U.S. patent number 3,715,853 [Application Number 05/083,704] was granted by the patent office on 1973-02-13 for boilable bakeable package and method.
This patent grant is currently assigned to Robalex Inc.. Invention is credited to Robert P. Bemiss.
United States Patent |
3,715,853 |
Bemiss |
February 13, 1973 |
BOILABLE BAKEABLE PACKAGE AND METHOD
Abstract
A laminated or multi-layer wall tray is provided which has a
self-supporting outer layer or wall portion of paperboard which can
be formed and handled as an independent self-supporting unit during
manufacture of the laminated tray. A plastic liner is heat-vacuum
formed into the paperboard tray or carton to provide a boilable,
bakeable, liquid-tight, leakproof lining for the tray which in its
entirety is of a boilable or bakeable character, and to provide a
strengthened structure of the composite tray of the outer
paperboard supporting structure and inner plastic film liner in
supporting structure. Both the liner and the paperboard are
preferably made of a thinness or caliper of a dimension less than
cqn be normally employed in such structures when used alone. At the
bottom of the paperboard outer structure has certain formed indents
around its bottom corner edge which provide resting portions or
stops for nesting of the tapered trays to be handled as a stack,
and also provide exit openings or vents for air from within the
carton or tray at required positions to the outside during the
thermo-vacuum forming of the liner. The method of fabricating or
combining the components of such a tray comprises the steps of
forming the outer paperboard structure or layer with the corners
locked or secured together in self-supporting fashion to receive
the plastic liner by thermo-vacuum forming process drawn inside of
the self-supported paperboard outer structure to correspond
identically to the inner profile of the paperboard container
thereby locking and if desired, adhering the molten plastic
material to the inside paperboard structure. A laterally
horizontally extending flange may be provided around the upper edge
of either the paperboard or the plastic, or both.
Inventors: |
Bemiss; Robert P.
(Hillsborough, CA) |
Assignee: |
Robalex Inc. (San Francisco,
CA)
|
Family
ID: |
22180143 |
Appl.
No.: |
05/083,704 |
Filed: |
October 26, 1970 |
Current U.S.
Class: |
53/433; 53/449;
493/101; 220/62.2; 206/518; 220/592.27 |
Current CPC
Class: |
B65B
1/02 (20130101); B29C 33/10 (20130101); B65D
81/3415 (20130101); B29C 51/162 (20130101); B65D
5/56 (20130101) |
Current International
Class: |
B29C
51/16 (20060101); B29C 51/00 (20060101); B65B
1/02 (20060101); B65B 1/00 (20060101); B65D
5/56 (20060101); B65D 81/34 (20060101); B29C
33/10 (20060101); B65b 031/00 () |
Field of
Search: |
;229/30,14PL,14R,14B
;220/97C,63 ;93/36.01 ;53/22A,27,112A |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Juhasz; Andrew R.
Assistant Examiner: Bray; W. Donald
Claims
I claim:
1. The method of manufacturing a laminated tray or carton structure
which comprises first forming an outer part or lamina of paperboard
in the shape of a tray or carton having a bottom and four side
walls, securing the respective walls together to form a
self-supporting paperboard part capable of being handled as an
individual unit, forming openings adjacent the bottom of the
paperboard part, supporting the paperboard part with openings in
communication with a vacuum source, placing a sheet of film over
the open top of the paperboard part, holding the sheet at its edge
portions as positioned peripherally about the paperboard part,
applying vacuum pressure to the inside of the paperboard part,
simultaneously heating the sheet of film so that the film is drawn
down into the tray or carton and against the bottom and side walls
thereof and into conforming structural relation to form an inner
part or lamina in mutual reinforcing relation with said outer
paperboard part, the step of forming openings adjacent the bottom
of the paperboard part is effected by forming struck-out portions
at the bottom corners between the side walls and the bottom wall
and in the vacuum forming of the heated film drawing the film
partially into said openings so as to provide a holding engagement
between the outer paperboard part and the inner film part.
2. The method of manufacturing a laminated tray or carton structure
as recited in claim 1 wherein the holding engagement between said
film and openings is readily releasable.
3. The method of manufacturing a laminated tray or carton structure
as recited in claim 1 wherein the holding engagement between said
film and openings is essentially unreleasable.
4. The method of manufacturing a laminated tray or carton structure
as recited in claim 3 wherein the essentially unreleasable holding
engagement is achieved by forming a portion of each opening in its
associated side wall with a pair of upwardly diverging edges thus
forming an interlock between the openings and the material drawn
therein.
5. A method of manufacturing a laminated carton comprising the
steps of folding a paperboard container blank to form an outer
container having a bottom wall and a body wall terminating at a
flangeless terminal uppermost edge, vacuum forming a sheet of
plastic material in situ within said outer container to form a
liner therefor, trimming the sheet in spaced outboard relationship
to said flangeless edge to form a liner flange projecting radially
beyond said terminal uppermost edge adapted to have a lid
heat-sealed thereto, packaging a product in said liner prior to the
heat sealing of the lid to said flange, and drawing a vacuum prior
to the sealing of the lid to said flange sufficient to draw at
least portions of the liner away from the outer container thereby
reducing final liner volume and accordingly reducing final product
head space.
6. A method of manufacturing a laminated carton comprising the
steps of folding a paperboard container blank to form an outer
container having a bottom wall and a body wall with openings at a
juncture therebetween, conveying said outer container to an
upwardly opening vacuum cup, forming a vacuum chamber between said
cup and outer container by imparting relative telescopic movement
therebetween, the height of the vacuum chamber being limited to the
area of the juncture and immediately above the openings therein,
heating a sheet of plastic material, drawing a vacuum through the
openings to form a liner in situ within the outer container while a
major surface area portion of the outer container body wall above
the juncture area is free and unsupported, and trimming the sheet
in spaced outboard relationship to the outer container body wall to
form a liner flange adapted to have a lid heat sealed thereto.
7. A method of manufacturing a laminated carton comprising the
steps of forming an outer container having a bottom wall and a body
wall, forming a liner within the outer container, releasably
interlocking a portion of the liner to a portion of the outer
container, packaging a product in the liner, drawing a vacuum
internally of the liner sufficient to draw the liner portion away
from the container portion to release said interlock whereby the
liner moves away from the outer container thereby reducing final
liner volume and accordingly reducing final product head space, and
thereafter hermetically securing a lid to said liner to maintain
the evacuated condition thereof.
8. The method of manufacturing a laminated carton as defined in
claim 7 comprising the further steps of forming openings in said
outer container, and forming said liner by drawing a vacuum through
said openings to form the liner in situ within the outer
container.
9. The method of manufacturing a laminated carton as defined in
claim 7 comprising the further step of forming a peripheral flange
on the liner, and heat sealing said lid to said flange.
10. The method of manufacturing a laminated carton as defined in
claim 7 comprising the further step of forming the body wall with
an uppermost flangeless terminal edge, forming a peripheral flange
on the liner projecting radially outboard of the flangeless
terminal edge, and heat sealing the lid to the liner flange
outboard of the flangeless terminal edge.
11. The method of manufacturing a laminated carton as defined in
claim 8 wherein the releasably interlocked portions of the liner
and outer container are those portions of the liner vacuum drawn
into releasably interlocked engagement with said openings.
12. The method of manufacturing a laminated carton as defined in
claim 8 comprising the further step of forming a peripheral flange
on the liner, and heat sealing said lid to said flange.
13. The method of manufacturing a laminated carton as defined in
claim 8 comprising the further step of forming the body wall with
an uppermost flangeless terminal edge, forming a peripheral flange
on the liner projecting radially outboard of the flangeless
terminal edge, and heat sealing the lid to the liner flange
outboard of the flangeless terminal edge.
14. The method of manufacturing a laminated carton as defined in
claim 13 wherein the releasably interlocked portions of the liner
and outer container are those portions of the liner vacuum drawn
into releasably interlocked engagement with said openings.
Description
DESCRIPTION OF THE INVENTION
This invention relates to vacuum-thermoformed laminated packages
such as tray or cartons, each package consisting of a fabricated
paperboard outer layer which has its respective corners secured
together in some conventional fashion, such as by a "Klik-Lok"
construction, or similar construction, or by adhesive securing so
that a self-supporting outer structure of paperboard is formed to
be used in manufacture and for the application of any graphic art
material desired in connection with the product container therein.
The second lamina comprises an inner layer of film which is
thermo-vacuum formed inside of the finished outer paperboard
lamina. The finished tray or carton is filled with product and
closed by a suitable lid or layer of film or coated paperboard. The
product can be heated by boiling or baking to the desired
temperature for use.
Packages somewhat similar to this have been known previously for
packing margarine, for example, the "Tritello" package employed in
Sweden under the "Flora" margarine label, wherein the manufacturing
machine contains machine molds for trapping precut paperboard
within the mold and forming it in the shape of a tray. Then the
film or plastic layer is formed adhesively inside the paperboard to
hold structures paperboard together in finished form. With these
prior structure it was necessary for the plastic to be in place and
secured to the paperboard to make a self-supporting structure, the
paperboard by itself being non self-supporting.
In accordance with the instant invention a competitive type package
of improved character is provided with a lower cost basis.
It is an object of the invention, therefore, to provide a
combination paperboard and film carton or tray of suitable
character to be subjected to either boiling or baking.
Another object of the invention is to provide a package of the
above character in which the tray can be constructed for nesting in
a stack and be provided with nesting indexing means or stops, which
also provide vents for the exhausting of air during the
thermo-vacuum forming of the liner.
Still a further object of the invention is to provide a structure
for a package of the above character wherein the package can be
used with a seal flange, a trap flange, with outer flange and with
a cover seal, either a separate cover or hinge type cover.
A further object of the invention is to provide a tray of a
laminated construction wherein a thinner thickness of outer layer
of paperboard and a thinner thickness of inner layer film can be
used while still obtaining a structure which equals or exceeds the
rigidity of a higher caliper or thickness of paperboard
material.
A further object of the invention is to provide a combination
laminated structure wherein an outer structure or layer of
paperboard of self-supporting character and an inner structure or
layer of film are provided wherein by subjecting the package to a
vacuum at the time of sealing the closure, the inner layer can be
formed to permit the exhausting of the air during the filling
operation so that no head space remains.
The above and other objects of the invention are attained as
described in connection with certain preferred embodiments of the
invention, as illustrated in the accompanying drawings, in
which:
FIG. 1 is a perspective view of nested trays or containers
embodying the invention;
FIG. 2 is a transverse sectional view through FIG. 1; It will be
understood that the thickness of the paperboard 10 and the film 11
has been exaggerated in FIG. 2 to enable clarity of the sectional
view;
FIG. 2a is an enlarged view similar to FIG. 2 of a top corner of a
tray;
FIG. 3 is a side view of a finished package which is closed by a
lid under vacuum conditions so that the inner liner is drawn in, in
the process of eliminating head space;
FIG. 4 is a sectional schematic view of a tray in the process of
manufacture, the self-supporting outer paperboard structure being
supported in a vacuum cup beneath the film for the inner layer.
Referring to FIGS. 1 and 2, each of the trays comprises an outer
paperboard structure 10 or lamina of upwardly diverging side wills
10a and a bottom 10b, and an inner layer of film 11 which is
thermo-vacuum formed inside of the outer paperboard structure 10
and the divergent sidewalls provide for nesting of the structures.
The film employed is preferably a high temperature film such as
nylon, high density polyethylene, or the like. In practice, the
thickness of the film will be from 0.006 to 0.010 mills, and the
thickness of the paperboard will be from 0.009 to 0.020 mills. In
thermo-vacuumforming a film into a recess the wall thickness is
reduced as film is stretched and thinned, and an 0.008 inch thick
film, for example, may be reduced to as little as 0.003 inch or
0.004 inch mills.
As shown in FIGS. 1 and 2, the paperboard structure or lamina has
its corner portions secured together by means of a conventional
"Klik-Lok" or similar structure 12. Other conventional securing
means such as by gluing, sealing, etc., can be employed at the
corners. In any event, the outer paperboard structure is
self-supporting and can be nested and stacked for subsequent use in
completing the package.
In the matter of nesting, a series of angle-shaped, indent,
struck-out portions or slots 16 (FIGS. 1 & 2) are provided at
spaced locations around the bottom edge of a carton to provide
supporting steps or resting means for another carton as shown, for
example, in FIG. 2 and these angle-shaped portions 16 are formed
inwardly, provide side apertures 16a for emission of air during the
vacuuming cycle and the processing operations as will be described.
As shown there are six of the indents provided in each tray as a
resting means and as an air emission means.
At the top the inner layer 11 extends outwardly in a flange 17
(FIG. 2a) to permit heat sealing of a coated paperboard lid to the
flange or heat sealing of a similar plastic layer to the flange to
form a weld. The flange 17 of the film is normally thinner than the
paperboard lid to which it is heat sealed but for purposes of
illustration in the drawings its thickness has been
exaggerated.
Referring to FIG. 3, a carton is shown filled with a product 20 and
has been closed by a paperboard lid 21 which is coated or film
lined so as to be heat sealed to the flange 17. At the time of
placing of this cover in place, the interior of the package is
subjected to a vacuum operation so that the inner layer 11 is moved
to a new position at 11a in certain portions, and 11b in others to
force the produce 20 from a level 22 upwardly toward the lid 21 at
a level 23.
Referring to FIG. 4 the process of manufacture of the tray is
illustrated schematically. The apparatus includes, for example, a
rectangular conveyor frame 32 suitably mounted in elevated position
so as to engage about a carton adjacent its top and locate it with
its bottom resting in a vacuum cup 31. The conveyor frame 32 is
shown above a pair of support rods 33, below a rectangular station
clamp frame 34. At the station, there is a supply of film 36 fed
across the top of the outer paperboard structure 10 and a suitable
cut off knife 37 is provided to cut the desired length of film to
be clamped by the rectangular clamp frame 34 against the
rectangular support frame 32.
Suitable guides 38 may be provided at either side to ensure proper
indexing of the carton with the vacuum cup 31 having a lower
position indicated in dotted lines at 31a and an upper position
shown in full lines where its raised side flanges 42 engage the
four walls of the paperboard structure 10. The bottom wall 43 of
the cup 31 has suitable vacuum passages 44 leading to a vacuum
fitting 46 by means of which vacuum can be applied to the space
within the cup and through the vent openings 16a to the inside of
the outer structure 10 of the carton or tray. At the same time an
overhead electric heater 47 is energized and brought to active
position to soften the film 36 so that it can be drawn inside of
the carton to form the inner layer 11. When the struck-out portion
16 is formed with tapered side walls as seen in FIG. 4 the film
drawn into this shape of opening will be effectively locked in
place and can only be withdrawn with great difficulty. When the
slot 16 is formed with straight side walls as shown at 16b in FIG.
3, a releasable interconnection or latch is provided by an indented
film portion 16c.
If desired, the inner layer of film 11 may be secured adhesively to
the outer paperboard structure 10 or the film may be heat sealed to
this outer structure where a compatible coating exists on the
paperboard.
While the above structure is schematic in nature, there are
conventional vacuumizing arrangements manufactured which are
capable of performing this operation in the manner described above
or in another manner, for example, the U.S. Pat. No. to Bergstrom,
3,492,773.
While I have shown and described a preferred form of the invention,
it is apparent that the invention is capable of variation and
modification from the form shown so that the scope thereof should
be limited only by the proper scope of the claims appended
hereto.
* * * * *