shape and size
depending on the products to be stored and shipped therein. The
carton base 202 may also be formed having a quadrilateral
cross-sectional shape, such as a rectangle, as shown in FIGS. 7 and
8, or in any other desired shape. The carton base 202 may also be
configured to both protect and insulate products stored within the
container 202, from the ground and/or floor environment and
elements such as extreme temperatures, moisture, or substantially
arid climates which may cause the products to dry out.
[0040] The lid 204 of the container 200 may be configured to create
a seal when connected or secured to the carton base 202, forming a
sealed interior space. The lid 204 may be of any known transparent
or colored material that can also provide a water vapor barrier.
The lid 204 may also be formed of, at least in part, a permeable
material that can regulate the atmospheric conditions within the
container 200. The seal formed by the lid 204 and the carton base
202 may be a liquid-tight seal and/or an air-tight seal, thus
preserving and maintaining a specific desired environment within
the container 200. The lid 204 may also secured and sealed to the
carton base 202 with the use of tape 230. The tape 230, as shown in
FIG. 7, can overlap a portion of the carton base 202 and the lid
204, continuously around the entire perimeter of the container 200.
The tape 230 may not only provide or improve the seal between lid
204 and the carton base 202, the tape 230 may also increase the
structural strength of the container 200.
[0041] The lid 204 may be formed having a quadrilateral
cross-sectional shape, such as a rectangle, as shown in FIGS. 6 and
7, or in any other desired shape. The lid 204 may include a
plurality of sidewalls 208, and a top surface 210. Each of the
sidewalls 208 may extend from the top surface 210 in a tapered,
non-perpendicular direction, such that the sidewalls 208 are not
squared, or at 90 degrees, from the top surface 210. These tapered
sidewalls 208 can provide easier removal from a fabrication mold,
for example, and may also allow multiple lids 204 to be stacked in
an overlapping manner during storage or shipping of the lids 204
when not engaged with corresponding carton bases 202.
[0042] The top surface 210 of the lid 204 may include a plurality
of raised platforms 212. The raised platforms 212 may include
substantially planar, or planar, top surfaces 212a. Each of the top
surfaces 212a may also be coplanar, or substantially coplanar, with
one another, thereby providing a series of substantially flat,
planar surfaces that can provide a foundation for stacking multiple
cartons 200 on top of one another. The raised platforms 212 may be
evenly and symmetrically spaced from one another.
[0043] The top surface 210 may also include a series of flow
passages 214, or channels, dividing each of the raised platforms
212 from one another. These flow passages 214 may be continuous
throughout the top surface 210 such that each flow passage may
extend to an outer perimeter of the lid 204. This flow passage
configuration can provide ample air flow between stacked containers
200. By providing ample air flow between stacked containers 200,
the temperature of each container 200 may be more easily regulated
when stacked, for example, on a pallet. Keeping each stacked
container 200 individually cooled can be imperative in preserving
the integrity of certain products stored within the containers 200,
such as plants and produce, for example.
[0044] Additionally, to further improve the internal climate of the
container 200, the lid 204 may include a ventilation surface 240,
which may include a plurality of ventilation holes 240a. The
ventilation surface 240 may be countersunk from the raised
platforms 212, to ensure that the ventilation holes 240a are not
closed off if multiple containers 200 are stacked on top of one
another. A permeable, anti-microbial sheet, or sachet, 242 may be
positioned on the ventilation surface 240 as a mechanism for
reducing the possibility of contamination of products within the
container 200. A film seal 244 may then be placed and secured above
the ventilation surface 240 onto a seal surface 246. The film seal
244 can then be used to retain and seal the anti-microbial sheet
242 in place above the ventilation holes 240a during use and
transport.
[0045] Referring to FIG. 9, carton base 202 may be manufactured as
a single sheet 300. Each cut line 302 of the sheet 300 may be cut,
to enable folding and the erecting of the carton base 202. Each
fold line 304 represents a scored line to be folded during
assembly, where a user or manufacturer may fold the sheet 300 to
form the carton base 202. After the cuts have been made along cut
lines 302, each sidewall 202a may be folded along the corresponding
fold lines 304 to a substantially vertical position with respect to
the bottom surface 202b. Then each of the folded double layer
corners 220a, 220b, 220c, and 220d may be folded along
corresponding fold lines 304 to form the folded double layer
configuration shown in FIG. 8. Once all of the folds and cuts have
been made, glue can be applied to the glue sections 306 such that
the glue sections 306 may be adhered to the corresponding
immediately adjacent sidewall 202a, as shown in FIG. 8. Other
adhesive, bonding or attachment mechanisms may also be used instead
of glue, depending on need or preference.
[0046] In an exemplary embodiment, the laminate layers 120, 121,
and 122, or liner 152, the combination of which may also be called
a linerboard, may include a first paper layer, such as Kraft Liner
Board (KLB), a second paper layer, such as Machined Glaze Bleached
Kraft (MGBK), and a resin layer, such as polypropylene, positioned
intermediate to the two paper layers. The specifications, such as
weight, of this linerboard may be customizable to meet varying
needs and demands. For example, the laminate layers may be: KLB 200
g/m.sup.2, resin 48 g/m.sup.2, and MGBK 40 g/m.sup.2 for a total
linerboard weight of 288 g/m.sup.2. In another example, the
laminate layers may be: KLB 170 g/m.sup.2, resin 48 g/m.sup.2, and
MGBK 40 g/m.sup.2 for a total linerboard weight of 258 g/m.sup.2.
In another example, the laminate layers may be: KLB 127 g/m.sup.2,
resin 48 g/m.sup.2, and MGBK 57 g/m.sup.2for a total linerboard
weight of 232 g/m.sup.2. And in another example, the laminate
layers may be: KLB 127 g/m.sup.2, resin 48 g/m.sup.2, and MGBK 40
g/m.sup.2for a total linerboard weight of 215 g/m.sup.2.
[0047] The linerboard may be tested and quality checked to better
ensure performance. Checks using a Sheffield instrument (or
Bendtsen) may be taken and recorded prior to a linerboard
production run to ensure the smoothest sides, of the paper layers,
are on the inside of the laminate adjacent to the polymer layer.
Acceptable Sheffield values for the 200 g/m.sup.2 KLB may be
350-400, and acceptable values for the 40 g/m.sup.2 MGBK maybe
150-200. To test the coating weight of the linerboard, an average
of a minimum of eight 100 mm.times.100 mm samples may be taken
evenly spaced across a text web. A variation of no greater than
plus or minus 7% may provide acceptable testing results. During
testing of the linerboard, any changes to a coating weight will be
subject to this variation factor.
[0048] The linerboard may be bonded to a corrugated cardboard base.
For example, the linerboard may be bonded to an interior surface of
the cardboard base, or a second exterior surface of the cardboard
base, or both the interior and the exterior of the cardboard
base.
[0049] In at least one embodiment, a corrugated cardboard layer
bonded with a linerboard may include the following specifications
for production. A good adhesive bond between the cardboard and the
linerboard is recommended, but not to the point that the board, a
combination of the cardboard and linerboard, is too stiff. For
example, it is known that a high solids starch with excessive
application will produce a board which will crack during the die
cutting.
[0050] Paper should not be over cooked during the corrugating
process otherwise it will likely be too dry and brittle and likely
crack on crease lines. It is advisable to wind the linerboard at a
double backer heater drum with the KLB layer to the drum surface
for two reasons, firstly, the Kraft Linerboard (KLB) is the
component which has to be glued to the medium and secondly, it is
thicker and therefore takes longer to heat. If the tissue, or MGBK
layer, faced the drum surface, it would likely heat more quickly
and increase the risk of damaging the polymer or resin layer.
[0051] The linerboard preheat drum should be set with a minimum
angle of wrap commensurate with producing and adequately bonding a
sheet. An acceptable angle of wrap is 25%, although it will depend
on the line speed. The linerboard should also be unwound so that
the KLB layer is touching the drum surface and not the tissue, or
MGBK layer.
[0052] The board should be as flat as possible coming off the
corrugating line, and to minimize the risk of curl developing in
storage, the sheets of board should be reversed on the stack every
20-25. It has been found that steam sprays, present on some
corrugating lines, can help minimize the sheet curl without
affecting the board moisture content or barrier.
[0053] The board may be put to a die cutter within 24 hours of
corrugating so that the board is at the optimum temperature and
moisture content. If the board is too hot and wet it will not
handle well on the press. Similarly, if it is too dry it will be
prone to cracking. Stored board sheets have successfully been
die-cut when they have been stored under ideal climatic conditions
and have been strapped.
[0054] A 6pt scoring rule with a flat top and corner radius, may be
used to score the board. Narrower rule has a tendency to cut the
board and flatter rules may produce a crease line which is too
wide. Wave style rule is also not suitable because of its tendency
to have many burrs and nip points. It may be necessary to have a
very light score so that the linerboard is not stressed to the
point of cracking.
[0055] Rules may be continuous with no joints on the exposed crease
lines. Joints that increase rules can be nip points which cause
damage to the liner, so must be avoided. The die must be fastened
to the rotary drum or flat bed with adequate securing bolts to
ensure the die does not chatter and produce variable depth of
crease.
[0056] A flat die is generally better to use because it may produce
a more dimensionally accurate blank and there is no risk of
slippage as the blank goes through the press. With a rotary die
there is always the chance that the board could slip as it is fed
through the machine and thereby alter the length of the cut. Anvils
may also be maintained to a higher standard than for conventional
boxes. Ideally, rotary presses with steel anvils may be used but as
they are not so common in box plants it may sometimes be necessary
to use presses with rubber anvils. Well worn rubber anvils may have
severe grooving and this can cause inaccurate creasing, hence the
anvils should be replaced more frequently.
[0057] To better ensure that the score depth is at the optimum
across the whole die it may be necessary to shim certain rules at
the back of the rule to raise it. This is particularly the case
when the die has crush areas, i.e. cork areas on the die located at
the point where flaps overlap on the box. When the board is
crushed, any adjacent scores will not be as deep as the rest of the
blank so the rule has to be raised.
[0058] In a disclosed embodiment a carton base may include folded
double wall ends, which may require a special technique of die
cutting to ensure the 180 degree fold does not crack the polymer.
It is also important that the ends fold squarely to ensure the box
assembles squarely.
[0059] The die may be made with two crease rules set 6 mm apart
with the center filled with either a hard plastic strip or cork.
The plastic, or cork, is used to compress the board between the two
crease lines and thereby reduce the folding resistance. It is also
beneficial to use a CITO channel on the make ready as this improves
the definition of the crease. The same technique is also required
for the triangular reverse folds on the one-piece easy seal box. It
must also be remembered that the end blanks should be fed to the
press with the KLB layer facing down, so the crease is applied to
the KLB side.
[0060] To ensure the disclosed container embodiments perform as
designed and control the gas exchange, it is important that hot
melt glue, used in constructing the container, is applied correctly
to produce an airtight seal. Although the hot glue seal is not
truly airtight because of the paper structure, the hot glue seal
should nevertheless be made so that there are no macro sized gaps
or even capillary pinholes. The glue beads should be
continuous.
[0061] The hot glue should also be of the correct type. It is
important that the glue is selected for the particular method of
application; for example, machine application requires a faster
setting glue than hand sealing. The glue must also tolerate chilled
conditions both during the application stage and the storage. In
storage, the glue must retain a good bond to the paper under low
temperature, humid conditions and not become brittle. Brittle glues
are prone to cracking which would impair the gas barrier and in
extreme cases, cause loss of strength. If boxes are pre-erected and
stored under ambient conditions prior to use, care must be taken to
ensure the glue also withstands such high temperatures otherwise
the seals will start opening.
[0062] Additional linerboard testing may include pinhole testing,
that may be carried out on a sample full width by 1 meter, for
example. Prior to applying turpentine, for example, a sheet may be
folded both in a machine direction and a cross direction. The
turpentine may then be applied to a flat and folded areas. After
two minutes, for example, the number of pinholes may be counted and
recorded. This check may be carried out at the start of a
production run, and every second of liner board roll throughout the
production run.
[0063] In the event of more than ten pinholes being present on the
flat sheet or on the crease line the polymer coating shall be
increased to the maximum tolerance setting of plus 7% of the
nominal coating weight and rechecked for holes. If the number of
pinholes has decreased to ten or less on the flat sheet or the
creased lines then the production run shall continue. If the number
of pinholes remains the same or has increased then the run shall be
aborted.
[0064] The linerboard may also have bond strength checks at the
start of a production run and at the start of every second roll
throughout the run to ensure fiber tearing bonds are achieved.
Barrier standards for the disclosed linerboard may include, barrier
gas transmission rates standards/specifications (cc/m.sup.2/24 hr @
20.degree. C.) are: 100--O.sub.2, 50--CO.sub.2, .+-.10 Range.
[0065] The three laminate layers 120, 121, and 122 of the carton
base 102 may have individually customizable compositions, depending
on the use of the container 100 and the type of product being
stored in the container 100. For example, the combination of the
board weight and the combination of resins can provide a water
vapor barrier layer. Such a water vapor layer can be provided as an
outside layer, inside layer, middle layer, or any combination
thereof. The custom ability of individual layers can also provide
flexibility in custom designing the carton for specific densities
of produce or products. The construction of the three layers using
a combination of corrugate material using such laminates, can
increase the strength and integrity of the carton to resist carton
collapse, particularly during extended shipping times, which may
impose external lateral and vertical stresses that occur during
transport. Modified atmospheres are created within the carton which
can be customized for specific produce through the sealing
procedures in forming the carton.
[0066] There is thus disclosed an improved corrugated container and
method of manufacturing the container. In the foregoing
specification, the present invention has been described with
reference to specific exemplary embodiments. Various modifications
and changes may be made, however, without departing from the spirit
and scope of the present invention as set forth in the claims,
including combinations of elements of the various illustrated
embodiments. The specification and figures are illustrative, not
restrictive, and modifications are intended to be included within
the scope of the present invention. Accordingly, the scope of the
present invention should be determined by the claims and their
legal equivalents rather than by merely the examples described.
[0067] For example, the steps recited in any method or process
claims may be executed in any order and are not limited to the
specific order presented in the claims. Additionally, the
components and/or elements recited in any apparatus claims may be
assembled or otherwise operationally configured in a variety of
permutations and are accordingly not limited to the specific
configuration recited in the claims.
[0068] Benefits, other advantages, and solutions to problems have
been described above with regard to particular embodiments. Any
benefit, advantage, solution to problem, or any element that may
cause any particular benefit, advantage, or solution to occur or to
become more pronounced are not to be construed as critical,
required, or essential features or components of any or all the
claims.
[0069] The phrase "consisting essentially of" as used herein is
intended to cover additional elements or functions that do not
materially affect the basic and novel characteristics of the
claimed invention. Thus, "consisting essentially of" is intended to
encompass not only those components specifically listed, but also
separate or additional components that do not materially alter the
specifically recited functions or elements.
[0070] The terms "comprise", "comprises", "comprising", "having",
"including", "includes" or any variations of such terms, are
intended to reference a non-exclusive inclusion, such that a
process, method, article, composition or apparatus that comprises a
list of elements does not include only those elements recited, but
may also include other elements not expressly listed or inherent to
such process, method, article, composition or apparatus. Other
combinations and/or modifications of the above-described
structures, arrangements, applications, proportions, elements,
materials, or components used in the practice of the present
invention, in addition to those not specifically recited, may be
varied or otherwise particularly adapted to specific environments,
manufacturing specifications, design parameters, or other operating
requirements without departing from the general principles of the
same.
* * * * *